New Mining Technology 2014

NEW

SPRING 2014

MINING TECHNOLOGY DRONES

DELIVER Mines of the future are prime targets for steady supply of air-borne information

PUBLISHED BY

CANADIAN Mining Journal

© 2014 Bel-Ray Company, Inc

WE ARE SO CONFIDENT YOU WILL LOVE SF-100 YOUR FIRST FILL IS ON US! *

When the pressure to perform is on, more mining operations trust Bel-Ray lubricants.

Bel-Ray creates lubricants to meet user-specific needs—lubricants that reduce wear, extend component life and withstand the extreme demands of mining. Plus, Bel-Ray oils and greases are packaged in globally compliant, multi-lingual labeling—an industry first from the leader in specialty lubricants. If you’re thirsty for maximum performance and efficiency, Bel-Ray is your thirst quencher.

SEE THE ENTIRE LINE OF BEL-Ray PRODUCTS aT BELRay.COM. *Qualifying customers who fully covert to Molylube® SF-100 Open Gear Lubricant may be entitled to four free 208 L drums of Molylube® SF-100 Open Gear Lubricant.

FLEX YOUR OPERATION

C O N Ta C T C U S T O M E R S E R V I C E @ B E L R ay. C O M

Advertorial

BEL-RAY SETS THE OPEN GEAR LUBRICANT STANDARD

B

el-Ray products have a reputation for being best in class when it comes to quality performance and innovative technology. The demands of current and next generation mining equipment mandates superior lubricants formulated to ensure the best protection and performance.

Bel-Ray’s top tier open gear lubricant: Molylube SF-100 Semi-Synthetic Open Gear Lubricant is designed to meet and exceed the most demanding applications and OEM specifications. The value and performance of the product has been proven around the world in the most challenging and harshest environments.

The confidence and strong following SF-100 has in the mining community comes down to the simple fact that it reduces wear, extends component life and reduces total cost of ownership.

Molylube SF-100 is a top tier greasetype open gear lubricant. There are seven grades of SF-100 formulated for application temperature range between -50C and +50C. Regardless of the grade, the same performance qualities are present: excellent load carrying capability, reduce wear, reduces equipment operating temperatures and energy consumption.

A very recent case study helps illustrate the benefits of converting to SF-100.

A Canadian mining customer expressed interest in evaluating SF-100 on two P&H 4100XPC-AC rope shovels. The customer was experiencing rapid wear on the saddle block wear plates on these shovels. The goal of our project with this customer was to extend the service life of the saddle block wear plates by converting the customer to SF-100. We were confident that once we could demonstrate the superior performance of the product on these two shovels the entire fleet of shovels would be converted.

In order to conduct proper testing new saddle block wear plates were installed and New Mining Technology

the rope shovels were properly converted.

The conversion process included ensuring there were no compatibility issues with the existing open gear lubricant, pre-lubing the components with SF-100, and introducing the SF-100 into the centralized lubrication system. Once the shovels were back in operation SF-100 quickly established a heavy and durable lubricating film on all parts and assemblies to which it was being applied including the saddle block and dipper handle assemblies.

The shovels in question have far exceeded the upper limit of the operating hour range at which the mine had been routinely changing the excessively worn wear plates. Wear rates of the wear plates has been significantly reduced. We invited the original equipment manufacturer out to inspect and provide their opinion on the

performance of the SF-100 related to their rope shovel. The concluding comment of the OEM representative was that overall lube performance was excellent and wear rate is significantly improved after converting to the Bel-Ray product. This customer was previously changing out wear plates every 800-1,200 hours. Bel-Ray customers around the world have achieved wear plate change intervals at 8,000-12,000 hours.

The test is ongoing however we are confident that we will see a massive increase on wear plate life based on proven performance we have experienced in the field. It speaks volumes that just a few months into our testing the customer converted their entire rope shovel fleet to the Molylube SF-100 Semi-Synthetic Open Gear Lubricant based on the results and performance they had observed.

NMT Spring 2014 3

Advertorial

PROXIMITY DETECTION IN THE WORLD OF MINING

P

roximity detection systems on mobile mining machinery to help reduce accidents have become an industrydriven initiative. Strata Worldwide has over 1000 HazardAvert® systems underground and at the surface currently oper-

4 Spring 2014

ating in mines around the world. These global operations have chosen to incorporate the technology into their safety procedures.

No matter the application, HazardAvert creates an electromagnet field around

machinery that interacts with a minerworn personal alarm device, or PAD. It creates a two-way communication between the person and the machine. As an individual or vehicle breaches this field, warning alarms alert the machine operator(s) and the individual. If a person or vehicle gets into a dangerous position, HazardAvert can be programmed to disable the machinery completely.

“There was an event in South Africa recently where a continuous miner operator, standing in an intersection became dizzy and fell,” explains Mike Berube, president and COO of Strata Worldwide.

“A co-worker immediately rushed to his aid, as he had fallen directly in the path of an approaching shuttle-car. The shuttlecar operator was not aware of the two individuals until the HazardAvert system detected them and stopped the machine.”

HazardAvert is a close-range proximity detection system that has been successfully used on both production and haulage-type machinery at underground and surface mine locations.

For more information please contact us at 800.691.6601. Visit us at strataworldwide.com Strata Worldwide L.L.C. is a global leader in mine safety solutions. The company’s safety product line includes wireless communications and tracking, emergency mine refuge chambers and proximity detection systems. Headquartered in Atlanta, Georgia, USA, the company has service and sales support in the mining regions of the U.S., Europe, Australia, South Africa, Mexico and South America.

NMT

New Mining Technology

NEW

MINING TECHNOLOGY Published by

Canadian Mining Journal 80 Valleybrook Dr., North York, ON M3B 2S9 Tel. (416) 442-5600 Fax (416) 510-5138 www.canadianminingjournal.com

Editor

Russell Noble 416-510-6742 rnoble@CanadianMiningJournal.com

Art Director Mark Ryan

Production Manager Steven Hofmann

Print Production Manager Phyllis Wright

Circulation Manager

Cindi Holder 416-442-5600, ext. 3544 cholder@bizinfogroup.ca

Publisher

Robert Seagraves 416 510-6891 rseagraves@CanadianMiningJournal.com

Sales

CONTENTS Editorial Index

Drones provide critical information on mine conditions........ 6

Micro-organisms help solve water problems in tailing ponds... 10

A case study on improving the efficiency of older mining equipment................................................. 14

Fibre optic system designed for harsh mining environments..................................................... 16

Paint and coatings help extend the life of mining equipment................................................ 18

Products to help make mining more productive.....................20

Western Canada, Western U.S.A. Bonnie Rondeau 416-510-5245 brondeau@canadianminingjournal.com Printed in Canada All rights reserved

ADVERTISERS INDEX Bel-Ray.........................................2.........................................www.belray.com Strata Worldwide ...................4.......................... www.strataworldwide.com Metso............................................9........................................ www.metso.com Henkel Canada Corp...........13........................ www.henkelna.com/mining EIMCO-K.C.P............................19.......................................... www.ekcp.com

CANADIAN Mining Journal New Mining Technology

PROVIX......................................21..........................................www.provix.net Carlo Gavazzi.........................22.............................www.gavazzionline.com AEL Mining Services.............24...................... www.aelminingservices.com Spring 2014 5

Feature

DRONES

DELIVER

By Rachael Bartels

T

he mining industry is currently in a phase where innovation is quickly turning tip-of-the-spear technologies into disruptive new capabilities that present opportunities for strong differentiation and massive leaps in efficiency.

One such area is related to the increasing sophistication of capabilities that drones provide. Drones or unmanned aerial vehicles (UAVs) are either human-

6 Spring 2014

assisted or independent vehicles that perform activities while flying or hovering above the ground.

While drones have been around for some time, the rapid development in affordable, lightweight, highly manoeuvrable drones equipped with the latest mining-related technologies has opened up a whole new range of opportunities for possible applications.

The Mine of the Future Let’s return to the Mine of the Future— circa 2020—where drones are playing an integral role right across the value chain, both on and offsite, delivering value in the areas of exploration and development, safety and security and operational productivity.

Among the planes at a regional mine airport, the newest member of FutureMine’s New Mining Technology

team is taxiing from its secure facility onto the runway and is about to take off and go to work for the day.

Back in the office at the Remote Operations Centre (ROC), a drone’s controller is manoeuvering it into position and liaising with air traffic control also for take-off.

Drones are now regulars in air space and are monitored under air traffic control protocols. Today’s schedule is a busy one. The controller has already been collaborating with the exploration team at the ROC to confirm today’s exploration and analysis activities and is now ready to deliver.

Sensors and processing equipment drastically smaller in size and exponentially more powerful compared to today’s equipment is now standard on-board drones including chemical, electromagnetic, gamma ray and biological sensors.

After a few hours flying into inaccessible terrain and 50 degree Celsius summer temperatures, the drone reaches the target zone and starts to map and send back a live feed of multifaceted resource data—supported by real-time analytics delivering detailed maps and preliminary models to depth which the collaboration teams at the ROC analyse and develop further to determine where they will focus their resources and planning efforts.

After completing the work in a number of hours, the drone is on its way back when it is redirected to support condition monitoring activities of a critical gas pipeline supplying one of FutureMine’s remote sites.

ROC controllers are monitoring the predictive analytics on the asset and are highlighting emerging integrity issues and a potential disruption—they’d love some “eyes on the ground” to correlate the information with a visual.

Soon the drone is delivering a live video feed with a 3D integrity model of the pipeline at the sector in question, in addition to vibration and thermal data to the Asset Health Team at the ROC to support their decision making.

Live video and sound filtering is not physically and financially achievable across a long, geographically dispersed asset, but with drones it can be done in a targeted way, in real time.

New Mining Technology

All in a day’s work The next day at one of FutureMine’s mine sites, the on-site drone is being prepared for another busy day.

The first task of the day is monitoring the morning traffic speeds and road rules observance for the mine’s employees and contractors travelling to work along the public and mine lease road.

Real-time data drives real-time performance management through the ROC with interventions on offending drivers taking place early in their journey via radio or via traffic wardens, potentially reducing serious safety incidents as well as driving an improved safety culture.

From there, the drone is assigned to the Mine Rescue Team, who is conducting its regular exercises, simulating one of its diverse range of major safety incidents and exploring how it could more effectively respond through the use of drones.

The team has modelled a dangerous plant explosion and is looking to test its options to rapidly deliver medical supplies including oxygen, radios and burn blankets into a highly dangerous environment.

Conducting a wet run under simulated conditions, the onsite controller manoeuvers a quad drone to safely and precisely deliver relief. At the same time, the drone is also able to take sensory readings on individuals for medical purposes and assess residual noxious gas levels to support further response planning.

Still on site, the mining team now reassigns the drone to conduct a range of activities to improve its survey productivity, accuracy and cost. The onsite controller directs the drone to map the stockpiles and mine face areas. The information is then used to support photogrammetry, or the use of photos to map a geometric area and accurately map the stockpiles.

This information is processed in real time enabling faster, more accurate gathering, processing and reconciliation of spatial data, supporting improved decision making and lowering survey costs.

Once finished on the stockpiles, the drone is assigned to conduct basic timelapse photography in a number of areas across the site value chain to monitor the shifting physical properties of key assets.

The combination of time-lapse photog-

raphy in conjunction with the sensory information set and predictive analytics enables the mine to closely monitor and safely manage large, geographically disperse assets that would benefit from aerial monitoring—such as an enormous leach pad and tailings dam assets. This also supports the management to meet their environmental obligations across the operation.

For the last task of the day, the processing area has asked for the drone controller to conduct some preliminary observations to support the planning of an upcoming shutdown. The team would like some physical observations on the condition of key assets which are difficult and dangerous to access while the plant is running. The highly skilled operator is able to successfully navigate the drone in narrow and dangerous places and is soon providing a comprehensive feed of live images in addition to sensory information back to the planners in the ROC on key equipment (such large tanks and oxygen plants) to support the planning efforts.

It’s been just another busy day for the versatile drone which has added significant value across the value chain at a modest cost. Who knows what tomorrow will bring?

Delivering Results The possibilities for the application of drones in mining are seemingly endless with new uses coming to light every week and more widespread utilization being reported across the industry.

There are potential benefits across the value chain, from safety and security (e.g. search & rescue, monitoring / providing information from dangerous and difficult locations) to exploration & development (e.g. aerial photography and remote sensing) and productivity (e.g. stockpile mapping, mine mapping & reconciliation and time lapse photography) just to name a few.

Leading mining businesses are rapidly making these kinds of capabilities available through their use and customization of drones. Turning these ideas into results of course requires coordinated planning across the value chain and focused execution.

NMT Rachael Bartels is Managing Director, Global Mining, Accenture

Spring 2014 7

Advertorial

SERVING THE WORLD

W

ith more than 70 locations around the world, Metso is your local partner for any service need, including life cycle services, spare and wear parts replacement, field services, preventive maintenance, advanced performance materials, automation solutions, plant diagnostics, equipment refurbishment, and a broad range of training courses. Our solutions are powered by ever-expanding global resources and an industry-leading OEM parts inventory. We also offer engineered-to-order equipment and custom rebuilds and retrofits – all based on OEM specifications and developed with our advanced knowledge of process technology.

Metso understands that your success depends on consistent, efficient operations, so we offer performance-based contracts and extended protection plans to help you reach those goals.

And whether you require emergency support or scheduled/ regular maintenance, one of Metso’s 1,700 field service technicians is always accessible. Our team is expertly trained to diagnose, maintain and repair Metso equipment, but their knowledge and capabilities extend to every aspect of your operation.

8 Spring 2014

Our approach to service is forward looking: Metso’s Process Technology and Innovation group (PTI) works tirelessly to develop solutions that provide extended wear life and maximum performance for your equipment, as well as the development of custom automation solutions for plants. Services like these – along with training courses to ensure your workforce is well versed in the technology – save our customers time and money and increase efficiency without the need for replacing equipment.

No matter what your particular needs, every service project and contract we engage in is supported by our commitment to health and safety. We go above and beyond industry standards and regulations to ensure we contribute to a safe and healthy working environment. When you choose Metso as your service partner, you can rely on support that is in line with your HSE goals and requirements.

NMT

Contact Information:

Email: minerals.info@metso.com www.metso.com New Mining Technology

We define performance the way you do.

Sustainable is smart.

Optimize your circuit with energy-efficient technology from Metso

From high-performing cone crushers, to the low-consumption design of vertical stirred mills, and the revolutionary HRC™ – Metso offers energy-efficient comminution technology for every stage of your circuit. With the right Metso equipment, you’ll benefit from more sustainable, less-costly operations. And you won’t sacrifice performance: Our equipment always delivers high availability, minimal maintenance and beyond-standard safety. metso.com – email: minerals.info@metso.com

Feature

SMALL

Water found in mines often contains high levels of bacteria but microorganisms may provide a solution to helping solve some of the problem.

IS THE NEW

BIG Using microorganisms to solve the world’s biggest problems

T

he mineral resource sector continues to be a mainstay of the Canadian economy. As more mineral deposits and gas reserves are developed, safety concerns remain paramount. We already know that bacteria can influence certain mining processes. We also know that the successful practical applications of technologies exploiting biological processes can be an important contributor to future cost competitiveness, safety and environmental performance in the mining industry.

Living things in and around a mine site, from a tiny microbe to a lodgepole pine, have a genome that codes their biological functions. Genomics aims to understand and apply this encoded information

10 Spring 2014

to link changes in traits in response to the surroundings. Accordingly, current challenges around biological processes in mining could be improved by genomics-based technologies by providing a new performance measure. Some examples include monitoring of effluent discharge; mitigation of risks of environmental impact; testing toxicity for fish and wildlife; improving recovery of target minerals; extracting residuals from lower grade ores; identifying new deposits of interest; and increasing the robustness of remediation.

WATER PURIFICICATION & RECYCLING Safety precautions around groundwater are of particular concern in the mining

industry: no one wants toxic compounds flowing into fish bearing streams and waterways. To meet optimal safety levels, mining companies use chemicals to treat dissolved metal and acid rock drainage.

These treatments, while effective, are also expensive and produce their own byproducts - which then must be carefully contained for years to come or treated further to ensure safety.

Bioremediation of wastewater is an area of growing interest: the process uses naturally occurring microbes that live in and around mine sites to ‘digest’ the toxic compounds and detoxify the contaminated water. In essence, the specialized organisms thrive on toxic chemicals, inteNew Mining Technology

grating them into their metabolism while neutralizing toxicity.

While bioremediation has been around for years, we are still learning how these toxin-digesting microbes work, how to best exploit their unique capabilities and how to optimize them to work better in challenging environments. Dr. Susan Baldwin, a professor in the University of British Columbia’s Chemical and Biological Engineering Department, is helping move the science towards application – making bioremediation a more economical and accessible option - by applying genomics.

The real benefit of applying genomics to bioremediation lies in the understanding we gain on how complex microbial communities living together in mine wastewater function and, more importantly, what makes them flourish. In order for these microbes to function effectively, it is imperative we know what sort of environment best fosters them—the type of nutrients, food sources, and conditions that maximize the growth and function of the most desirable group of microbes.

Dr. Baldwin and her team are working to discover microbes with particular abilities to treat a wide variety of waste streams and to then develop bioreactors in which to grow and use these microbes. Microbes live in diverse environments, including those that are extreme with toxic metals, strong acids, sulfurous compounds and other chemicals. Dr. Baldwin looks for microbes thriving in these harsh environments and transforms mine-related toxic compounds into more benign forms. Her efforts are also directed toward replicating conditions for optimum performance in full-scale bioreactors at mine sites.

Many mine sites can become longterm sources of environmental concern for liable companies and governments.

For example, more than 6,000 abandoned mines have been identified in Ontario alone and other provinces face similar challenges. Bioremediation, or the harnessing of natural communities of microbes to clean up a polluted site, can be a cost-effective solution to mitigating environmental effects at some of these sites. However, it is not yet completely clear why bioremediation is successful in some cases but fails in others. Providing a more thorough understanding of what New Mining Technology

Tailing ponds have long been an environmental concern in many parts of the country.

microbes can do is another example for the power of genomics-based technologies and another instance where science helps to put safety first.

TOXICOGENOMICS In another application, ‘omics technologies, which include genomics as well as proteomics and metabolomics (information on all proteins and metabolites in an organism), are playing an important role in analyzing the toxicity of mine water discharge. Environmental contaminants are a safety concern not only for their direct impact on the ecosystem but also for longer-term and far-reaching effects.

Exposure to metals such as copper, zinc and cadmium can cause significant adverse effects so there is a need for relevant and precise predictors of biological outcome. Detection and identification of a potential pollutant is the first step in assessing toxicity but it is in no way a predictor of biological outcome. Current fisheries management practices expose aquatic species to contaminants in laboratories and assess toxicity based on death or survival of the exposed species.

Toxicogenomics decodes molecular level expression of toxicity in an organism, and provides biomarkers that predict toxic response or susceptibility to it. Dr. Graham van Aggelen, Head of the Environmental Toxicology Laboratory at Environment Canada’s Pacific Environmental Science Centre is developing toxicogenomics capacities and expertise. He sees the ultimate application in non-lethal testing of sentinel species such as Salmonids and Amphibians for a combination of toxins and under various exposure levels.

In collaboration with University of Victoria and the BC Ministry of Environment, van Aggelen published research last year in Aquatic Toxicology that described the feasibility of non-lethal sampling of fish fin for the determination of potentially harmful effects of a wide range of environmental contaminants using ‘omics tools.

Other innovations at the Environmental Toxicology Laboratory include analysis of gene and protein activity to determine whether the water sample meets standard quality database indicator limits, providing a potential new tool for regulators and consultants. Van Aggelen’s work also offers insight into the level of impact mine development in a highly mineralized geological area can make on resident populations. Using genomics it is possible to track and model the effects of increased release of metals into a naturally impacted environment.

THE FUTURE OF ‘OMICS & MINING ‘Omics are providing promising tools and there is a significant potential for industrywide applications. Genome British Columbia, a non-profit research organization that invests in and manages large-scale genomics projects, is investing in research that aims to provide relevant and practical solutions to end-user operations to catalyze applications. Applied genomics research conducted in BC will not only provide benefits to the province, but is expected to be taken up by companies across Canada and around the world.

NMT For more information visit Genome BC on the web: www.genomebc.ca/mining Spring 2014 11

Advertorial

High Odour Products Impair Productivity Low Odour Maintenance Products Promote Healthy, Productive Work Environment

T

he profitability of a mine is dependent on its ability to reduce downtime, and improve productivity.

Unscheduled downtime is expensive and any reduction in downtime can pay dividends to the bottom line.

Increasing productivity is a never ending struggle in the resource mining sector and can often involve confusing and difficult to implement solutions.

If the introduction of a product involves both reduced downtime and increased productivity, the entire mining industry listens.

Henkel recently introduced a new generation of Nordbak crusher backing compound that promises exactly that; reduced downtime, and increased productivity.

Loctite Nordbak PC 9020 is a new low odour, high performance backing compound formulated with the use of new advanced epoxy technologies to achieve high compressive strength, high impact resistance and low shrinkage.

Due to the low odour, low VOC formulation maintenance crews can work faster and with fewer breaks, reducing downtime and increasing productivity. Also due to the increased compressive strength, higher operating temperature, and high impact resistance, PC 9020 will likely last longer in service and require less frequent servicing of crusher cone surfaces.

Henkel has truly listened to its customers and delivered a unique product that truly helps increase profitability in the resource mining sector. Loctite Nordbak PC9020 is available in 2 and 5 gallon pail sizes with participating distributors. NMT PRODUCT

ITEM #

CONTAINER

COVERAGE CUBIC IN. @1/4” THICKNESS

LOCTITE® PC 9020TM NORDBAK® BACKING Compound

1694850

2 gallon

340

1694859

5 gallon

850

NEW

12 Spring 2014

MIXED COLOUR

MAX. OPERATING TEMPERATURE (F)

COMPRESSIVE STRENGTH (psl)

Hardness shore D

WORKING TIME AT 77˚F (minutes)

Functional cure at 77˚F (hours

Blue

220

19,000

83

20

8

New Mining Technology

Low odour crusher backing You asked...we delivered Make your work environment safer and more pleasant by using our new Loctite® PC 9020™ Nordbak® low odour Crusher Backing Compound. Henkel R&D has created a high performance version of its traditional crusher backing compounds with the exclusive benefit of low VOCs and low odour. Help ensure the safety of your workers and your crushers using Loctite® PC 9020™ Nordbak®.

Features: • Low VOCs, increased safety • Low odour, low shrinkage • High compressive strength • High impact resistance Blue colour change technology ensures product is fully mixed • Blue • Consolidates product selection for different applications

To arrange direct factory support for your applications, or to learn about additional Nordbak® wearing composites and Fixmaster® epoxies, call 1.855.436.5354, or visit henkelna.com/mining.

All marks used are trademarks and/or registered trademarks of Henkel and/or its affiliates in the U.S. and elsewhere. ® = registered in the U.S. Patent and Trademark Office. © Henkel Corporation, 2013. All rights reserved. AD-152-13.

Feature

IMPROVING

EFFICIENCY OF

OLDER MINING EQUIPMENT T

oday’s tumultuous, cyclic industry has challenged mining companies to maximize productivity and make processes safer, cleaner and more efficient.

A 2010 survey of mining executives commissioned by Mincom asked respondents to identify their current challenges by level of urgency. It may not come as a surprise that ‘ensuring workplace safety’ topped the list with 71 per cent of respondents identifying it as a top priority. Also high on the list were ‘improving performance and operational effectiveness’ (67 per cent) and ‘addressing environmental concerns’ (37 per cent).

It’s clear that conservation and productivity are issues everyone in the mining industry faces. How can we make operations safer, cleaner – and spend less time and money? Often we see these issues as mutually exclusive.

Investing in technology that meets both needs Sandvik Mining is developing mining equipment that meets the top safety and efficiency standards, and is investing in technology that can be retrofitted to older equipment to improve its operation. For instance, the Sandvik Compressor Management System (CMS) provides a solution to the inherent inefficiencies of rotary blasthole drills that have a direct connection between the engine and com-

14 Spring 2014

pressor. The system isolates the compressor and eliminates the need to maintain pressure when the machine is not drilling.

This reduces the load on the engine, saving a significant amount of fuel and reducing wear and tear.

Here’s how it works: •S TART-UP: Holds the inlet butterfly closed to allow the engine to crank, start and accelerate to low idle •O FF-LOAD: Regulates receiver pressure and evacuates the main compressor •O N-LOAD: Throttles the volume of the compressor •S HUT-DOWN: Unloads the compressor from the engine to allow for cooler engine shutdown

This patented solution can be installed on new or existing Sandvik rotary drills and has been proven to reduce fuel consumption by 20-35 per cent, extend the life of the engine and compressor and lower emissions. Sandvik Mining first tested the CMS at the Drayton Coal Mine in Hunter Valley, Australia. The system, retrofitted to a DR460 rotary drill, produced a whopping 33 per cent fuel savings. The CMS nearly doubled the engine’s life by easing the wear and tear. Following this trial, the Sandvik Mining team set out to duplicate these results with Cloud Peak Energy.

The right partnership Cloud Peak Energy is headquartered in Wyoming and is one of the largest coal producers in the United States, supplying the country with about 4 per cent of its sustainable electricity. The company operates three surface coal mines in the Powder River Basin (PRB) and is the only pure-play PRB company – meaning it is the only company that mines exclusively in the PRB. As one of the safest coal producers in the New Mining Technology

the terms were set – if the system delivered 90 percent of projected savings, Cloud Peak Energy would purchase the CMS at full price. If it underperformed, Sandvik Mining would remove the system at no cost.

Cloud Peak Energy chose to have the Sandvik CMS retrofitted onto a 14-yearold rotary drill at its Cordero Rojo coal mine in Gillette, Wyoming. The companies chose this machine because it has been in full production for years, providing a solid reference point for the historic fuel consumption. And though the rig is approaching 60,000 hours, Cloud Peak Energy expects to keep the machine in production for years to come, giving time to track the progress of the CMS over time.

Sandvik Mining estimated that the CMS would save 23 per cent of fuel. Once the system was installed and calibrated, Sandvik Mining technicians used the Engine Control Module (ECM) data as a reference point.

United States, Cloud Peak Energy specializes in the production of low sulfur, subbituminous coal. The company is comprised of properties acquired from several other companies throughout the years, and it is recognized for its exemplary performance in its safety and environmental programs.

So, when Sandvik Mining was looking for a new partner to prove its CMS technology in the United States, Cloud Peak Energy was an obvious and ideal choice.

New Mining Technology

Installation When the trial was proposed, Cloud Peak Energy was interested in the benefits but questioned if the system could actually save 25-30 percent of fuel savings. Sandvik Mining representatives were confident the CMS would deliver, and they knew Cloud Peak was the right partner to prove this product, so they took an unconventional approach – they offered Cloud Peak Energy a one-time guarantee. Before installation,

Exceeding expectations Before the installation, the drill was using 22.9 gallons of fuel per hour. After running the Sandvik CMS for five weeks, the rig was only using 16.9 gallons per hour – a reduction of 26.2 per cent. This cut translates to savings of approximately 24,000 gallons of fuel*, $108,000* and more than 300 tonnes of carbon emissions* annually – on fuel alone. With the Sandvik CMS, Cloud Peak Energy will save thousands of dollars on fuel every year. Additional savings are expected from increasing the engine life.

The Cloud Peak Energy drill operator cited that the most significant difference in fuel savings could be seen when he was changing out steels or tramming to a new hole location. There was also a noticeable difference in how the CMS helped start the machine in cold weather – conditions which operators at the Wyoming location are no strangers to. Pleased with the trial results, Cloud Peak Energy purchased two new Sandvik drill rigs for 2013 with Sandvik CMS installed.

NMT *based on 4,500 hours of operation and $4/gallon

To learn more about Sandvik Mining equipment and tools, service and technical solutions for the mining industry, visit www.mining.sandvik.com.

Spring 2014 15

Feature

FIBER OPTICS FOR

HARSH MINING ENVIRONMENTS

I

n subterranean mining operations, access to communication networks deep underground is critical for transporting data, voice, and video, and other supporting applications that are essential for efficient and safe operations.

Whether accessing sophisticated ERP or Maintenance Management Systems, engaging in fleet management, video surveillance, or access control, or protecting miners with wireless locator systems, these networks serve as a literal lifeline between workers deep within mines and surface operations.

For this, mining networks require more than permanently installed network cabling, it also requires unique deployable systems designed for quick installation, extension and even relocation as the active mine site area moves, or equipment is moved in and out.

Ruggedized Fiber Optic Systems Given the increasing bandwidth requirements and concerns about electromagnetic interference (EMI), fiber optic cable is quickly replacing the more traditional choice, copper. Designed to survive the rigors of a mining environment, this extremely ruggedized cabling can withstand everything from dust and

16 Spring 2014

debris to chemical exposure, temperature extremes, radiation, electrical power transients, interference, fire, moisture, humidity, water, crush, tension, flexing, impact, and vibration.

The fiber optic cable, however, is only a component of a complete, deployable system, explains Rick Hobbs, Director of Business Development at Optical Cable Corporation (OCC). OCC is a company that designs and manufactures fiber optic cabling, connectors and assemblies for harsh environments such as mining.

According to Hobbs, other key elements include hardened cable jacketing; “genderless” connectors for quick deployment without regard for male or female ends; and hybrid options that include copper along with fiber to provide power for underground Wi-Fi networks.

Hardened Cabling For locations that require compliance with MSHA’s Part 7, Subpart K of Title 30 of the Code of Federal Regulations (CFR) signal cables mining applications, OCC typically recommends its MSHA-rated B-Series Breakout Cable.

MSHA cables are designed to withstand the rigors of difficult pulls, high tensile loading and severe crush occurrences and New Mining Technology

can repeatedly endure the abuse associated with the extreme demands in surface and sub-surface mining.

The B-Series Breakout Cable is one of OCC’s most rugged, high strength cables.

Each individual, color-coded sub-cable has its own tight-buffered coating to protect each fiber.

In addition, these cables have a tightbound outer jacket, which is pressure extruded directly over the cable’s core.

This combination of a helically stranded core, and a pressure extruded outer jacket provides an overall cable construction that offers crush and impact protection and increased tensile strength.

“The Breakout Cable is essentially a double-jacketed construction,” says Hobbs.

“Instead of 900 micron buffers and an outer jacket, each of the 900 micron buffers has a 2.5 millimeter sub-unit protecting it.”

As an alternative, if cost is an issue and the conditions warrant it, MSHA-rated distribution style cabling is an alternative.

This cable is also extremely rugged, featuring the helically stranded core and extruded outer jacket, but not the additional 2.5mm sub-cable for each fiber.

According to Hobbs, other MSHArated cable designs are available, offering escalating degrees of cable protection to meet the specific needs of an application.

These include alternative jacket materials, such as PVC and polyurethane, which are specifically tailored to meet the mechanical and environmental needs of the application. Additional options within each cable type include jacket materials for applications requiring lower coefficient of friction, chemical resistance, and temperature flexibility for both low and high extremes. Water tolerant options are also available that take advantage of the qualities of tight buffered cable and super absorbent polymer aramid yarn.

Hybrid Cables, Connectors For applications that can benefit from fiber optics and copper, hybrid cables offer both within the same cabling sheath.

A distinct advantage of a hybrid cableconnector solution is that the customer can bundle both the high performance of fiber with the copper power or control signal in one cable. This reduces the number of cables that must be designed, purchased and deployed into a system.

New Mining Technology

Fibre optic cable systems have many applications including this installation at the Daytona Speedway in Florida.

Hybrid cabling also facilitates installation of wireless access points underground.

Unlike traditional wireless networking devices that require 110-Volt AC power for each device, with a hybrid system 12vdc or 48vdc power can be supplied in the same cable to power wireless routers, as well as other electronic devices.

As a result, certified devices are able to communicate throughout the network, including devices such as VOIP devices and IP Cameras.

This provides personnel, even deep within mines, with the means to communicate with each other and even make calls outside the mine.

Wireless systems also play a key role in providing post-accident miner locator tracking and two-way communications, a requirement of the Mine Improvement and New Emergency Response Act of 2006.

Some of the available tracking systems involve small, wearable radio frequency identification (RFID) locator tags that can be attached to miners or a piece of equipment. These tags communicate with wireless access points or nodes placed in strategic locations throughout the mine to pinpoint their location.

Genderless Connectors “Genderless” connectors, designed for quick deployment, are able to connect with one another allowing the user to connect fiber optic cables without regard for male of female ends.

Companies such as OCC have further simplified the genderless design with user friendly mating interfaces (the company’s EZ-Mate family) capable of “blind mate” and/or applications that require thousands of mating cycles.

The connector system is designed to resist extreme harsh mechanical and environmental conditions including high vibration, mechanical and thermal shock, and fluid immersion.

With genderless connectors, multiple identical cable assemblies can be daisychained together over a distance of up to several kilometers while maintaining polarity. Polarity can be an issue when connecting an odd number of traditional male to female gender connectors. In such cases, additional connectors, which add signal loss, are required to correct polarity.

In high traffic areas where the risk of damage to installed cabling is elevated, spare assemblies, fitted with genderless connectors, can be stored to allow for fast and easy replacement with minimal interruption to operations.

Increasing Conversion to Fiber Optics According to Hobbs, there are many mining companies that are converting to fiber optics as the costs for components continue to drop, making fiber a better solution than copper in most applications.

Even die-hard copper devotees are moving to fiber and when they do, they rarely look back.

“When System Engineers realize the increased bandwidth opportunities afforded by installing a fiber network, they usually expand their requirements, and identify creative new ways to utilize the technology to provide innovative solutions for their applications,” says Hobbs.

NMT For more information about deployable fiber optic system for harsh environments, Visit the web site www.occfiber.com.

Spring 2014 17

Feature

CUTTING

COSTS Paints and Coatings can help owners protect equipment and save money

By John Reiser*

T

he production processes that are developed in the mining and minerals industry are manufactured to be exposed ​​in very aggressive environments. Chemical and abrasion on structures and equipment, regardless if they’re made of steel or concrete, are subject to significant deterioration. This causes damage and added high cost to the operation that can be reflected in the destruction of equipment and structures in the arrest of the production process which becomes very costly. Also potential personal misfortunes with accidents, which would require large sums of compensation for an employee, thus directly harming the image of the mining operation and company.

Manufacturers of paints and coatings worldwide that have major centres for Research and Development (R & D Labs) distributed globally in its international subsidiaries have developed high-tech products for durable protection from the elements, structures and equipment used in the mining industry. The difference between these paintings and coatings and what we normally know as conventional paints (e.g. those called domestic or decorative or those for light duty purposes, etc.), is its chemical composition, structured around polymeric components, highly resistant chemical and physical properties in extreme conditions to which they are exposed. With this, and only this, we see longer life of components, equipment and structures used in the production processes of the mining industry.

18 Spring 2014

New Mining Technology

Today, in addition to the important features described in the previous paragraph, some of the paints and coatings dedicated to this highly modernized process, have invested large sums of money in developing new products that add operational elements to the painting process. These coatings provide added value and significant performance to a company’s mining operations and that we can describe in three fundamental concepts:

1 Paint 100% solids, which are paints or coatings whose composi-

tion does not contain volatile solvents, which allows utilization of the total contents of the container and application of the thicknesses required in fewer layers (hands), thereby saving time and cost of labour in the process of painting or coating equipment for a mining facility structure. In addition to this, there is clearly a quantitative reduction in the emission of pollutants (organic solvent) to the environment, which makes these materials considered ecologically desirable. Many new paints or coatings are now manufactured with “HAPS” Free Solvents, (Hazardous Air Polluting Solvents). Also non-photo chemically reactive coatings are becoming more desirable as well with increasing restrictions on coatings throughout North America.

2 Paints and coatings which are fast drying allows expedited handling of pieces in the painting process with less time,

thereby reducing the retention periods of these components in steel fabrication facilities. Components which are manufactured as well as in the maintenance processes provide a significant decrease in time that equipment and structures will become un-operational in the mining operation. This reduction in detention time thereby reduces process costs.

3 Rapid Return to Service (RRS), this concept, complements the

previous two mentioned and allows equipment or painted structures operational in a very short period of time. This concept compared to traditional paints will obviously provide a benefit to the mining and minerals process.

As you can see, Industrial Paints and Coatings have placed focus in the mining and minerals processes. Developing products with new technologies is an extremely important activity.

These new technologies are working to provide the client an exceptional paint/coating for their special processes, which enables the mining and minerals industry to continue working with minimal shut down time and without suffering damage to their facilities or expensive costs and increases profits. * John Reiser is Mining Market Focus Manager, North America, for The Sherwin Williams Company.

(An ISO 9001-2008 Company) Leaders in “Solids-Liquid Separation Technology” Leading manufacturer of equipment for Liquid - Solid Separation like Thickeners, Horizontal Vacuum Belt Filters, Rotary Vacuum Drum Filters, Clarifiers, Classifiers etc., for Mineral Processing, Chemical Processing, Food Processing, Refining, Pulp and Paper, Power Plant, Municipal & Industrial Water and Wastewater Treatment Regd. Office: “Ramakrishna Buildings” 239, Anna Salai, Chennai 600 006, INDIA Ph.: +91 44-2855 5171 / Fax: +91 44-2855 5863 E-mail : ekcp@vsnl.com Website: www.ekcp.com

New Mining Technology

Spring 2014 19

Products

MULTI-PURPOSE DOMES MegaDome is pleased to showcase two of its portable units being used for various applications. The building (inset below) is an insulated, XP60 MegaDome structure, sold to Cliff Natural Resources for the Bloom Lake site that will serve as a repair/ washing shop for machinery and the main photo shows an insulated, XP40 MegaDome structure, sold to Tata Steel in Schefferville, to house concrete manufacturing facilities and store aggregates.Â

TRACK DRILL

Caterpillar announces its new MD5150C Track Drill, the first of the C Series drills, designed for drilling holes from 4 inches (101.6mm) to 6 inches (152mm) in diameter. The MD5150C offers a choice of three different rock drills, patented carousel rod changer, ergonomic cab and many other features that boost productivity and reduce operating costs. Compared to the MD5125, which the MD5150C will replace, the new drill has 18 per cent more power, a compressor that can deliver 33 per cent more air volume and 40 per cent more air pressure, 19 per cent faster tram

20 Spring 2014

speed and 40 per cent greater ground clearance.

The rock drill also features an automated lube system, which eliminates the need to stop the machine for manual greasing every two hours.

The MD5150C dramatically reduces setup time, thanks to its innovative carousel rod changer.

The system holds six rods and accommodates two lengths and multiple diameters of drill steel.

Powerful dual-rod grippers and a unique gate design let the rod and gate move simultaneously, reducing cycle time.

New Mining Technology

Products

VIBRATING WIRE Major Wire Industries Limited now offers a full line of new 1-foot x 2-foot (305mm to 610mm) Flex-Mat 3 Self-Cleaning Modular screen media panels. This new screen media size fits virtually any flat-surface screen deck, so screening operations using traditional 1-foot x 1-foot (305mm x 305mm) and 1-foot x 2-foot polyurethane and rubber panels can increase their

New Mining Technology

existing screening capacity and in-spec material throughput up to 50 percent. Screening operations can choose between pin-, grooved-, snap- and step-types in opening sizes of 30 mesh, or 0.0197 (0.5mm) inches, up to 1.575 inches (40mm).Both Flex-Mat 3 Modular’s 1-foot x 1-foot and 1-foot x 2-foot panels provide up to 50 per cent more screen media open area than

traditional rigid polyurethane and rubber panels.

In addition, each new 1-foot x 2-foot Flex-Mat 3 Modular panel increases total screen media open area by up to 55 per cent when compared to using two traditional 1-foot x 1-foot polyurethane or rubber panels to cover the same screen deck area. No screen box changes are necessary to switch to the larger panels.

Spring 2014 21

Products

IMPACT CRUSHER

IROCK Crushers is pleased to announce the availability of its TC-20 Track Impact Crusher, featuring a larger feeder, a high-performance four-bar impactor and heavy-duty components. The TC-20 produces a uniform, cubical product, and the machine’s hydraulically adjustable aprons provide better control over sizing. The unit has the versatility to process soft to medium rock, recycled concrete and recycled asphalt. The rotor measures 40 inches by 56 inches and can process a variety of materials up to 24 inches in diameter. A

440-horsepower Caterpillar® C-13 Tier 3 engine powers the crusher, which can process up to 500 TPH. The track crusher features a fixed, Hardox hopper with a 15-cubic-yard capacity. It is paired with a 52-inch by 16-foot vibrating grizzly feeder, which has ¾ inch liners on the pan and side walls. The feeder is up to 3 feet longer than comparable units, making it possible to feed material with a large wheel loader.The TC-20 features a standard crusher bypass chute to reduce unnecessary wear on the crusher.

Cone Crusher

Telsmith has just launched its T400 Cone Crusher that is designed to deliver 300 kW performance and a crushing capacity output range from 135 to 545 MTPH. Ideally suited to a variety of tough quarry and mining applications, the T400 Cone Crusher is engineered for maximum productivity, and lower operating costs. For increased uptime and safety, the unit features a large clearing circuit, which is engineered to safely and quickly allow any uncrushable materials to pass. Designed with a maximum feed opening of 305mm, the T400 Cone is complete with a 1321mm diameter head; a 1397mm receiving hopper; replaceable mainframe liners; epoxy-secured manganese steel crushing members and more. To minimize downtime and reduce inventory costs, the T400 enables the use of a single bowl for all liners over its range of operation.

SIL3 Pull Cord Switch System (Approved by TÜV according to EN61508-SIL3 and EN954-1 Cat. 4)

Addressable up to 5km per zone For new or retrofit applications

Real Time Diagnostics No more searching for tripped switches 888.575.2275 www.GavazziOnline.com Gavazzi@CarloGavazzi.com 22 Spring 2014

New Mining Technology

E Q U I P M E N T M A I N T E N A N C E & R E PA I R Bent, Bruised, But not Broken

Those words describe just about every piece of heavy equipment in use today.

In fact, any machine that isn’t “bent” or “bruised” a little probably isn’t a working machine because more than likely, it’s “broken!”

And that’s bad for business.

As every owner and operator knows, downtime can put them out of business and for that reason, Equipment, Maintenance & Repair (EM&R) takes a look at what’s available to help prevent equipment failure.

Tips on equipment, maintenance and repair, plus the latest in products and services, will be featured in the pages of EM&R. Coming this June, EM&R will provide its readers with a ‘new’ look at an ‘old’ problem.

Contact us now to let the mining industry know how you can help maintain their equipment and machinery’s optimum performance levels.

Advertising closes MAy 5.

MAteriAl due MAy 12.

Readership: 25,000**

Canadian Mining Journal

www.canadianminingjournal.com

averages 28,250 unique visitors each month.***

You can view our media kit at: www.canadianminingjournal.com/mediakit AAM Audited Circulation: 10,123* – the only Audited mining publication in Canada. * June 2013 AAM Audit Statement ** Statistics based on responses to our July 2013 readership survey *** Google Analytics October 2013

EquipmEnt maintEnancE & REpaiR a 16 page centre-spread supplement bound within the June/July edition of

Canadian Mining Journal

PleAse contAct: Robert Seagraves rseagraves@canadianminingjournal.com 1-416-510-6891

Bonnie Rondeau brondeau@canadianminingjournal.com – 1-416-510-5245 Toll Free Canada: 1-800-268-7742 extension 6891 or 5245 U.S. Toll Free: 1-800-387-0273 extension 6891 or 5245

Wealth Unearthed Our diverse range of robust electronic delay detonators are designed to cope with the most challenging mining environments

Advancing, constantly evolving and defining the future of electronic initiation technology in the global mining industry Showcasing our cutting-edge products and value-adding services from 21-24 April 2014 at

For more information on AEL Mining Services, contact: AEL Latin America Tel: +562 2928 1300 | Fax: +562 2928 1315 Adress: Av. Nueva Tajamar 481, Of.1601, Torre Norte, WTC 7550099 Las Condes, Santiago, Chile www.aelminingservices.com