Quarry Apr 2019

How do you crush first time, without having to resize or stockpile oversized products?

ECCENTRIC SOLUTION FOR SURFACE EXTRACTION

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TIPS FOR MAINTAINING CRUSHER EFFICIENCY

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

How an eccentric roll crusher has been successfully adapted to the quarrying application.

APRIL 2019

STRIVING FOR THE ELUSIVE WATERMARK Why water infrastructure is the key to a smarter, more resourceful Australia.

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IN THIS ISSUE APRIL 2019

VOLUME 27, ISSUE 04

FEATURES 26 HIGH PRODUCTION JAW DEBUTS IN AUSTRALIA The new Metso Lokotrack LT130E mobile jaw crusher will be launched in Australia later this month.

27 KIMBERLEY PRODUCER TOPS UP HIRE FLEET A contracting business in Australia’s northwest is reporting promising results with two mobile jaw crushers.

34 MORE PRODUCT, LESS REPEAT LOADS

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CRUSHER EFFICIENCY How do you crush first time, without having to resize or stockpile oversized products?

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ECCENTRIC SOLUTION An eccentric roll crusher has been successfully adapted to the quarrying application.

FULL PAGE ADVERTISEMENT PAGE 4

A producer and a supplier have installed a tertiary cone crusher to minimise recirculating loads.

38 FAMILY BUSINESS ‘ACES IT’ WITH UPSIZED SCALPER A family company’s task of satisfying construction materials demand has been eased by the addition of an enlarged scalper to its fleet.

42 IS IT THE END OF THE ROAD FOR ROADS? Roads are vital to our way of life.

Now, they are being transformed by innovative technologies.

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BUY NEW OR REBUILD? Is your crushing plant ready for an upgrade or a complete replacement?

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How do you crush first time, without having to resize or stockpile oversized products?

ECCENTRIC SOLUTION FOR SURFACE EXTRACTION

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TIPS FOR MAINTAINING CRUSHER EFFICIENCY

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18

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

How an eccentric roll crusher has been successfully adapted to the quarrying application.

Quarry April 2019

40

ELUSIVE WATERMARK Why water infrastructure is the key to a smarter, more resourceful Australia.

APRIL 2019

STRIVING FOR THE ELUSIVE WATERMARK Why water infrastructure is the key to a smarter, more resourceful Australia.

16.08.18 16:41

COVER ADVERTISER: Designed initially for mining, the thyssenkrupp eccentric roll crusher has been adapted to quarrying as a workable primary crusher.

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EVERY MONTH 06 FROM THE EDITOR

46 IQA NEWS

08 FROM THE PRESIDENT 10 NEWS THIS MONTH

News from New South Wales, Queensland, and Western Australia

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47 FROM THE IQA CEO

44 IQA CALENDAR

50 GEOLOGY TALK The Great 1906 San Francisco Earthquake

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EDITORIAL

WHY POLLIES COULD LEARN FROM A FUTURE, INSPIRATIONAL VISION

A

nd so it begins …As this issue hits desks, another federal budget will be handed down, followed by a snap election campaign – likely to last a month for a poll date in May. Politicians of all persuasions will hit the hustings – some may even visit your site in high vis gear!

What you can safely bet on is that as much as there are stark policy differences this time between the contenders – on taxation, wages, industrial relations, energy and climate – there isn’t likely to be an inspirational vision, particularly for long-term infrastructure planning.

That’s why Warwick Lorenz’s opinion piece on page 40 is a breath of fresh air.

It advocates a vision of an Australia that in 50 years will have invested in water infrastructure to develop its primary industries, and decentralised and grown its population to make its inland regions more liveable and prosperous, and therefore more attractive to city dwellers and skilled migrants.

It’s an ambitious vision, it isn’t confined to a short-term window (ie the electoral cycle) and it encourages Australia to invest in skilled labour from around the nation and globally. Further it provides leverage for growth of the extractive industries, particularly as quarrying becomes more prominent in the regions.

Lorenz’s article is pertinent given the Federal Government recently announced its population policy – to lower the annual migration intake of permanent migrants from 190,000 to 160,000 in the 2019-20 financial year – while devising new regional visas for skilled migrants.

Unfortunately these measures – designed to appease disgruntled urban voters in state and federal elections – could cancel each other out.

Australian Chamber of Commerce and Industry (ACCI) chief executive James Pearson described the policy as an “economic own goal”. He argued an influx of “younger skilled migrants … delivers economic benefits [and lowers] our average working age”. He added the

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reduction makes it “more challenging [for business], particularly in regional Australia where it is hard to find people with the right skills when and where they are needed”.

quarrymagazine.com

Lorenz’s concept of decentralisation is similar to the ACCI’s position. He contends we could be a population of up to 70 million people by 2070, “spread across the country, with a revived manufacturing sector”, servicing a global market of “11 billion”.

Associate Publisher Angela Han

The challenge will be tapping into the resources that create new water infrastructure, rebuild manufacturing and generate regional employment.

There’s concern in the eastern states now that infrastructure demand is outstripping aggregate supply. Where will the construction materials come from? State governments will need to identify and protect new tracts of land rich with aggregate reserves for future supply, improve the speed and timing of approvals processes for new quarries, and encourage and foster the use and growth of recycled aggregates to maintain road, rail and building infrastructure (see page 11). Businesses need incentives to invest in the regions and to recruit locally and from abroad.

With better planning from governments, and with a full buy-in from stakeholders (the extractive, agricultural, transport, water and energy industries), there is no doubt Lorenz’s vision could become reality. However, it’s a question of political will. Do politicians today have the “ticker” to follow through? Or will we have to wait another generation before the vision is realised?

Good luck in engaging – or politely side-stepping pollies - in high vis gear this month!

DAMIAN CHRISTIE Editor

Official publication of the Institute of Quarrying Australia Publisher Coleby Nicholson

WARWICK LORENZ’S VISION ISN’T CONFINED TO A SHORTTERM WINDOW AND IT PROVIDES LEVERAGE FOR GROWTH OF THE EXTRACTIVE INDUSTRIES.

Editor Damian Christie damian.christie@quarrymagazine.com Journalist Tim Robertson tim.robertson@gunnamattamedia.com Advertising Sales Toli Podolak sales@quarrymagazine.com

Quarry is published by: Gunnamatta Media Pty Ltd Locked Bag 26, South Melbourne, VIC 3205 AUSTRALIA Phone: +61 3 9696 7200 gunnamattamedia.com info@gunnamattamedia.com Design & Production Manager Jo De Bono art@gunnamattamedia.com Accounts Paul Blewitt finance@gunnamattamedia.com Subscriptions info@gunnamattamedia.com Press releases damian.christie@quarrymagazine.com Copyright: All material appearing in Quarry is subject to copyright. Reproduction in whole or in part is strictly forbidden without prior written consent of the publisher.

Disclaimer: The views and opinions expressed by authors are not necessarily those of the publisher. All statements made, although based on information believed to be reliable and accurate at the time, cannot be guaranteed and no fault or liability can be accepted for error or omission.

Gunnamatta Media Pty Ltd strives to report accurately and fairly and it is our policy to correct significant errors of fact and misleading statements in the next available issue. Any comment relating to subjective opinions should be addressed to the editor where the opposing position may be published to encourage open debate.

The publisher reserves the right to omit or alter any advertisement and the advertiser agrees to indemnify the publisher for all damages or liabilities arising from the published material.

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TRAINING PORTFOLIO TO BE EXPANDED FOR SUPPLIER MEMBERS The Institute of Quarrying

W

ith membership such a fundamental part of the Institute of Quarrying, not only in Australia but within all IQs globally, the value of membership is always front of mind for the organisation and decisions made by the IQA board.

On reviewing the membership and analysing the types of roles members hold in the industry, it is evident it is not only quarrying professionals directly engaged in operational or producerrelated roles – quarry manager, operator, weighbridge clerk etc – who see value in their membership, but also many of the suppliers who contribute significantly to our industry.

Without our suppliers, the organisation most likely wouldn’t exist and the industry would be a much different place, with support and advice being harder to come by, let alone gaining access to plant and equipment!

Suppliers make up about 34 per cent of our membership, and the IQA recognises that this segment also has educational and professional development needs.

Having had regular and recent conversations with many of our sponsors and major supplier organisations, the IQA believes it can add value to these organisations and our members through educational opportunities that are both industryand role-specific.

Being able to build relationships and rapport and quarrying practices and processes (“quarrying 101”) are all common requests for training from those involved in supplier or customer relationship roles.

The IQA will work in the coming months to develop content relevant to members in supplier organisations.

Another area of focus for the IQA is addressing recent competency changes, and particularly the difficulty in many states training people and

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Quarry April 2019

Australia

satisfying competencies to fulfil mandatory proficiency requirements.

After our recently announced offer of mandatory competency training for quarry managers in partnership with industry-specific registered training organisations, we have released a tender to identify and secure other training providers to allow a broader delivery to our entire membership.

This will also include modules to assist with exam preparation (where this is required) as part of the attainment of certification for statutory roles.

These offerings have come directly from the membership and we will continue to listen to the needs of our members as we build relevant training content. As I’ve previously mentioned, to inquire or participate in any of our educational offerings, you can contact IQA CEO Kylie Fahey via email: ceo@quarry.com.au I also want to take this opportunity to thank Brad Rooney and the conference organising committee for their dedication and commitment to date to the 2019 national conference. I recently visited the venue in Geelong, the home of the Geelong Cats AFL team, and I have no doubt this world-class venue will provide for one of the best IQA conferences in many years.

The conference theme of “The Future of Quarrying” has set the tone for an exciting speakers’ program. With more than 50 per cent of the exhibitor spaces already sold, I’m confident the 2019 event will be one to remember.

Registrations can now be made online via the IQA’s website: conference.quarry.com.au Have a safe and productive month ahead.

CLAYTON HILL President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au WITHOUT OUR SUPPLIERS, THE INDUSTRY WOULD BE IN A VERY DIFFERENT PLACE.

The Institute of Quarrying Australia’s goals are: 1. To provide world class professional development for the extractive industries.

2. To establish an Australasian Academy of Quarrying.

3. To align service offerings with industry needs.

IQA CONTACTS: Chief Executive Officer Kylie Fahey PO Box 1779 Milton BC QLD 4064 Phone: 0477 444 328 ceo@quarry.com.au Company Secretary Rod Lester Phone: 0408 121 788 rgl@rlester.com.au Finance Officer Gemma Thursfield Phone: 0402 431 090 gemma@quarry.com.au Web Maintenance, Graphic Design, ePrograms, IT Support Ryan Spence Phone: 0422 351 831 ryan.spence@quarry.com.au General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.

NEWS

EXPANDED MIDDLE CREEK SITE COMMENCES OPERATION ‘WE PREDICT UP TO 15 JOBS IN THE NEXT FEW YEARS. THAT’D BE A BIG POSITIVE TO A SMALL COMMUNITY.’ ZAC ROWLANDSON MIDDLE CREEK QUARRIES

Oberon Earthmoving’s Middle Creek Quarries site will produce 150,000 tpa of quarry products and another 100,000 tpa of organic and soil processing.

After years of planning and consultation, Oberon Earthmoving’s expanded Middle Creek Quarries site in Oberon, New South Wales, is ready to ramp up production.

The quarry, which has been in operation since 2010, will increase its throughput as part of the expansion.

Under the terms of the development application (DA), an extra area of 15ha has been approved for development.

However, the first stage of development will only encompass 7ha, according to Middle Creek Quarries owner Zac Rowlandson.

The DA permits the site to produce 150,000 tonnes per annum (tpa) of quarry products and another 100,000 tpa of organic and soil processing.

As previously reported by Quarry, the strongest opponent of the expansion was neighbouring tourist attraction Mayfield Gardens. It is one of the world’s largest privately owned cool climate gardens, located approximately 5km from the site.

In order to alleviate community concerns, Oberon Earthmoving was involved in a conciliation process.

“There were two main parties at the conciliation hearing: Mayfield

[Gardens] and a closer neighbour. We worked through the exact concerns of each, mainly traffic and hours of work, made some concessions and reached an agreement where all parties were satisfied,” Rowlandson told Quarry.

Oberon Earthmoving agreed to plant extra trees, erect some screening and put some measures in place to ensure ongoing consultation.

Throughout the long process, Rowlandson said he’s been encouraged by the community’s support.

“We received a lot of positive support within the local community, both privately and publicly during the approval process. It’s very reassuring and appreciated at a time when things are up in the air,” he said.

“Obviously it depends on the uptake of the product but we predict up to 10 to 15 direct jobs over the next few years and that’d be the biggest positive to a small community.”

Although some time away, Oberon Earthmoving has already made plans for the site’s rehabilitation.

“The rehabilitation is a long way off but we’ve planned it out step by step to improve the final result and to keep the cost reasonable,” Rowlandson said. “The final landform will be free draining and re-established pastures for grazing with planted areas using native trees and shrubs.” •

CONVEYOR SUPPLIER EXPANDS INTO APAC REGION Kinder Australia has launched a new international website to expand its business into the Asia Pacific (APAC) region.

Kinder, which has supported the bulk materials handling industry since 1985, is a renowned supplier and manufacturer of conveyor and bulk materials handling equipment for a variety of industries, including quarrying.

“The vision of continuous productivity, innovation and expansion has been central to our values,” Kinder Australia’s CEO Neil Kinder said. “Our new international website – kinderpac.com – is a big leap for the Kinder K brand. It’s a significant milestone ... and is strategically aligned

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to the company’s global expansion plans. It’s also in response to the growing demands and opportunities presented by the APAC mining, quarrying and extraction industries.”

The website can be currently be read in Indonesian.

“We have commenced with the Indonesian translation as a start and we are planning other languages as part of stage 2, with French next on the list,” Kinder said.

“Our close proximity to the Asia Pacific region, particularly Indonesia, as well serviceability of existing Indonesian clients makes it an ideal country/region to target.”

Kinder’s APAC operations will be

Kinder’s embarkment into the APAC market will be supported by a 3500m² warehouse in Victoria.

supported by its 3500m² warehouse in Braeside, Victoria, in addition to planned local distribution networks. The warehouse stores more than 8000 conveyor hardware components and accessories. •

GRANTS FOR INNOVATIVE ROAD SURFACE PROJECTS Recycled concrete, glass, plastics and rubber could assist in the future construction of walkways and roads.

Boral has received an award for its use of specialist learning technology designed to improve capability and compliance and, ultimately, make workplaces safer.

The Victorian Government has announced $1.5 million worth of grants this year for innovative road surface projects by construction materials companies, local councils and higher education institutions.

The announcement was welcomed

by Ken Slattery, CEO of the industry’s peak body Cement Concrete and Aggregates Australia (CCAA). He said the public grants were on top of millions of dollars that had been contributed directly or in kind by CCAA members to the initiatives.

“As an industry that contributes over $15 billion to the national economy, we are committed to the use of recycled materials where viable ... to minimise the pressure on the sourcing of raw materials,” Slattery said.

“Many of the projects ... are at the forefront of research and development initiatives globally, and we welcome [the Victorian Government’s support].”

As part of these grants, the Victorian Government will contribute $200,000 to the next stage of work undertaken

An asphalt premix containing a high density plastic, courtesy of Alex Fraser Group.

by Boral Limited with RMIT University, Melbourne, on a premix concrete that uses recycled plastics and rubber.

A project by the University of Melbourne and Downer EDI Works, which is trialling a permeable pavement, using recycled concrete, brick, glass, plastics and rubber, under real traffic conditions, has been awarded $176,000.

Slattery said the grants recognised that concrete is a highly versatile, cost-effective construction material and that the concrete industry is a major consumer of other industries’ waste and by-products, which can be used as fuel and supplementary materials in the production process. •

TASMANIAN OPERATION SEEKS TO RAISE PRODUCTION The Scottsdale Quarry in northeast Tasmania is applying to increase its annual production. Venarchie, a division of Fulton Hogan Industries, has operated the Goanna Road site, in North Scottsdale, east of Devonport, since 2006.

“The primary reason for this application is that Venarchie would like to screen all of the extracted sand on site and this requires Level 2 activity approval,” Venarchie’s contracts administrator Allison Madson told Quarry.

“Venarchie currently has Level 1 activity approval with Dorset Council to extract up to 5000m3 per annum and screen up to 1000m3 per annum on site.

“Level 2 activity requires approval

BORAL LEARNING TOOL RECEIVES COMMENDATION

from both Dorset Council and Environmental Protection Authority Tasmania (EPA). Level 2 activity allows the extraction of up to 20,000m3 (28,000 tonnes) per annum of sand and also allows for the screening of this amount of sand on site,” she said.

If the application is successful, the quarry will be operational seven days a week from 2020. It is anticipated there will be 966 truckloads - or 1932 movements - annually.

The awards from US-based independent research and analyst firm Brandon Hall Group recognise organisations that successfully deploy programs that achieve excellent measurable results in the areas of learning and development, talent management, leadership development, talent acquisition, workforce management, sales performance and corporate initiatives.

In 2015, Boral started to implement Seertech’s iLearning Plus management system across its 6000 employees in more than 430 sites nationally to track all training records and learning requirements.

“It means we are now able to see what training is expiring and complete on-line training all in one place, while also allowing managers to produce up to date reports and identify compliance and training gaps for their teams,” Boral’s national capability and development manager Giovanna Romeo said.

Bill Fisher, Boral’s executive general manager of human resources, said the award recognised the company’s continuing commitment to further lift safety performance.

“As a leader in the building and construction industry, our highest priority is to ensure our workers are safe, but this can only happen if you have the right training and compliance systems in place,” Fisher said. •

The anticipated life of the quarry, according to Venarchie, is approximately 20 years.

The Tasmanian EPA is assessing the application. The Environmental Effects Report can be viewed at epa.tas.gov.au •

Boral’s Giovanna Romeo with Seertech Solutions’ Dylan Rowe.

Quarry April 2019 11

NEWS

MARBLE SITES UNEARTHED IN THE GREEK ISLANDS Three ancient Karystos shale marble quarries have been discovered on the Greek island of Evia. The Greek Ministry of Culture and Sports announced that the discoveries were made during the installation of new wind turbine parks.

In ancient times, particularly throughout the Roman period, marble was quarried extensively on Evia, the second-largest and closest island to Athens.

The popularity of Karystian marble in Rome saw it used extensively in the construction of monolithic pillars, including those still standing in the Roman Agora. The same stone can also still be seen in famous landmarks in Athens, including at Hadrian’s Library.

When the ancient quarry of Anatoli in Kafireas was unearthed, two main faces of rock that had previously been partially covered with dirt were revealed. The principal rock faces used for mining are at different heights, carved into the side of the mountain.

One of three ancient marble quarries.

Large rectangular blocks were also scattered around the immediate area. Archaeologists at the site spotted two columns under a layer of fine mining gravel. Half of each column had crumbled away into stone chips.

The Trikorfos quarry, discovered nearby, is located high up on a rocky hillside. Archaeologists have uncovered two small rock faces that bear the marks of mining activity.

At a second Trikorfos quarry, there were a number of other structures uncovered, including a small circular object thought to be used for collecting water. It was covered with slate slabs, which could have been for washing mining tools. •

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Quarry April 2019

COMMUNITY CONCERNS OVER QUARRY REHABILITATION THE NSW JRPP WILL HAVE THE FINAL SAY ON THE BELL QUARRY PROPOSAL

The Lithgow City Council has voted to reject a development application (DA) for the rehabilitation of an inactive site at Clarence, New South Wales, based on community opposition.

Council’s objections will be lodged with the NSW Joint Regional Planning Panel, which will have final say on the application.

The proposal is to fill the former Bell Quarry with about 1.2 million cubic metres of virgin excavated natural material, excavated natural material and other clean fill material sourced from earthworks projects across Sydney and the local region.

According to the Environmental Impact Statement (EIS) prepared

by GHD on behalf of Bell Quarry Rehabilitation Project Pty Ltd, the rehabilitation process would involve vehicle haulage at a rate of up to 140,000 tonnes per annum (tpa), emplacement and compaction of soil material within the existing quarry voids, shaping of fill to closely represent the pre-quarry landform, and development of a water management system to control surface water discharges throughout the rehabilitation program and from the final landform.

An aerial shot of the Bell Quarry at Clarence, New South Wales.

The key objectives for the project over a 15 year period would include rehabilitation of the site to a condition more closely representing the original landform and that of the adjoining Blue Mountains National Park and the provision of ongoing local employment opportunities.

Two NSW departments made opposing submissions to Lithgow Council during the planning assessment phase. The Office of Environment and Heritage supports the DA, subject to strict conditions and recommended amendments, while the Environment Protection Agency opposes it. •

NEW DEERE CONSTRUCTION DEALERS APPOINTED AFGRI Equipment has been appointed to distribute John Deere’s construction and forestry equipment in Western Australia, effective as of 1 May, 2019. This follows Hitachi Construction Machinery’s announcement in February that it would cease distributing John Deere’s earthmoving products.

After a relationship that spans 56 years in the agricultural space, Patrick Roux, chairman of the board of AFGRI Australia, said Deere was encouraged “to approach us to manage its construction and forestry equipment retail network in the region”.

AFGRI will operate across five branches in WA: Geraldton, Albany, Esperance, Boyup Brook and Perth.

“We will endeavour to look after the construction and forestry customers to the best of our ability, backed by our strong track record and a proven commitment to Western Australia,” Roux said. “We aim to bring the same passion we have for the agricultural sector to the construction and forestry equipment ranges.”

RDO Equipment has been appointed the authorised John Deere Construction & Forestry dealer in the eastern states and the Northern Territory.

According to its website, when RDO begins its distributorship on 1 May, it will “assume the responsibility of supporting more than 1600 machines sold since 2010 in the geographic area [it will be] serving”. •

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NEWS

NEW DISCOVERIES SHED LIGHT ON STONEHENGE Excavations at two ancient Welsh quarries have provided more evidence about the origins of Stonehenge’s bluestones.

According to a University College London (UCL) study, the largest quarry is almost 290km from Stonehenge, on the outcrop of Carn Goedog, on the north slope of the Preseli hills, in Pembrokeshire, western Wales. A team of archaeologists and geologists have investigated the site for eight years to better understand why the bluestones were brought to Salisbury Plain 5000 years ago.

“We’re [keen to find out] what was so special about the Preseli hills 5000 years ago, and whether there were any important stone circles here, built before the bluestones were moved to Stonehenge,” Professor Mike Parker Pearson, from UCL’s archaeology department and the team leader, said.

According to the study in the journal Antiquity, the bluestone outcrops are formed of dolerite pillars that could be eased off the rock face. Neolithic quarry workers needed only to insert stone wedges, made of soft mudstone, into the vertical joints between pillars, then lower each pillar to the foot of the outcrop.

It is believed at least five of Stonehenge’s bluestones came from Carn Goedog but that they would not, as per popular theory, have been transported by sea to Salisbury Plain.

“Some people think that the bluestones were taken southwards to Milford Haven and placed on rafts …” Professor Kate Welham from Bournemouth University said.

“But these quarries are on the north side of the Preseli hills so the megaliths could have simply gone overland all the way to Salisbury xxx Plain.” •

INDUSTRY EXPERTISE SOUGHT FOR MINING THE MOON “AUSTRALIA HAS A NATURAL ADVANTAGE FOR OFFEARTH MINING.” PROF ANDREW DEMPSTER

A team of engineers at the University of New South Wales wants to capitalise on Australian expertise and lead the charge to mine the moon.

In a recent announcement at a Space Industry Association of Australia (SIAA) forum that discussed Australia’s role in the United Nations Moon Treaty, the group outlined steps to put together a multi-university, agency and industry project team to investigate the possibilities of mining on the moon.

“Australia has a natural advantage for off-Earth mining,” Professor Andrew Dempster, director of the Australian Centre for Space Engineering Research at the University of New South Wales (UNSW), said. “We have some of the very best mining research, technology and automation tools in the world, and the largest mining companies.

“While overseas teams have been looking at solving some of the problems behind space mining, our project wants to examine how we could actually get this done, firstly from a practical engineering point of view, but also closing a viable business case.”

In the past three months, there’s been renewed interest in the possibility of mining the moon for water. First, the European Space Agency announced that it plans to start mining for water and oxygen on the moon by 2025. Then, in the United States, a collaborative study was published about commercial exploitation of water from the moon.

Professor Dempster, working with UNSW mining expert Professor Serkan Saydam, hopes to reduce the perceived commercial risk of offearth mining.

The goal is to show that it is possible to create the machinery, mining methods, energy resources and communications required to mine the moon.

The best known commercial application of extracting lunar water is in making rocket fuel. The components of water are hydrogen and oxygen and these can be used to power rockets.

Making rocket fuel out of water on

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Quarry April 2019

An artist’s concept of a possible exploration program on the lunar surface.

the moon could significantly minimise the cost of carrying out space missions. Currently, rockets leaving Earth must carry all the fuel they need, which is enormously expensive. If rockets could refuel in space, they could reach distant locations at a much reduced cost.

“Projects such as this one will help deepen Australia’s expertise in offearth mining and facilitate the growth of the space industry in Australia,” Mark Hoffman, the UNSW’s Dean of Engineering said.

In the next 20 years, the global space industry is expected to grow to $AUD1 trillion. Professor Dempster believes Australia should become engaged with these possibilities early to ensure it has the capabilities to compete in an increasingly competitive market.

“What we need to do is reduce the perceived risk to potential investors, including large mining companies, in a space mining venture,” he said.

In an article for The Conversation, Dempster wrote: “The ultimate aim of space mining is to exploit asteroids, the most valuable – known as 511 Davida – is estimated to be worth $USD27 quintillion (that’s 27 x 1018 or 27 million million million dollars). Another estimate puts that value closer to $USD1 trillion, which is still a lot of potential earning.”

But there are significant commercial risks associated with off-earth mining.

The high level processes are familiar, such as prospecting, mining methods, processing, and transportation, but the specifics of doing those things in such challenging conditions – vacuum, microgravity, far from Earth, and so on – are not. •

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REDUCED CYCLES TIMES, MAXIMISED PERFORMANCE The Loadmaster Alphaα100 is a CAN-based loader scale system that combines the latest sensor technology and signal processing techniques to deliver precise, consistent weight information. Accurate weighing data enables operators to load correctly the first time, eradicating return trips to the stockpile and reducing vehicle movement, fuel usage and machine and tyre wear.

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LATEST TECHNOLOGY, COMBINED WITH POWER, COMFORT Volvo CE’s L350H wheel loader can be customised with three hydraulic modes depending on the operator’s preferred responsiveness – soft, normal or active. The Comfort Drive Control enables the operator to steer the machine from a small lever, which is particularly effective for fast-paced truck loading operations. The uniquely designed eco-pedal applies a mechanical pushback force in response to excess use of the accelerator, thus encouraging economical operation, reduced machine wear and increased fuel efficiency.

More information: CJD Equipment, cjd.com.au

16

Quarry April 2019

To submit new product and equipment releases, email: damian.christie@quarrymagazine.com

DUAL TILT DOZER FOR MORE PRODUCTIVITY Komatsu’s D475A-5EO heavy-duty dozer features an automatically controlled hydraulic drive radiator-cooling fan, which reduces fuel consumption and noise levels. The turbocharged after-cooled diesel engine provides an output of 664kW and is also EPA Tier 2 emissioncertified. The automatic lock-up torque converter saves fuel and increases speed and power transmission efficiency on long pushes. The D475A-5EO can be customised as a dual tilt dozer to further increase productivity, while also reducing operator effort.

More information: Komatsu Australia, komatsu.com.au

BREAKER WITH IMPROVED TOOL GUIDANCE The Montabert V65 features overflow protection, blank firing protection, automatic frequency adjustment and a hydraulic accumulator to ensure ease of use. It can automatically adjust its working frequency of up to 15 different speeds, even when set to minimal flow, resulting in improved productivity. Thanks to an exclusive patented system, the upper bushing absorbs any torque force transmitted to the tool by the material.

More information: Montabert, montabert.com

LOWER OPERATING COSTS, IMPROVED DURABILITY The Caterpillar 950 GC loader is well suited for stockpiling, load and haul work, hopper charging and truck loading. It features Z-bar loader linkage, which provides assertive digging capabilities, high breakout forces, and lift and reach capability to handle a wide range of loading applications. The 170kW, EU Stage IIIA Cat C7.1 engine features a new fuel-injection system.

The Engine Idle Management System and on-demand electronically controlled, hydraulically driven, variable-speed cooling fan further optimise fuel efficiency while lowering sound levels.

More information: Caterpillar Australia, cat.com/en_AU.html

STEEL REPAIRS MADE EASY The K-Magna-Patch is a reusable, magnetically fastened polymer patch that provides cost-effective instant repair to steel equipment. It is a quick and secure means of repairing holes in steel pipes, elbows, silos, chutes, bins, hoppers and other steel equipment subjected to abrasion.

Using a rubber pad on the inside against the area to be sealed, the K-Magna-Patch provides a quick, efficient solution to leaks, allowing the user to keep production going until a scheduled permanent repair date.

More information: Kinder Australia, kinder.com.au

Quarry April 2019 17

CRUSHING

TIPS FOR MAINTAINING EFFICIENCY IN CRUSHING CIRCUITS

Today, the demand for highly specified aggregates means smaller top-sized products are finer than in the past. This means the crushing application has to be just as precise. What are the best tips for crushing materials at the first go, without resizing or stockpiling oversized products?

E

fficiency can be defined by the ratio of work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding.

In the past, quarries produced a range of single-size aggregate products up to 40mm in size. However, the trend for highly specified aggregate has meant products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20mm; it is not unusual for material coarser than 10mm to be stockpiled for further crushing.

The following are tips and best practices to keep your site crushing efficiently and reduce the number of fines produced.

JAW CRUSHERS A jaw crusher is a compression-type of crusher. Material is reduced by squeezing the feed material between a moving piece of steel and a stationary piece. The setting or the space between those two pieces of steel controls the discharge size. The tighter the setting, the smaller the output size and the lower the throughput capacity. Jaw crushers are mainly used in primary crushing; they are rarely used as a secondary crusher.

As compression crusher, jaws generally produce the coarsest material because they break the rock by the natural inherent lines of weakness. A jaw crusher can be an excellent primary crusher when used to prepare rock for subsequent processing stages such as washing, classifying or a secondary crusher.

General efficiency tips • Grease lubrication systems are preferred over an oil-lubricated system.

• An annual radial clearance check of the mainframe bearing should be recorded to track bearing wear.

• Minimum discharge setting should not exceed full load amps.

18

Quarry April 2019

A jaw crusher can be an excellent primary crusher when used to prepare rock for subsequent processing stages.

• Do not crush oversize material against the barrel of the jaw. That area is not considered part of the crushing chamber.

• Periodic oil sampling of the bearings is advised, when oil lube is used.

• The discharge conveyor and under crusher hopper should be wider than the discharge width of the crusher.

• Sufficient tension must be placed on the toggle plate to ensure proper alignment.

Efficiency tip Try to choke-feed any compression-type crusher. Remember, we are using gravity and the weight of the material to push or force material through the chamber. Since in a compression machine the material breaks to fill the air pockets or voids in the chamber, a non-choke chamber will produce a slabbier output than a choke-fed chamber.

Feeding for efficiency Jaw crushers are routinely choke-fed, as this

maximises production capacity and ensures particles are uniformly broken. This promotes stone-on-stone crushing, which breaks up flaky or slabbier particles. If you are seeking fewer fines, trickle-feeding material into the jaw crusher could achieve this; however, this would have an adverse effect on particle shape and would also reduce throughput capacity, hindering the crusher’s efficiency.

Ideally, the feed rate should not be switched from choke to non-choke, as this would cause problems downstream at the secondary processing plant. In practice, many jaw crushers are fed in this intermittent fashion due to gaps in the delivery of feed material from the quarry. Jaw crusher feed should be pre-screened using a grizzly screen prior to crushing, to remove material finer than the closed side setting (CSS).

Efficiency tips In practice, many jaw crushers are not fed to their design capacity; this is because the

Australia’s leading designer and manufacturer of rubber torsion spring motor bases. subsequent processing plant does not have sufficient capacity to handle the volume of material that would be produced if the jaw crusher were working to capacity.

Crushing setting: Efficiency Ideally, the reduction ratio of a jaw crusher should be 6:1. There are different ways to calculate reduction ratio, but the best way is something called the P80 factor. The reduction ratio is then calculated by comparing the input feed size passing 80 per cent versus the discharge size that passes 80 per cent. The finer the CSS, the greater the proportion of fines produced. The CSS of a jaw crusher helps determine the nip angle within a chamber, typically 19 to 23 degrees. Too large an angle causes boiling in the crushing chamber; this is where the jaw plates cannot grip onto the rock and it keeps slipping up and down, avoiding being crushed. The nip angle gets flatter as the machine is set tighter.

The settings on a jaw crusher are designed to produce material ideal for secondary crushing. The best particle shape is typically found in material about the same size as the CSS. Smaller sizes will contain a higher proportion of elongated particles because they have passed through the crusher without being touched. Larger sizes may also contain a higher proportion of elongated particles, as they are further from the CSS, which can cause bridging issues in downstream machines. The bottom line is that the best particle shape and performance comes from a choke-fed chamber.

CONE AND GYRATORY CRUSHERS Cone crushers and gyratory crushers are also compression-type machines that crush material between moving and stationary pieces of steel. The setting between the two pieces of steel controls the output. Though the chamber is round in shape, the moving piece of steel is not meant to rotate. Instead a wedge is driven around to create compression on one side of the chamber and discharge opening on the opposite side. Cone crushers are used in secondary and tertiary roles as an alternative to impact crushers, when shape is an important requirement but the proportion of fines produced needs to be minimised. Even though the reduction in fines produced may be only a few percentage points, this could represent a significant amount of material in a large operation and, ultimately, increase an operation’s bottom line and profitability.

General efficiency tips • Be especially careful that a cone crusher does not get ring bounce or chatter.

• Variable flow controlled by level sensors will ensure consistent feeding and maintain a full crushing chamber.

• Low oil temperature should prevent operation of the unit.

• High oil temperature should stop the crusher feed and allow the unit to cool down. After the machine has cooled, further investigation of the high temperature condition is needed before the machine is operated again.

• No oil flow should prevent operation of the unit. If the condition occurs during operation, the feed should be stopped immediately, with the crusher stopped 30 seconds later.

• Gradations of cone feed and crusher discharge must be monitored as a crushing/reduction performance indicator and as a liner wear indicator. This should be done at least once a month, and more often if required at the site.

• Daily inspections below the crusher should be made to ensure

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no bridging, plugging or foreign material is under the crusher.

Efficiency tips Increasing the CSS in an attempt to reduce the amount of fines produced may have the opposite effect; it may lead to a greater proportion of oversized material, which would need re-crushing in the remaining crushing circuits and would ultimately lead to a higher proportion of fines being produced. The further in the crushing process, the greater the amount of fines produced.

A McLanahan cone crusher.

feed to assist crushing action. More than 10 to 15 per cent will likely cause ring bounce due to the pressures in the chamber.

It is critical that a cone-type crusher be choke-fed to produce the best product shape and quality. It is not as important in a jaw, as material is not generally stockpiled after the jaw. Since the cone is in the secondary and tertiary stations, particle shape assisted by a choke-fed chamber is important, as it creates finished products in these stages.

Feeding for efficiency Uniform distribution of feed material around the cone crusher inlet is a good practice.

This allows production of a consistent product, as well as efficient, reliable operation of the crusher. Choke-feeding is important for cone crushers because it maintains a good particle shape by facilitating an inter-particle crushing action.

Trickle feeding is not the best option because it increases the proportion of flaky material in the crusher product, hindering its efficiency.

It is a good rule to maintain about 10 to 15 per cent of material finer than the CSS in the

Efficiency tip Pre-screening of the feed to remove the fines, especially in tertiary crushing, is a good practice; it helps to avoid packing of material in the chamber while maintaining an efficient, effective crushing action and increasing your crusher efficiency.

Crushing setting: Efficiency The liner profiles are designed for a range of product sizes, from extra coarse (EC) to extra fine (EF). The EF liner profile will result in the highest fines proportion for a given cone crusher. It is important to find the right liner for the feed gradation and desired product. If the liner is too large, feed material will drop too far in the chamber before being crushed. Too fine a liner will prevent material from entering the chamber at all.

Monitoring the crushing force as registered

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Hydraulic Excavators By routinely choke-feeding jaw crushers, producers promote stone-on-stone crushing, which breaks up flaky or slabbier particles.

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through the load on the crusher motors, as well as the pressure on the hydraulic mantle adjustment mechanism, will give forewarning of crusher packing problems before they affect your efficiency.

Efficiency tip The finer the CSS, the greater the proportion of fines produced.

The finer setting also lowers throughput volume. It is important to match the CSS of the crusher to the top size of the product to be produced. If the circuit is being closed at 25mm (1”) to produce a 25mm minus product, the crusher should be set at, near or slightly below 25mm.

IMPACT CRUSHERS An impact crusher uses mass and velocity to break down feed material. First, the feed material is reduced as it enters the crusher with the rotating blow bars or hammers in the rotor. The secondary breakage occurs as the material is accelerated into the stationary aprons or breaker plates. Impact crushers tend to be used where shape is a critical requirement and the feed material is not very abrasive. The crushing action of an impact crusher breaks a rock along natural cleavage planes, giving rise to better product quality in terms of shape. The quality of these products makes them ideal for use in highly specified road, stone and concrete aggregate applications.

General efficiency tips • Primary impactors should be of a solid rotor-type to reduce maintenance costs.

• Impactors should have a connected wattage sufficient to ensure 110 per cent utilisation. Crusher applications, speed and setting are the factors affecting this.

• Impactors should be consistently fed, based on the amperage drawn.

• Impactors should be fed evenly over the full width of the rotor.

• Precise calculations are needed to achieve the correct material penetration into the rotor.

• The efficiency of a secondary or tertiary HSI decreases with the mass and size of the material. The smaller the size, the less effective the crushing.

Efficiency tip Establishing the proper rotational speed of the blow bars or hammers is critical for efficient reduction and production. Also, the angle of the feed plate that introduces the feed material to the rotor assists in the efficiency of the machine. Improper rotor penetration will result in decreased performance.

Feeding for efficiency Size reduction in an impact crusher relies on energy being conveyed into the rock from the rotor, and it begins with your feed.

The initial impact is responsible for more than 60 per cent of the crushing action, with the remainder made up of impact against an

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CRUSHING

adjustable breaker bar and a small amount of inter-particle collision. This is why it is vitally important that the feed arrangement to an impact crusher ensures an even distribution of feed material across the full width of the rotor. This will allow for even distribution of energy into the feed material and uniform wear patterns, ensuring consistent product gradation and power consumption.

Efficiency tips Even feed will ensure the impactor wears uniformly and continues to meet product specifications and ultimate efficiency.

Establishing the proper rotational speed of the blow bars or hammers is critical for efficient reduction and production. Also, the angle of the feed plate that introduces feed material to the rotor assists in the efficiency of the machine. Improper rotor penetration will result in decreased performance.

Crusher setting: Efficiency Size reduction and, ultimately, the crusher

setting are directly proportional to the rotor speed; it largely dictates how many fines are produced. Slower rotor speeds can be used as a means of reducing fines, but may result in a product with more oversize or return than is wanted. Slower rotor speeds are preferable as a means of minimising the wear on crusher components and for achieving less fines production and optimal product size.

The product grading from an impact crusher will change throughout the life of the wear parts, particularly the impact hammers or blowbars. As the profile of the hammer changes with increased wear, the product grading becomes coarser. Many modern impact crusher installations have a variable speed drive arrangement that allows an increase in the rotor speed to compensate for wear on the impact hammers.

In many impact crushers, a third curtain or crushing chamber can be added to increase reduction in every pass through the machine. This can be important in finer product applications, where the third

chamber can provide the desired output gradation. A third chamber that increases the reduction will also increase the power needs and, normally, the wear cost.

Efficiency tip Decreasing the gap between the hammers and impact curtain increases particle retention in the chamber. This increases the size reduction ratio; however, it also reduces efficiency throughput capacity and increases fines production.

Crushing efficiency begins with common crusher knowledge. Once you have a machine – a jaw, cone/gyratory or impact crusher – how you feed it and how you set it will affect its efficiency. By taking many of the steps outlined above to achieve the best crushing outcome, producers can reduce the amount of fines they produce and save more dollars for their pockets. • Source: McLanahan Corporation

CRUSHING

A thyssenkrupp ERC 25-25 test plant at a hard rock quarry in Germany.

AN ECCENTRIC SOLUTION TO THE PRIMARY CRUSHING CONCEPT Designed initially as a smaller option for miners in underground primary crushing operations, the eccentric roll crusher can be adapted to the quarrying application as a workable primary crusher in mobile operations above ground.

C

ompact but powerful, ultra-productive with excellent crushing performance, highly energy efficient and well balanced.”

These are attributes featured in promotional literature describing the new eccentric roll crusher (ERC) from thyssenkrupp Industrial Solutions.

The supplier says the ERC redefines the concept of primary crushing hard rock.

As such, it is suited not only for use in underground operations but also in open pit mines and quarries, where its qualities are particularly useful in semi- or fully mobile operations.

For decades, gyratory and jaw crushers have proved their worth in crushing hard rock.

However, their application is limited by their high headroom, requiring capital-intensive construction of large-scale, costly caverns when used in underground operations.

Moreover, in open pit operations they are only partially suitable for mobile use because of design-related residual imbalance-induced forces.

Although low-headroom crushers such as double roll crushers and sizers have become established as primary crushers in the industry, design constraints mean they

are not considered capable of efficiently and economically processing hard rock.

The new ERC, with its patented design of pre-screening and crushing features, combines a compact design and the ability to crush hard rock with high throughputs in an energy-efficient manner.

OPERATIONAL BENEFITS The ERC offers significant operational benefits. Its installation height is between 20 and 55 per cent lower than similar-performing gyratory or jaw crusher options, in an overall lighter package.

At the same time, the ERC is highly productive and energy-efficient. Its kinematics with a constantly large stroke promote a more profound crushing intensity and higher throughput rates.

High inertia moments in the roll and flywheels enhance the ERC’s energy efficiency. Its integrated pre-screening device allows for efficient bypassing of fines to significantly reduce power consumption, compaction risk and the wear rate of crushing tools.

The steady rotation of the freely rotatable crushing roll, when exposed to feed material, results in exceptionally uniform wear and

high utilisation of crushing tools.

The symmetrical arrangement of the eccentrically moved crushing roll allows for easy balancing, so foundation forces and vibrations are reduced to a minimum. As a result, the ERC is particularly suitable for use in semi- or fully mobile applications.

Smart control is another decisive advantage. Thyssenkrupp’s patented hydraulic gap setting/retraction system allows for safe and simple automatic adjustment of the gap, liner wear compensation and release of tramp metal or other non-crushable material content.

Further, the ERC is equipped for Industry 4.0, incorporating a comprehensive monitoring system that allows for local or remote control and the automation of equipment parameters from the crusher’s display. In addition, an optional thyssenkrupp data acquisition system offers reliable recording and storage of relevant operational data for trouble-shooting, condition monitoring and preventative maintenance.

OPERATING PRINCIPLE Material is fed into the crusher by an apron feeder, push feeder or the like. Fine particles in the feed are screened out by the integrated Quarry April 2019 23

CRUSHING

Figure 1. An illustration of accumulated energy in the eccentric roll crusher.

static grizzly and bypassed through the crusher housing.

Coarse particles are transferred into the crushing chamber.

A rotating eccentric shaft, axially guided by two sets of roller bearings mounted in the crusher housing, generates an oscillating movement in the freely rotatable, horizontally arranged crusher roll.

Consequently, the crushing gap between the crusher roll and the jaw in the crusher housing changes continuously, which means the feed material is crushed by compressive forces as it falls by gravity, until the product exits the crushing chamber at the bottom.

The eccentric shaft is driven by a V-belt drive, with the inertia of two flywheels mounted onto the shaft accumulating crushing energy (see Figure 1).

The kinematic principle applied in the ERC ensures the stroke remains the same throughout the entire crushing chamber.

This unique feature significantly increases the comminution intensity compared with commonly used crushers. The jaw itself does not move during the crushing process but is supported by a fully hydraulic gap setting/retraction system with a patented safety device.

This system allows for automatic adjustment of the gap, compensation of liner wear and release of tramp metal or otherwise uncrushable feed material content.

After the detailed design of this roll crusher, a prototype of the machine was built and extensively field-tested in a six-month campaign at a hard rock quarry in Germany.

The crusher model ERC 25-25 selected for this purpose has a crushing roll of 2500mm in diameter and width. The feed opening to the crushing chamber is 2500mm wide and 1230mm high.

Both the coarse and fine run of mine feed were processed, plus selected lumps of up to five tonnes. The equipment parameters were varied with regards to eccentric shaft speed and gap closed side setting (CSS). The corresponding operating data was collected with and without the integrated grizzly.

PILOT PLANT During this pilot operation, average capacities of 2000 to 3000 tonnes per hour (tph) were recorded.

The desired product size of 0-200/x mm was achieved at various settings, with P80 at CSS of 140mm recorded with about 130mm.

The integrated grizzly effectively bypassed fines and contributed between 30 and 40 per cent of the total equipment capacity.

The power consumption at nominal capacity ranged between

200kW and 500kW, depending on crusher settings. However, the high energy efficiency of the ERC was confirmed by the power consumption of 0.1 to 0.2kWh/t.

The ERC from thyssenkrupp offers new standards in the primary crushing of hard rock thanks to features not found in conventional crushers.

This opens up numerous new application areas in the processing of mineral raw materials. The ERC roll crusher series comprises four units, ranging from the ERC 18-14 entry model to the top-end ERC 25-34 model, with throughputs between 600 and 10,000 tph.

The first ERC for commercial operation – the ERC 25-25, capable of generating an output of 8000 tph – has already been sold and will be on show at the bauma 2019 trade exhibition in Munich, Germany in April.

“We are constantly seeking new solutions for our customers that improve crusher availability and efficiency and reduce installation and operating costs,” said Detlef

Figure 2. The main components of the ERC 25-25 crusher.

Papajewski, the head of mineral processing at thyssenkrupp Industrial Solutions’ mining technologies business unit.

“With the new ERC we have developed a technology that is the first of its kind. Its innovative design combines the advantages of conventional primary crushers with solutions to their typical disadvantages, such as large height. As a result, the ERC can be used in underground and surface mining operations and in quarries to process ore and hard rock more effectively.” •

Source: thyssenkrupp Industrial Solutions MORE INFORMATION & FURTHER READING Szczelina P, Drescher F, Silberman F. Compact, robust and high performance: New ERC 25-25 eccentric roll crusher revolutionises primary crushing in underground mines. A thyssenkrupp reprint from AT Mineral Processing Europe 05; 2017. thyssenkrupp-industrial-solutions.com/media/ products_services/mineral_processing/crushers/ sonderdruck_thyssenkrupp_screen_300617_final.pdf

CRUSHING

LARGE, HIGH PRODUCTION JAW CRUSHER DEBUTS IN AUSTRALIA

T

utt Bryant Equipment (TBE), the national distributor of Metso mobile plant and equipment, will launch a new primary crushing solution – in the form of the Metso Lokotrack LT130E mobile jaw crushing plant – in Australia this month.

The new Lokotrack’s heavy-duty design offers a reliable, high capacity solution, even with the hardest feed materials. For optimised energy efficiency for crushing operations, the mobile jaw crusher can run on an external electrical drive or, in locations where this is not possible, an integrated Caterpillar C15 engine and 500 kVA generator power package.

The LT130E incorporates a Nordberg C130 jaw crusher for large-scale quarrying applications. A deeper 1000mm (40”) feed opening can handle coarser feed material and greatly reduces the need for blasting. A small nip angle and kinematics ensure aggressive crushing along the whole length of the crushing cavity and for all rock conditions.

The tracked jaw crusher is easy to adapt to existing processes. You only need to adjust the height of the main conveyor hydraulically and start the process with an advanced Metso IC (intelligent crusher automation) control system.

It connects the unit to the existing Lokotrack crushing and screening plants with a wireless Metso ICr remote monitoring system or an interlocking cable. All maintenance locations are easily accessible, making daily routines easier and safer.

The LT130E can be optimised to move smoothly between different sites. All the electric and hydraulic connections have quick couplings for easy disassembly. Optimised lifting points, along with user-friendly and safe hydraulic features, reduce downtime, while a new easy split feature makes portability and set-up much easier. For contracting purposes, the plant can be set up within a matter of hours.

The easy split advantage utilises hydraulic 26

Quarry April 2019

The new, large Lokotrack LT130E is built for optimised energy efficiency in crushing operations.

SPECIFICATIONS: LOKOTRACK LT130E* FEATURES

TYPE/CAPACITIES

Transportation dimensions (depending on specification)

21.5m (length) x 3.5m (width) x 3.85m (height), 132 tonnes (weight)

Crusher

Nordberg C130, with feed opening of 1.3m x 1m (51” x 39”)

Engine

Caterpillar C15 Acert engine (403kW, 500 kVA generator) – external power source option.

Feed hopper volume

11m³

Feeder

B13-50-3V

Main conveyor

H14-16E (with adjustable height)

Process control

Metso IC900

*Remote monitoring system and optional extras available

cylinders to lift the crusher and feeder above the chassis for transfer to a standard trailer (illustrated above). The chassis of the LT130E can be driven to the trailer by using a remote controller – just as with all Lokotrack mobile plants.

TBE is the largest multi-franchised equipment distributor in Australia, with more than 80 years of experience supplying a quality range of equipment and services to mining,

quarrying, construction, recycling and other Australian industries. It has been Metso’s exclusive distributor of Lokotracks in Australia since 2012 and more recently had the territory extended into Papua New Guinea.

TBE provides national coverage with service centres and equipment distribution. • Source: Tutt Bryant Equipment

CRUSHING

KIMBERLEY PRODUCER TOPS UP ITS HIRE FLEET WITH MOBILE JAWS

T

he Kimberley and Pilbara regions of Western Australia and the Northern Territory are some of the hottest, most remote areas of Australia, where the faint hearted do not venture, let alone maintain a professional, diverse contracting business for nearly 20 years. The Kimberley Quarries team thrives in this hostile, competitive environment.

Since 2000, Kimberley Quarries has become a successful company with extensive experience supplying products and services to the mining and construction industries. The company operates the Nillibubbica Quarry, 100km east of Broome and contracts out quarrying, mobile crushing and screening, drill and blast and equipment hire in the Kimberley, Pilbara, and mid-west

regions, and the Northern Territory.

Kimberley Quarries promotes a quality service and continually produces high specification products for clients with a focus on repeat business. It is a quality assured company, maintaining an excellent safety record, good customer relations and consistent supply of quality products.

The company has many years of material supply to a regional customer base that includes Mineral Resources Western Australia, numerous shires and private contractors developing highly specified infrastructure projects like airports.

Some of Kimberley Quarries’ large repeat business clients include the major construction materials houses of Boral, Holcim and Adelaide Brighton, which have all

utilised the contract quarrying and crushing services for the numerous quarries in the region. They have also engaged Kimberley Quarries on major infrastructure projects at Wheatstone, Cape Preston, Cape Lambert, Gorgon Projects and Tindal Airbase, with highly specified products supplied and challenging quarantine requirements met.

Kimberley Quarries has 12 quarry managers, eight of whom have in excess of 20 years’ quarrying experience.

The management team recognises the importance and benefits of a well trained work force and believes training increases productivity, improves quality, promotes a better safety culture and fosters more job satisfaction. As a result, there has been a very low turnover of employees that has lead

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CRUSHING

to the continuity of an experienced team.

After many years of working its equipment hard in an extremely challenging environment, the company considered replacement options for its ageing primary jaw crushers. Its research lead to Tutt Bryant Equipment (TBE), the national distributor of Metso’s Lokotracks. With a few local references to draw from, the Kimberley Quarries management decided to purchase the Lokotrack LT120 jaw crusher.

“The key points that lead to this decision was the machine’s safety, high power crushing, ease of maintenance and its transportability,” Kimberley Quarries’ Pilbara area manager Dave Young said.

Metso’s uncompromised safety approach to the LT120 has led to feed hopper side wedges being hydraulically secured from the ground. The Metso IC control unit provides a safe and easy operation. All conveyors have lanyards attached on the sides, with the ability to be switched for isolating the unit during maintenance. Proper stairs and access

platforms create a safe working environment.

A reliable, efficient mobile crushing plant is a sum of several factors working together smoothly. The new Metso C120 jaw crusher, with its 1200mm x 870mm (47 x 34”) feed opening, provides more capacity in the toughest applications. The hydraulic drive encourages trouble-free operation and enables the crusher direction to be changed in case of blockage. The Caterpillar C13 Acert engine module provides optimal power to the high inertia flywheels.

Quick, easy maintenance was a major driver in the Lokotrack LT120’s design. The jaw die bolts are easily accessible, and the composite covers protecting the flywheels can be safely and easily opened. Good access and proper platforms make a difference in daily operational safety.

Thanks to compact dimensions combined with agile tracks, the Lokotrack LT120 is a very portable unit. The chassis design with good clearance at both ends enables simple loading onto a trailer. The feed hopper sides equipped

WHEN WORN OUT BECOMES NEW AGAIN SANDVIK REBORN SOLUTION - CONE CRUSHERS In these cost-conscious times for our industry, replacing a complete crushing system is often not feasible or even necessary.

Our Sandvik REBORN solution rebuilds your crusher system by exchanging your worn out Sandvik crusher for a new one, and reutilizing your crusher auxiliaries and infrastructure. Your new crusher is backed by our three-year extended warranty*, and includes on-site services to help you maximize productivity.

Why leave anything to chance? Contact our sales team at ROCKTECHNOLOGY.SANDVIK

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with a patented securing system allow the unit to be ready for crushing only moments after arriving on-site. The side conveyor stockpiling capacity can be easily installed on either side of the unit.

TBE’s Metso technical support team delivered and commissioned the first LT120 unit to Kimberley Quarries in January 2018.

Within a few weeks of operation, Kimberley Quarries placed the order for another unit, which arrived in Perth in March 2018. TBE’s WA branch service team performed a quick turn-around, preparing the unit for immediate dispatch to an awaiting Kimberley Quarries project. Both units have since exceeded more than 1000 hours of operation each.

TBE continues to support Kimberley Quarries with parts and service support as required, much to Young’s satisfaction. “The Tutts guys have really looked after us and the machines are performing better than expected,” he said. • Source: Tutt Bryant Equipment

A brief introduction to Komatsu’s expanded crushing product line In the wake of Komatsu’s acquisition of Joy Global in 2017 to form Komatsu Mining Corporation, the company has significantly expanded its Joy crushing product line. The company now offers a complete range of feeder breakers, reclaim feeders and sizers – suitable for a wide range of quarrying and processing applications.

n FEEDER-BREAKERS

n SIZERS

Joy feeder-breakers are derived from a product line that Joy Global acquired from Stamler Corporation in 2006.

More than 4200 feeder-breaker installations have been supplied to quarrying and processing operations around the world. Joy feeder-breakers consist of dual-strand conveyor chain which drags raw material under a breaker shaft fitted with picks. The advantage of a feeder-breaker is that the material flows horizontally through the machine, so the overall installation height can be significantly lower than other crusher types of comparable capacities.

Komatsu also now offers both primary and secondary sizers.

Joy primary sizers feature pick technology developed for Joy feeder-breakers, shearers and continuous miners.

A sizer drives a pick into the mineral, which breaks the rock in tension, taking advantage of the fact that the tensile strength of most minerals is 10-15% of their compressive strength.

Joy sizer picks have been designed to minimise labour requirements, so no torch, welding or special tools are required to remove and replace picks.

Joy picks as standard have a tungsten carbide insert, with a chromium carbide overlay available as an option for abrasive applications.

Joy primary sizers can produce a product size of between 150-250 mm.

Our secondary sizers can be configured to output product sizes of -100 mm, -50 mm, -38 mm or -25 mm. Joy secondary sizers feature bolt-in wear castings, with weld on white iron or alloy teeth depending on application.

n RECLAIM FEEDERS Joy reclaim feeders are similar to feeder-breakers except there is no breaker shaft; instead the feeder typically has a pile of material which it reclaims on to a conveyor belt.

Reclaim feeders can be fed with a dozer, excavator or belt conveyor.

n SIZER APPLICATIONS Sizers are a good crusher choice for operations that have to handle sticky materials.

Primary sizers have cleaners which scrape the sticky material off the rolls, while secondary sizers have teeth that mesh together to displace material.

Sizers are also a good choice if fines generation is a concern.

Essentially, a sizer acts like a screen, letting undersize material pass through unaltered, but crushing the large lumps.

This allows sizers to achieve very high capacities in a compact package, making them particularly suitable for mobile applications.

1300 566 287 | komatsu.com.au

CRUSHING

The Sandvik Reborn solution enables old crushers to be rebuilt from the ground up, aided by the latest advancements in technology.

BUY NEW OR REBUILD: DOES A ‘REBOOT’ OFFER A NEW LEASE ON LIFE? Is your crushing plant ready for an upgrade or complete replacement? Turkka Kulmala says a new alternative to the conventional crusher overhaul, with innovative thinking, is a rebuild solution.

C

onventional wisdom in crusher maintenance involves two basic approaches: regular replacement investments in new crushers, or overhauls specified for the conditions at hand.

It’s not unlike buying a new car at regular intervals as opposed to making a continuous effort to keep an old car in a good state of repair.

Both approaches, naturally, have their merits and disadvantages. Investing in regular replacements increases capital spending, but helps to minimise maintenance costs. Extended ownership with regular overhauls can be financially more attractive, but the owner may have to accept longer downtimes.

Some suppliers to the industry offer a third way, such as Sandvik’s Reborn rebuild solution, which could be compared to upgrading a used car with a new engine.

Reborn combines a 100 per cent new, factory-built Sandvik crusher with a systematic service package, where usable auxiliaries and surrounding process infrastructures are reutilised.

A part of the Sandvik 365 service concept, the Reborn rebuild solution is combined with a three-year extended warranty that applies to all major components, including onsite service.

30

Quarry April 2019

‘BORN AGAIN’ Reborn essentially standardises the rebuild process into a systematic, six-stage service product: pre-feasibility assessment, budgetary quotation, crusher auxiliary audit, new crusher installation under Sandvik supervision, on-site training, and regular condition (see boxout).

The exact scope of each Reborn package is defined during the pre-feasibility study, depending on the specific crusher model.

The standard scope in all cases includes a replaced crusher and hopper, a bottom shell liner upgrade with a hard, highly wearresistant steel grade and a new offline filter.

The hydroset cylinder protection is also included as a default for all models.

The most commonly usable auxiliaries and infrastructure surrounding the crusher include the main motor, drive system, lubrication and hydraulic systems, coolers, control, automation and electrical components, foundation, feeders and conveyors.

The pre-feasibility assessment reveals whether the auxiliaries can be reused with normal spare parts exchange and modifications. If so, this results in a quote at a fixed cost and scope.

This can be followed by a Reborn auxiliary audit – a full inspection of all auxiliaries to list the actions to be taken prior to, or in combination with, the Reborn installation.

INSPECTIONS, TRAINING Inspection: Three to four inspections are planned and conducted annually by certified engineers. Generally, they coincide with liner changes, to avoid downtime. They take one to two days, and the data gathered helps diagnose maintenance issues. From there, corrective action can be enacted immediately.

This is a proactive, predictive and preventative maintenance philosophy, saving the producer time and money in the long term. A three-year extended warranty is included in the offering, which helps maximise equipment uptime and addresses ongoing issues.

Training: Sandvik not only supervises installation but provides on-site training to equipment operators. It helps new and veteran workers get to grips with the machinery quickly, ensuring they respond effectively to maintenance challenges. The two and a half days of training consists of theoretical operations, plus maintenance training, equipping operators with the knowledge to keep equipment performing at its peak. It also prepares employees for the tasks they will face when operating the unit in its real-life environment.

The installation under Sandvik supervision is followed by on-site training to lay a solid foundation for effective operations and crew safety. Periodic condition inspections verify that the specifications and targets are met and that preconditions for continuous improvement exist.

LIFE CYCLE ASPECT Reborn replaces the complete crusher, to upgrade its performance and restore availability rates close to those of a new unit at a lower operating cost, yet with significantly lower capital expense compared with purchasing an entirely new crusher system.

A key feature of the Reborn solution is a pronounced and integrated life cycle aspect, leveraging the expertise advantage of the original equipment manufacturer compared with third-party overhaul firms. The extended three-year warranty covers 85 per cent of the list price of the specified components, typically including top and bottom shell, main shaft and head centre, gear and pinion,

CAPITAL AGGREGATES/DELTA MATERIALS, MARBLE FALLS, TEXAS, USA The US aggregates producer had a Sandvik CS440 cone crusher installed about 15 years ago for secondary crushing of competent sandstone.

The feed material is from a primary jaw crusher, while the crusher itself feeds a tertiary crusher further downstream.

After 15 years of operation, the CS440 had started to suffer mechanical issues.

However, the ASRi 2.0 setting control system was recently updated.

As the lubrication system was also in good repair, only the crusher required refurbishment.

The Sandvik Reborn solution offered a cost-effective alternative to a complete overhaul by replacing only the worn-out components, with minimal downtime.

Reliability benefits were achieved by solving the mechanical problems, compared with the potential problems after an off-site weld and machining repair.

1800 727 991 (Free call AUS)

sales@precisionscreen.com.au precisionscreen.com.au

« « « « «

MOBILE CRUSHERS MOBILE SCREENS & SCALPERS CONVEYORS & STOCKPILERS WASHING PLANTS & PUGMILLS HAMMERS & ATTACHMENTS

DRY HIRE AVAILABLE PARTS & SERVICE SUPPORT

PRECISIONSCREEN SCORPION RECLAIMER 804

« 8’ x 4’ x 2 deck screenbox « The hydraulic system is designed to be capable of running up to three independent stockpilers « Built in Australia for Australian conditions

SPECIAL REPORT CRUSHING

hydroset cylinder and cylinder cover, piston, hub, dust collar and eccentric.

On-site training responds to needs arising from matters such as changes in personnel, which can also create maintenance challenges. A two and a half day theoretical operation and maintenance training course gives the operators a comprehensive introduction to maintaining and operating the unit properly in its real life environment, giving them the practical skills to maintain optimal performance.

Three to four annual condition inspections by certified engineers are planned to coincide with liner changes, to avoid extra downtime.

Measurements are carried out and reported according to a set protocol designed by Sandvik. The one to two days of inspections provide data to diagnose any progressing maintenance issues and to propose corrective actions as required.

The aim is a proactive, predictive and preventative maintenance philosophy: the owner can draw from accurate data-based predictions and prevent any issues in a

producers processing hard types of rock and thus experiencing greater than average wear and tear.

Sandvik Reborn offers a completely new crusher, but makes use of the existing infrastructure.

controlled manner before they become acute.

For example, the status report can include a quote for an imminent bearing change that should advisably be scheduled for the next maintenance stop.

End users most likely to benefit from the Reborn service are mines and aggregate

DOWNTIME SOLUTION Another area where the solution offers high potential includes any operation with low downtime tolerance.

The well defined service concept with clear component interfaces serves to eliminate uncertainties resulting in downtime. It eliminates the risk of omissions in orders of spare parts, typical with regular overhauls.

In essence, the Sandvik Reborn solution keeps the crusher continuously updated with the latest design upgrades. It offers full reliability and performance levels comparable with a new crusher, plus additional value – the extended warranty and service offering – at a very competitive cost compared with a complete overhaul. • Text by Turkka Kulmala. Originally published in Solid Ground magazine, a Sandvik Rock & Technology publication. Visit solidground.sandvik

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CRUSHING

TERTIARY CONE DELIVERS

MORE PRODUCT, LESS REPEAT LOADS A US-based quarry producer and a supplier have successfully collaborated on the installation of a tertiary cone crushing plant with the aim to minimise recirculating loads.

M

aintaining optimum yield from any cone crushing circuit is achieved by combining the latest cone crushing technology with solid application expertise and highly responsive equipment life cycle management.

The latter is essential when fine-tuning a crushing circuit for peak performance – and this is best driven by a producer/equipment manufacturer “partnership” that ensures the highest production capacities and the lowest percentage of recirculating loads.

Circuits with high recirculating loads eat up more capacity and wattage in the crusher while also increasing wear, and unnecessary recirculating loads send saleable material back to the crusher rather than to the finished product stockpile.

Minimising recirculating loads is an imperative for producers such as the RiverStone Group, which operates 15 quarries throughout the US states of Iowa and Illinois.

As a family owned business since the late 19th century, the company “prides itself on pushing the envelope in productivity and innovation”.

RiverStone is known for its abundance of Class A quality stone products, which meet stringent US quality assurance standards.

At its Colona, Illinois-based Cleveland Quarry, the company recently upgraded its plant with higher capacity primary and secondary crushers. For optimum yield of finished product at its tertiary circuit, it installed a new P500HD Patriot cone crusher manufactured by Superior Industries.

The result has been greater plant uptime, long-term efficiency, reduced wear costs, minimal recirculation load and increased production capacities at lower costs per tonne. Delivering a speedy return on investment, the site has nearly doubled its tonnes per hour output since the installation of the new crushers.

Cleveland Quarry’s plant superintendent Scott Skerston calculated the circulating load 34

Quarry April 2019

RiverStone’s plant superintendent Scott Skerston calculated the favourable circulating load ratios of the P500HD Patriot cone crusher.

ratios of the Patriot cone crusher. He found that at a closed side setting (CSS) of 25mm, the cone processes finished product at a 78 per cent throughput; and at a 12.7mm CSS, the throughput percentage reaches a high of 83 per cent.

“We’re getting maximum efficiency, and very little recirculating load, while averaging 80 per cent of our crushed material going directly out to the finished, saleable product stockpile,” Skerston said.

In part, he attributes this to the cone’s spiral tooth bevel gearing system, which “engages more gradually, giving an efficient transfer of horsepower to the rock, rather than to the structure of the machine”.

As a result, the cone is proven to perform at higher speeds with less noise and vibration.

“With its uptime and availability at more than 97 per cent, the Patriot cone maximises our production of Class A quality concrete,

stone and asphalt chips,” Skerston said.

“Before we added all the new crushers, we ran at just over 400 tonnes per hour. Now we’re running steady at 800 tonnes per hour due to our crushing advancements.”

NEXT LEVEL CRUSHER TECHNOLOGY Skerston said the design improvements on the Patriot cone crusher made it far more durable, reliable and user-friendly than olderstyle cones.

Unlike most crusher models, he said, the Patriot cone crusher’s counter-shaft spins in a counter-clockwise rotation, which causes the crusher to open if clamping pressure is lost, reducing the risk of catastrophic failure.

“This feature literally saved us last production season when a simple solenoid valve failed and would not reset the clamp pressure,” Skerston said. “The counterclockwise rotation allowed the cone to open, preventing any damage to internal

components. When older-style cones lose clamp pressure, the bowl tightens down, often snapping the shaft and leading to machine failure.”

Another feature that prevents costly damage to the new cone’s crushing chamber is the tramp relief system.

“First, it’s designed with fewer accumulators for minimised maintenance, but most important is the inclusion of a secondary pressure relief valve that ensures the crusher will open if a tramp event occurs,” said Superior Industries’ crushing product manager Michael Schultz, who has more than two decades of crushing industry experience.

“This means that even if an accumulator fails, the secondary relief valve will provide immediate pressure relief, allowing the crusher to open.”

In addition, Schultz points to the inverted design of the tramp release cylinders, where the hydraulic cylinder rod seal is not exposed during operation, greatly reducing the potential of contamination and failure.

The P500HD Patriot cone crusher has undergone significant design improvements.

He said the Patriot cone crusher was more robust than the typical cone, because “it’s beefed up to increase the strength of the unit with a heavier duty adjustment ring, base frame, eccentric and clamp ring, and bowl castings. We’ve made sure it will withstand the toughest applications.”

AUTOMATION PACKAGE Schultz said Vantage Automation, an inhouse cone crusher automation package, was the latest addition to the Patriot series.

“It’s completely built in-house by the Superior Industries team, with no third parties

involved, allowing one-call service and support, and offering a complete automation package that is far more affordable than competitive systems.”

Vantage Automation monitors all the crusher’s vital functions.

“An automation package should be simple and easy to use. Importantly, it acts as a warning system that alerts operators to conditions such as bowl float, excessive amperage or temperatures, and lubrication or low-flow oil issues,” Schultz said.

“Our mission is sharing hands-on expertise and partnering with producers throughout the

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an Astec Industries Company

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CRUSHING

life cycle of the plant and its components.”

As the RiverStone Group upgraded its crushing circuits, Skerston worked closely with Chris Wade, a customer service and technical support technician for Superior Industries, which operates a 21,336m2 crushing equipment and parts distribution centre in Pekin, Illinois.

“Chris, along with the service and parts support team, have specialised in cone crushing for many years. They know how to analyse our application to make us more efficient,” Skerston said.

“It’s such an advantage to rely upon the knowledge of the equipment manufacturer.

The product and parts support is excellent, and the Patriot cone does just what it’s designed to do.”

In Australia, the distributor of Superior Industries’ crushing, screening and washing equipment is 888 Crushing & Screening Equipment. • Source: Superior Industries

WHAT IS VANTAGE AUTOMATION? Superior Industries’ Vantage Automation software monitors and controls crusher parameters, automatically adjusting unit settings or shutting down the machine when harmful conditions occur. Designed for simple, straightforward operation, the software maintains optimum crusher production without operator interruption.

It is applicable for the Patriot range of P200, P300, P400 and P500HD crushers.

The software is available on a HMI touchscreen, which comes as part of the package, along with a 10-metre tether cord for remote locating. The touchscreen virtually eliminates the need for electrical push buttons and operator intervention, meaning motor starts and stops can be safely controlled from the pad itself.

The software monitors CSS, amperage draw in real time, liner wear conditions, and the counter-shaft RPM sensor, and can

generate performance analysis reports. It will also alert users to potentially harmful conditions, such as lube oil temperature and pressure, lube filter condition, hydraulic clamp and tramp releases, ring bounce/ bowl float, lube oil and hydraulic tank levels, and the eccentric bushing temperature.

Vantage Automation also provides access to Superior’s in-house engineering team, allowing users to directly ask questions of the source developers.

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GOING MOBILE

FAMILY BUSINESS

‘ACES IT’ WITH UPSIZED SCALPER A family quarrying business has never been busier, thanks to local and national infrastructure project demands. The task of meeting the hunger for construction materials has been made easier by the acquisition of an enlarged scalper to the company’s mobile fleet.

Q

uarrying runs through the Lewis family’s veins; its involvement in the industry dates back to the early 1980s. The family business started as a small road construction business, winning materials with a dozer and loader.

Brian Lewis, the owner of Lewis Quarry, recalls that crushing rock began with a jaw crusher comprising a feed of 76cm x 38cm (30” x 15”). Since then, the business’ operations have continued to expand and the equipment has been upgraded to meet changing needs.

“When we were starting out we grew slowly and never had any big equipment, but every time we did have to buy something new, it was always the next size up,” Lewis said.

“Over a period of a few decades, we’ve got to where we are now.”

For the past 23 years, Lewis Quarry has operated its own site in the Clarence Valley, in the Northern Rivers region of New South Wales. It is a hard sandstone quarry, which has to be drilled and blasted, with a footprint of about 15ha to 17ha. Under the current development application, its output per annum is capped at 246,000 tonnes. “[In 2017], with the equipment we have at the moment, we crushed our quota in six months,” Lewis said.

The quarry services the local community and provides material for everything from riverbank protection rock to roadbases.

In recent years, construction materials demand has increased with the advent of the Pacific Highway project and, as a result, Lewis Quarry has had to upgrade its equipment once again. It formed a relationship with Lincom 38

Quarry April 2019

The Warrior’s feed log regulates the material flow; once the material exceeds a certain weight, it slows down or stops.

Equipment “quite a few years back” and has owned and operated various stackers and crushers previously.

“Then they came up with the Powerscreen Warrior 2400, which was exactly what we needed,” Lewis said. The Warrior 2400 has played a major role in enhancing the efficiency of the site’s operations.

TRIPLE-SHAFT TECHNOLOGY The Warrior 2400 has been specially designed for large-scale operators in

the quarrying and mining sectors, and is capable of handling larger feed sizes and throughputs.

It features a heavy-duty incline screen with a high amplitude triple-shaft drive mechanism, lending it to screening, scalping, two- or three-way splitting and stockpiling materials.

“The Warrior 2400 is different to everything else on the market,” said David McDermott, the area sales manager for Lincom on the east coast of Australia.

“It’s the only scalper with triple-shaft

technology, which means we can make it more aggressive. You can also adjust it to fit any application.”

It’s a sentiment shared by Lewis. “There’s no comparison with other equipment. When we had two screens in the system we had to be very careful because we could overload them and we’d have to spend an hour trying to dig them out. But the Warrior won’t really let you do that,” he said.

“Basically, the feed log regulates the flow and once the material gets above a certain weight, it just slows down or stops. In screening that’s crucial. Because it’s such a big screen, I’d hate to have to dig it out. The mere fact that the system can actually control the feed is invaluable.”

RESPONSIVE SERVICE One of the other major selling points for Lewis Quarry was Lincom’s after-market service.

Because of their existing relationship, Lewis knew what to expect, and he hasn’t been let down. “You never have to worry about whether there’ll be back-up if something goes wrong.”

Lincom’s service is personalised, which makes it more responsive to calls for help, according to Lewis. He compares it with previous experiences he’s had with large multinational companies: they were less engaged with his business’ needs and, as a result, it was difficult to get quick resolution when something went wrong.

“If you’re in trouble, Lincom get you out of trouble,” Lewis said. “The back-up is brilliant – we can’t complain at all.

“And they [Lincom] keep a hell of a lot of parts, whereas some other manufacturers want to charge you freight from overseas.”

The Warrior’s capacity has improved productivity, which has led to more efficient crushing capabilities and, ultimately, reduced Lewis Quarry’s costs.

“In the past, we needed two scalpers to keep up with the jaw. Now we have the Warrior, we can manage to do with one screen what used to take two screens to handle. So it’s an efficiency thing with regards to both fuel and wear and tear,” Lewis said.

Lincom worked closely with Lewis Quarry to understand its specific requirements and provide the best solutions.

“Lewis Quarry needed big tonnage for the Pacific Highway project and the Warrior is the biggest scalper on the market,” McDermott said. “It is 6m x 1.8m on both decks, top and bottom.”

According to Brian Lewis, the Warrior 2400 (left) has helped enhance the efficiency of the site’s operations.

Lewis Quarry’s mobile plant and equipment has been processing up to 7000 tonnes of aggregate daily.

SPECIFICATIONS – WARRIOR 2400 THREE-WAY SPLIT

TWO-WAY SPLIT

45 tonnes*

43 tonnes*

17.3m

17.2m

Width

3.0m

3.0m

Height

3.6m

3.6m

Length

18.5m

18.3m

Width

15.3m

9.6m

Height

5.2m

4.9m

Length

6.1m x 1.93m

6.1m x 1.93m

Output

800 tph

800 tph

Max feed size

750mm

750mm

10m

10m3

Diesel/hydraulic

Diesel/hydraulic

RAL 5021

RAL 5021

TOTAL WEIGHT Transport

Working

Length

Screen unit

Hopper size Power unit Plant colour

3

* Weight will vary depending on machine specification.

Running the bigger equipment has also allowed Lewis Quarry to reduce its number of on-site operators.

“We only have four full-time employees in the quarry and we often utilise our fourth employee on truck driving or some other job,” said Lewis.

As of mid-2018, Lewis Quarry was processing about 7000 tonnes of material per day. Once the Pacific Highway is finished

in another two years, “then we’ll revert back to a quiet life,” Lewis said.

“And the Warrior will be able to cope with anything that comes along.”

As for the Lewis family, the plan is to continue quarrying for many years. Brian’s sons already work in the business and, with the quarry still on its original cut, he predicts there’s a lot of life left in the site. •

By Tim Robertson and Damian Christie

Quarry April 2019 39

SUSTAINABILITY

WATER, DECENTRALISATION AND THE ECONOMY IN THE 21ST CENTURY As Australia enters election mode this month, Warwick Lorenz outlines his vision of the nation we should be in the next 50 years – one that invests in water infrastructure to develop its primary industries, and to decentralise and grow its population to make its inland regions more liveable.

W

e Australians can change our prime minister in five minutes, we can build the Harbour Bridge, the Opera House and the biggest iron ore mines in the world, but we have trouble thinking ahead of the game.

We have 7.5 million square kilometres of territory inhabited by 25 million people. We are the most arid continent on Earth and the most underpopulated!

We are the wealthiest country in the world per capita, with the best lifestyle, yet we fail every time to think more than three years ahead when it comes to politics, the budget or the development of the country.

BOUNDLESS OPPORTUNITIES Sixty per cent of Australia’s population lives in four cities. Eighty per cent of the population lives within 40 kilometres of the coast. How’s that for decentralisation? The rest of the country is empty.

Our wealth, to a large extent, is based on $220 billion of mineral and resource exports per year to the booming nations of southeast Asia. We also rely on $60 billion of agricultural production, of which we export $40 billion!

We are in the iron ore, coal and food and fibre business. We are satisfied with 25 million people in a world that has more than doubled its population in the past 60 years.

How about the future? Fifty years from now we should be a population of 50 to 60 or even 70 million people, spread across the country, with a revived manufacturing sector providing growth and exciting employment opportunities, and a market of 11 billion people across the planet wanting to buy our resources, our manufactured and valueadded products, and our services.

The reality is we have to populate the country before we lose control of our ability to maintain our borders. World population increase is unstoppable. It has been achieved by continued improvements in medical science, solving the world’s food 40

Quarry April 2019

It’s hard to imagine a national government today undertaking ambitious projects like the Hoover Dam ...

production issues with modern farming and eliminating massive world wars.

MOVING TO DECENTRALISATION Overpriced real estate in the big capital cities is a fact of life that we all seem to love. We love feeling richer, but the real answer is to make the country liveable.

Take a trip through the Midwest of the USA and you find great, rich cities such as Des Moines or Ames or Omaha out there on the Great Plains – some of it the most productive land in the world. The difference is, they have water and we don’t!

Water is the answer and water security should be the major priority for every politician in the country at any level. Water security will enable us to spread and grow.

Imagine inland cities down the east coast with populations between half a million and one million people. The water would bring increased agricultural stability and security.

Protection from drought means investment not just in growing produce but in its processing.

That means loads of jobs with opportunities for

people to build great lives in country areas.

Companies such as Teys, the third- or fourth-generation butchers who own some of the biggest abattoirs in the country, should be inspirational. Teys will put abattoirs wherever there is product to be processed and employ hundreds of people doing it. Their abattoirs run like hospitals and are a classic example of how an industry can be generated by entrepreneurs with an appetite for risk, intelligence and courage.

With 50 million people, Australia could be building tractors again in regional areas. Wow, could we actually start up our steel mills again and go back into production? We have more iron ore and coal than anybody in the world, yet we shut our major steelworks down.

Imagine living in a green country city with satellite villages. Sounds idyllic, and you can still take holidays on the coast!

DAMS OF THE NORTH The CSIRO has recommended the concept of building six dams in northern Australia.1 It’s been 70 years in the

South Wales and Queensland.

The CSIRO predicts the Darwin catchment would bring 2500 jobs and $2.3 billion could be created from in-stream surface water storages at Mt Bennett on the Finniss River in the Northern Territory.

These are big projects that will bring life back to the land, but we have to ask the question: why is there no similar plan to bring water into New England in NSW, and to do more with the Ord River in Western Australia’s Kimberley region?

A centre-pivot irrigation, which is critical to agricultural production. Australia is an exporter of $40 billion of agricultural products, including food.

… or China’s Three Gorges Dam, the world’s largest hydroelectric system. It comprises 28 million cubic metres of concrete.

making and finally the CSIRO has woken up!

Politicians such as Barnaby Joyce have been pushing for the creation of these dams across the north for years.

The Fitzroy River in Rockhampton is a classic opportunity to add $1 billion of agricultural production and create jobs for 2500 Australians. An additional bonus of damming the Fitzroy is the flood protection it would afford the Great Barrier Reef.

During the massive floods in April 2017 we saw the Fitzroy deliver double the volume of Sydney Harbour every day for six days in a row from the river’s watershed. That landed on the Barrier Reef! If a mining company or a farmer had done that, the Greens would have been hysterical. As it happens, nobody said a word.

The CSIRO’s new plan is to build three dams in the Carpentaria region. By coincidence, the Carpentaria is part of the Great Artesian

Basin, which has one huge problem - that of replenishment! The Carpentaria region is the only part of the basin that is regularly replenished because of monsoonal rainfall in that part of the country.

Federal Resources Minister Matt Canavan told the ABC there was a $700 million direct benefit and a $1.5 billion economy-wide benefit, plus 7000 jobs to be pulled out of the new program in the north.

That’s just the beginning. “In terms of being able to boost our farm production as a nation, boost our food production, take the potential of growing Asian economies, it’s a big deal for the country”, Canavan said.

The bargain price for construction of the Mitchell Dam in Far North Queensland is estimated to be only $755 million, half as much as we just gave in handouts to desperate farmers in drought-stricken New

CONSTRUCTION, EARTHWORKS You can’t grow the inland economy or population without providing reliable water supply.

You could say much the same thing about power. We wonder why our state and federal governments seem emasculated on the subject of long-term planning and strategic objectives.

It’s hard to imagine a political party of either persuasion today building the Hoover Dam or China’s Three Gorges Dam, or even considering starting the Snowy Mountains Scheme. Considering Australia is heading for 40 million people by 2050, you have to ask: Will we tolerate the paralysis resulting from increased population living in four major capital cities? That’s a frightening future that needs to be rectified now.

Why is this of interest to the quarry industry?

The answer is obvious. There’s a huge amount of earthworks to be done in the development of infrastructure for Australia.

Gear gets bigger and better all the time.

The gear and resources are there, the money apparently is available, and all it takes is the will to harness what we know in terms of skills, finance and imagination to make it all work.

Let’s think of the future and use the past, including the devastating drought in New South Wales and southern Queensland, as stepping stones for a bigger and better Australia. • Warwick Lorenz is the managing director of Australian Pump Industries. Apart from being fanatical about drought-proofing Australia, his position is always that we should be taking a 20-, 30- or even 50-year projection of where Australia and Australians are going.

Email: wlorenz@aussiepumps.com.au REFERENCE & FURTHER READING: 1 Vukovic D. Giant dams proposed for northern Australia could support year-round irrigation. ABC News, 30 August 2018. abc.net.au/news/2018-08-30/ giant-dams-report-northern-australia/10181682

Quarry April 2019 41

SMART BUSINESS

IS THIS THE END OF THE ROAD

FOR ROADS AS WE KNOW THEM?

Road infrastructure has been vital to the way we live – and to the quarrying industry in particular. Now, as the Industrial Internet of Things ushers in a wave of innovative technologies, Anton Hartman explains that roads themselves will be transformed …

S

prawled across a bike path in Nuenen, Netherlands, 50,000 solar-powered stones are embedded in the pavement to glow in the dark and resemble Vincent van Gogh’s famous Starry Night. It was a commemoration of the 125th anniversary of the painter’s death – a “techno-poetry” that Dutch artist and urban architect Daan Roosegaarde described as “technical combined with experience”, a fusion of art and purpose.

But more than honouring a famous artist and his painting, Roosegaarde’s ingenious, unconventional and sustainable idea for lighting up our pavements is a statement on the transformation of roads for the future, or the lack thereof.

“Why do we put so much focus on vehicles, innovation and mobility but neglect the surfaces they drive on?” he asks. “Infrastructure defines our cities and landscapes way more than the cars.”

It seems that on our journey to the autonomous future, we have forgotten our roads, literally.

But it’s inevitable, as the Fourth Industrial Revolution ushers in new technologies, that the way we conceptualise and build our roadways will be utterly reconfigured. What’s the use of having smart cars if our roads are dumb? And with opportunities for innovative reinvention like never before, have we possibly come to the end of roads as we know them?

WHAT OUR ROADS WILL BE MADE OF …

Realities like globalisation and urban overpopulation demand we replace traditional materials and techniques with sustainable solutions, as well as the fossil fuel guzzlers that wear out the pavement.

New construction materials offer alternatives with in-built renewability capabilities. Dr Rajagopalan Vasudevan, dean and professor of chemistry at India’s Thiagarajar College of Engineering, found that molten plastic mixed with a stone and bitumen mix is an excellent

42

Quarry April 2019

binder, creating a stronger and longer-lasting road. An estimated 100,000km of roads in India are made up of plastic, inspiring companies such as MacRebur Plastic Roads Company to use it as well to build roads in the UK, Canada, Australia and New Zealand.

Similarly, the use of fly ash and slags from mineral refineries in concrete construction has been beneficial in reducing carbon emissions and for the disposal and neutralisation of waste. Innovations like self-healing concrete are extending the lifespan of old concrete, with self-activating limestone-producing bacteria that congeal in pavement cracks as they form.

Modern pavement engineers are pushing the boundaries of form and function, seeking effective ways to close the loop on conventional construction outputs. In 2018, architects Carlo Ratti Associati (CRA) and Sidewalk Labs (owned by Google’s Alphabet) launched a prototype of Dynamic Street, a series of “hexagonal modular pavers which can be picked up and replaced within hours or even minutes” and enable us to change the function of the road with much less disruptions to the street.

According to CRA, Dynamic Street “explores the different patterns that can be created on the hexagonal grid, as well as the integration of lights into individual pavers. Each paver can also potentially host a plug and play element – that is, vertical structures such as

poles, bollards or even basketball hoops”.

Just imagine how that would transform the construction and function of our roads.

PRIZED JEWEL Solar roads may be the solar industry’s prized jewel, thanks to their large exposed surfacing that can harness solar energy to illuminate road markings and generate electricity. As Roosegaarde puts it: “Energy is everywhere.

We just need to know how to harvest it.”

While there have been criticisms on its efficiency and cost-effectiveness compared with rooftop solar panels, several projects around the world continue to work on developing the technology and explore how roads can play a greater role in generating energy.

In the Netherlands, the N329 – Road of the Future – has replaced streetlamps with glow in the dark lines on the pavement made of photoluminescent paint, designed for recharging by sunlight before glowing at night for up to 10 hours. North Holland’s Dutch SolaRoad pilot project created a 100-metre cycleway that generated enough electricity to power one household for a year.

Most notable is China’s latest 1000m smart road. Paved with solar panels, mapping sensors and electric-battery rechargers, the pilot project aims to be the first stage of “intelligent highway” design that weaves the

autonomous vehicle (AV) revolution into one digital and unique experience.

‘SMARTENING’ OUR ROADS Coupled with the wave of innovation to design for sustainability, there is an equal imperative to make new and old infrastructure “smarter”.

As AVs dominate streets and highways, roads need to act as an intuitive and technologically integrated system that can host these transport innovations. In the future, roads will not be seen simply as empty conduits to move vehicles from one place to another, but environmentally regenerative, digitally responsive networks.

Magnetisable concrete is the latest invention that could revolutionise the electric vehicle (EV) industry. By embedding a highly controllable, resident-coiled technology into a designated lane, EVs can charge up on the go. The result is a streamlined highway, void of charging stations and an unbeatable value-for-money EV industry.

Naturally, the reconstruction and retrofitting

of roadways will demand a new eye for urban planning, and a new perspective about public/ private partnerships. While all developments to “smarten” our roads are still in the works, all sectors have to collectively start thinking outside the box now before it’s too late.

In fact, Singapore’s Smart Mobility 2030 is consolidating perspectives and inputs from the Land Transport Authority (LTA) and the industry on how to develop a comprehensive and sustainable Intelligent Transport System (ITS) ecosystem in the country. It is conducting research and development of AV technology in preparation for its deployment in Singapore.

It makes sense. The AV revolution will require third party involvement in planning, technology consulting, design and other nontraditional services that accompany smart road development to make this utopian idea a reality.

“Mobility is a fundamental right. It underpins all aspects of societal development allowing everyone, from individuals up to whole nations, to develop and prosper,” says Olga

Landolfi, Telematica Trasporti e Sicurezza Italia Secretary General in the International Road Federation Vienna Manifesto on ITS. “ITS has already demonstrated [that it is] an essential tool for improving mobility and quality of life.

The challenge now is to start using it to its full potential, to maximise the benefits that ITS can bring to society.”

Despite all they promise in road safety, ecological efficiency and connectivity, smart roads have a long way to go in the public and private eye. Greater education, research and investment models are needed to expedite their rollout and pave the way for AV innovation.

It’s not a question of which comes first: the road or cars? If we want to make the dream of autonomous vehicles a reality, we must remember the path we are travelling on. • Anton Hartman is a pavement and materials engineer at Aurecon, Johannesburg, South Africa.

2019 IQA EVENTS ACT BRANCH 12 July 15 Nov

Dinner meeting (Venue TBA) Dinner meeting (Venue TBA)

NSW CENTRAL WEST SUB-BRANCH 14 June

Women in Quarrying seminar

QUEENSLAND BRANCH 17 May IQA Annual Golf Day, Oxley Golf Club 14 June Quarrying Safety & Health Conference, Brisbane 7 Aug Dinner meeting & AGM, Brisbane Sept (Date TBA) CMEMC 2019

CENTRAL QUEENSLAND SUB-BRANCH 19 July

Annual Golf Day, Rockhampton

NORTH QUEENSLAND BRANCH

26 July Annual Golf Day, Cairns 13 Aug Branch AGM, Townsville 13 Sept Annual Golf Day, Townsville 8 Oct Technical and dinner meeting, Townsville 30 Oct Technical and dinner meeting, Cairns 15 Nov Christmas Party, Townsville

SOUTH AUSTRALIAN BRANCH 24 May Technical and dinner meeting (venue TBA) 12 July WIQ SA Conference, Adelaide Pavilion 30 Aug AGM/dinner, National Wine Centre 8 Nov Pullman Adelaide Hotel

VICTORIAN BRANCH 16 May

Student presentation night

14 May Technical and dinner meeting, Cairns 21 May Technical and dinner meeting, Mackay 19 June Safety & Health Seminar, Townsville

VICTORIAN SUB-BRANCH 30 May 25 July 12 Sept 21 Nov

Dinner meeting, Wang Miliwa Dinner meeting, Bendigo Dinner meeting, Ballarat Dinner meeting, Bendigo

WESTERN AUSTRALIAN BRANCH 8 May Breakfast meeting, Beaumonde on the Point, East Perth 28 June Brikmakers clay brickworks site visit and sundowner 7 Aug Breakfast meeting, Beaumonde on the Point, East Perth 3 Sept AGM and dinner meeting, Imperial Court Restaurant 22 Nov Annual golf day, Joondalup Resort

All dates and venues for the above branches are correct at time of press. Not all branches had confirmed their activities/ dates. For further information about IQA branch activities, contact your local branch representative (see IQA branch contacts on page 48) or visit quarry.com.au

PDP WORKSHOPS & EVENTS To register for the PDP courses outlined below and for further information, visit: quarry.com.au, click on link to ‘Education’, followed by ‘Upcoming Professional Development Programs’.

IQA 62ND ANNUAL CONFERENCE Geelong Football Club, Kardinia Park Geelong, Victoria 1-3 October (Tuesday to Thursday), 2019 “The Future of Quarrying” will be the theme of the annual conference which will be hosted at the home of the Geelong Cats AFL Football Club. The conference program will focus on numerous topics, including: the maximisation of limited natural resources through technology; the benefits of effective management of workplace diversity; new developments in emerging fixed and mobile plant technology; environmental and economic trends impacting on the industry; and much more. In a first, the conference program will be hosted on a Tuesday, Wednesday and Thursday.

For more information and to register, visit conference.quarry.com.au

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Quarry April 2019

CONDITION MONITORING OF CONVEYORS WPDP 8 April 2019 Condition monitoring of conveyors is a practical troubleshooting guide to several issues that quarries witness regularly.

Although a seemingly small part of a large process, conveyors can be capital-intensive.

This webinar will provide a troubleshooting approach to preventative conveyor maintenance, touching on key elements of belt tracking, cleaning and skirting. It is suitable for quarry managers, supervisors and maintenance staff, and contractors who oversee conveyor audits.

BAUMA 2019 8-14 April 2019, Munich, Germany Bauma attracts visitors from more than 200 countries to Munich every three years.

It is the perfect platform to see the most important new developments from around

the world. Bauma 2016 covered 605,000m² of exhibition space, comprising 3425 exhibitors from 58 countries. The event welcomed 583,736 visitors from 219 countries.

Numerous suppliers to the Australian extractive industry will be amongst the exhibitors, eg allmineral, Astec, Bonfiglioli, Caterpillar, CDE, Doosan, Dressta, Haver & Boecker, Hitachi, Hyundai, Isringhausen, Kleemann, Komatsu, Liebherr, Montabert, McCloskey, McLanahan, Metso, the Terex Group, Topcon, Trimble, Volvo, Wirtgen, and many more. For more information, contact the bauma visitor hotline, tel +49 899 491 1348, email info@bauma.de or visit bauma.de

PRINCIPLES OF EMERGENCY MANAGEMENT PLANNING AND RESPONSE WPDP 12 April 2019 All Australian and New Zealand quarrying legislation implies or specifies that quarrying operations must have a comprehensive,

The Institute of Quarrying Australia

resourced, tested and updated plan to respond to emergency situations.

This webinar will outline principles and methodologies of quarry emergency planning and response, including definitions, interpretations and legislative requirements and all aspects of emergency management and response. It is suitable for quarry managers, supervisors, leading hands and other employees with responsibilities for the planning and management of emergencies.

For more information, visit quarry.com. au/Public/Education/InfoSheets/wPDP/ Principles_Emergency_Management_ Planning_Response.aspx

CCAA INDUSTRY INSIGHTS BREAKFAST MEETING 12 April 2019, Brisbane The CCAA’s next Industry Insights breakfast meeting will explore key political and economic insights for Queensland that will impact on the construction materials industry’s outlook for 2019. For more information and to register, contact Vanessa Finnerty, CCAA, tel 07 3227 5200 or email vanessa.finnerty@ccaa.com.au

CCAA CONCRETE PRACTICE COURSES & WORKSHOPS 21-22 May, Sydney 5-6 June, Melbourne 19-20 June, Brisbane 2-3 July, Adelaide 24-25 September, Perth This course will provide participants with a detailed understanding of concrete material and behaviour in relation to physical properties, production, placing and associated on-site operations such as reinforcement and potential causes of failure. It comprises of two parts: (i) 14 eLearning modules that have been developed to enhance the industry’s knowledge of concrete and featuring embedded activities and assessments in a sequential, easy to follow, and easy to navigate format; and (ii) workshops held around the country that will feature presentations from industry experts, Q&A panel sessions with industry experts, group work and case studies, and a final assessment. Participants will be required to complete all modules prior to attending the workshop, allowing five to six weeks to

complete the modules. Registrations will close five weeks prior to each workshop and attendance at the two-day workshop is vital to complete the course. A personalised certificate will be issued upon successful completion of parts 1 and 2 of the course.

The cost of admission is $1800 (inc GST) for CCAA members and $2200 (inc GST) for non-CCAA members. To register, contact the CCAA’s learning and development manager Ceridwen Jones, tel 02 9667 8319, email ccaaeducation@ccaa.com.au

QUARRYING SAFETY & HEALTH CONFERENCE 14 June 2019, Brisbane This day-long event, co-hosted by the CCAA, the IQA and the Queensland Department of Natural Resources, Mines and Energy (DNRME), will feature thought-provoking keynote speakers, a DNRME update and other presentations on practical issues impacting the quarrying industry. For more information and to register, contact the IQA’s Queensland branch secretariat, tel 0419 782 688 or email qld.admin@quarry.com.au

CENTRAL HIGHLAND REGIONAL COUNCIL SHEPTON QUARRYING BUSINESS FOR SALE

Expressions of Interest closing 4pm Thursday 18th April 2019.

For an IM please contact InSitu Advisory Pty Ltd at info@insituadvisory.com OR CALL 02 8998 5260 www.lgtenderbox.com.au/login

IQA NEWS

The Institute of Quarrying Australia

Queensland branch chairman Rob Sloman (centre) with recently inducted and elevated members.

NSW Central West sub-branch members visited Shadforth Quarry on 15 February.

NSW CENTRAL WEST SUB-BRANCH NEWS Thirty members gathered in Orange on 15 February to look at the latest innovations in fixed plant optimisation. With plant modifications a substantial capital investment, ensuring that any new or modified gear is “fit for purpose” is clearly a critical decision.

Heiner Gonzel of Sandvik provided an overview of the company’s Optiagg software which allows quarry operators to model different crusher chamber configurations and construction materials to produce optimal particle size distribution, increased product to waste ratios and improved efficiencies.

Heiner ran through a recent optimisation exercise at Boral’s Peppertree Quarry that resulted in an increased product rate for the site of about 200 to 750 tonnes per hour.

He also discussed another project where the plant was producing material with poor size distribution, resulting in excess scalps and crushed dust and difficulty meeting specifications.

The Optiagg software identified that the primary cause was the single core crusher with sub-optimal feed stock. By modelling installation of a second cone crusher with a wider range of particle sizes in the feed stock, Sandvik was able to demonstrate proof on concept. Use of a mobile crusher confirmed the results of the modelling and the operator then had the information required to make commercial decisions about fixed plant upgrades.

As has become a tradition at these 46

Quarry April 2019

meetings, the group enjoyed an extended lunch and opportunity to network and reconnect, before heading to Boral’s Shadforth Quarry for a site inspection and further discussion.

The branch committee is grateful to Sandvik and Boral for facilitating the day and looks forward to the next meeting on 14 June which will be partnering with the NSW Women in Quarrying network. We look forward to discussing how we as operators can facilitate the engagement of women in the industry locally. It should be a great event.

Guest speaker Greg Glennon discussed effective controls to minimise injury risks.

By Mitchell Bland

QUEENSLAND BRANCH NEWS Technical meeting kick-starts 2019 Greg Glennon, the eastern region operations manager for Otraco International, was the guest speaker at the Queensland branch’s first technical meeting for the year. Greg reported on the guidance note supplied by the Queensland Department of Natural Resources, Mines and Energy (DNRME), designed to assist in identifying hazards associated with tyres, wheels and rims, and effective controls to minimise the risk of injury and death from uncontrolled movements and pressure release events.

These controls should then be incorporated into the site’s health and safety management system.

Brendan Ford from the April Ford Agency enlightened attendees with an interesting presentation on social media, and how to connect quarries with local communities,

The Quarrying Safety & Health Conference attracts more than 200 delegates each year to the one-day program and accompanying trade exhibition.

customers and stakeholders. Brendan explained how to align social media strategy with marketing strategy.

Branch chairman Rob Sloman presented new membership certificates to: • Bill Taylor (Ausrocks) – upgraded to a Fellow of the Institute.

• Luke Blanchard (Fulton Hogan).

• Jai Hunt (Fulton Hogan).

• Andrew Weller (Sibelco).

Quarrying Safety & Health Conference, Brisbane, 14 June This year’s conference program is shaping up to include the biggest range of speakers

FROM THE CEO

PROFESSIONAL DEVELOPMENT UNDERPINS FUTURE PLANNING Registrations are now open for the 2019 IQA conference in Geelong.

The theme - “The Future of Quarrying” – is particularly relevant. With new or emerging technology, resource constraints, changes in health and safety, community and regulatory requirements and changing markets, planning for the future is critical.

A key part of the future is our workforce, particularly the need for a competent and flexible workforce. A competent workforce is vital to all aspects of business.

Whether it is relates to improving priority areas such as health and safety, and environment and output, or planning for succession or expansion, attracting and retaining the right people is vital.

Developing our workforces with the right competencies can ensure we not only meet regulatory responsibilities but also develop skills to meet changes in the industry and the work environment.

The IQA is continuing to deliver professional development through conferences, technical presentations and formal training.

A review has commenced to look at the Institute’s training products and how they are delivered to ensure they will meet future needs. Part of this review will involve identifying ways the IQA can better support organisational development and improve competency across industry.

If you require any training or development for yourself or your team, please contact the IQA, tel 02 9484 0577, email admin@quarry. com.au or visit quarry.com.au For expressions of interest or registration at the 2019 national conference, visit conference.quarry.com.au KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

THE ONE AND ONLY SU PPLI ERS

DIRECTORY

2019 A COMPREHENSIVE

LIERS

N QUARRY SUPP

AUSTRALIA DIRECTORY OF

Hard Rock Quarries Maryborough, QLD Expressions of Interest

ON SALE NOW! At 320 pages, with over 130 categories, the Quarry Suppliers Directory is where operators and purchasing officers find products and services for their quarry.

If it ain’t in the Suppliers Directory, it ain’t worth knowing!

• Freehold • 2 x Extraction Permits • TMR Certification • WHITE PIT 16.1Ha - Produces roadbase, surge rock and marine rock - one of only 2 quarries that can supply marine armor rock on the Fraser Coast.

• BLACK PIT 33Ha - Produces roadbase, sealing asphalt aggregates, rail ballast and surge rock • Contract in place with Queensland Rail to supply rail ballast.

• Location approximately 25km west of Maryborough, QLD. • Largest freehold resource in the Fraser Coast • Mobile plant and equipment on site available for purchase subject to negotiation.

To get your copy of the 2019 Suppliers Directory call 03 9696 7200 or email info@quarrymagazine.com

All enquiries - email admin@hrq.com.au

IQA NEWS and industry topics yet, ranging from reports on crystalline silica to collision management, risk evaluation for mobile equipment, drone technology, case studies and the inspectorate update. IQA CEO Kylie Fahey will provide an update on the IQA and the Australian Academy of Quarrying.

The accompanying trade exhibition is already a sellout with the following organisations participating: Komatsu (gold sponsor), Astec Australia (gold sponsor), Groundwork Plus, Cotral Australia, the MinRes Training Institute, Coolfog (Access Environmental Systems), Breathe Safe, Kinder Australia, Global Road Technology, Hammersley Australia, Clean Space Technology and OHMS Hygiene.

At the time of print, one gold sponsorship package is still available for this year’s conference. The package represents great value, including a trade stand, delegate registrations, a 10-minute session in the conference program, signage and acknowledgement. For more information, contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry. com.au

For more information, contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry.com.au

By Jennifer Milward

WESTERN AUSTRALIAN BRANCH NEWS Cameron Howell from TransTasman Energy Group at the Cairns sub-branch meeting.

Technical and dinner meeting, Cairns The first technical/dinner meeting for the Cairns sub-branch was held in February. The TransTasman Energy Group sponsored the dinner meeting, with guest speaker Mark Desira from the DNRME. Mark reported on the QGL02 Guideline for Management of Respirable Crystalline Silica in Queensland mines and quarries.

Date claimers – 2019 14 May: Technical and dinner meeting, Cairns

Date claimers – 2019 17 May: Annual golf day, Oxley Golf Club

21 May: Technical and dinner meeting, Mackay

19 July: Central Queensland sub-branch annual golf day, Rockhampton

19 June: Safety and health seminar, Townsville

7 Aug: Technical meeting and branch AGM, Brisbane

26 July:

IQA annual golf day, Cairns

13 Aug:

Branch AGM, Townsville

24 Sept: Technical/breakfast meeting, Brisbane

13 Sept:

IQA annual golf day, Townsville

15 Nov: Technical/lunch meeting, Brisbane

By Jennifer Milward

NORTH QUEENSLAND BRANCH NEWS Technical and dinner meeting, Townsville What a start to 2019! The first dinner meeting for the year had to be rescheduled due to the severe weather event that struck the Townsville region in February.

Despite the turmoil of the floods, 30 guests attended the rescheduled dinner meeting at the North Queensland Club. Just as he was at the Queensland branch’s 19 February meeting, Greg Glennon, the eastern region operations manager for Otraco International, was the dinner guest speaker. Greg again provided information on the guidance note supplied by the DNRME on tyre, wheel and rim management.

48

Quarry April 2019

The WA branch’s next two events will be of great interest to all members. The first is a breakfast meeting on Wednesday, 8 May with guest speaker Richard Sellers, the director-general of the Western Australian Department of Transport, speaking on WA’s transport infrastructure priorities. The breakfast will be held at Beaumonde on the Point in East Perth and is kindly sponsored

by Boral.

In June there will be a site tour of the Brikmakers clay brickworks in South Guildford, followed by a sundowner. This event is proudly sponsored by Urban Resources.

Details about both events will be distributed to members and will be posted on the IQA website.

For more information about these coming events or other branch activities, contact the WA branch secretariat, tel 0417 027 928 or email wa-admin@quarry.com.au

By Celia Pavri

8 Oct: Technical and dinner meeting, Townsville 30 Oct: Technical and dinner meeting, Cairns

IQA NEW MEMBERS

IQA BRANCH CONTACTS ACT

Peter Hewson: 0429 001 476

NSW

Gemma Thursfield: 0402 431 090

Northern Gemma Thursfield: 0402 431 090

GRADE

NAME

BRANCH

Associate Associate Associate Associate Member Associate Associate Member Associate Associate Associate Associate Associate Associate

David Henry Young Mervyn John Hain Michael James Jackson Luke James Martyn Benjamin Joseph Grose Clinton Richard Sutton Jordon Luke Staker Bradley Godden Dean Heath Rickards Brendon James Mayo James Nicholas Johnston Amanda Minaro Michaelle Millsom Michelle Rowe

WA QLD QLD VIC QLD QLD NSW VIC VIC QLD NSW NSW NSW NSW

Hunter Gemma Thursfield: 0402 431 090 Illawarra

Dylan Treadwell: 0418 632 057

Central West Mitchell Bland: 0428 462 987 NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Gladstone Jennifer Milward: 0419 782 688 Townsville Jennifer Milward: 0419 782 688 Cairns SA

Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505

Tasmania Nicholas Palmer: 0418 126 253 Victoria

Eli Carbone: 03 8637 4723

Vic Sub-branch Craig Staggard: 0407 509 424

WA

Celia Pavri: 0417 027 928

2 LOTS TOTALLING 40HA* AVAILABLE COMBINED OR SEPARATE

Nowergup, 21 Dayrell Road & 80 Gibbs Road

*Outline indicative only

*Outline indicative only

*Outline indicative only

SALE

Brett Wilkins 0478 611 168 brett.wilkins@raywhite.com

Expressions of Interest Closing Tue 30 Apr 2019 4pm (AWST) • • • •

Land area 19.3ha* & 20.75ha* Zoned Rural Resource under City of Wanneroo DPS No 2 Good access to major transport routes 21 Dayrell Road is considered Industrial Investigation under the Green Growth Plan, ideal for sequential land use • 80 Gibbs Road - 57,600kL water Licence * approx

Russ Parham 0499 552 255 russ.parham@raywhite.com Lachlan Burrows 0499 552 296 lachlan.burrows@raywhite.com

raywhitecommercialwa.com

GEOLOGY TALK

THE GREAT 1906 SAN FRANCISCO EARTHQUAKE

A devastated San Francisco, seen from the Lawrence Captive airship, after the 1906 earthquake. The quake was felt over an area of 321,000 square kilometres - spanning Los Angeles, Oregon and Nevada.

The northern segment of the San Andreas Fault runs through the San Francisco Peninsula.

One of the United States’ most famous natural disasters, the Great San Francisco Earthquake of 1906, is notable for furthering geologic field studies of seismic activity. Bill Langer explains why earthquakes occur and the kind of minerals they can yield.

minerals and metals (including gold) in the now supersaturated water crystallise in a process called flash deposition.

A single earthquake can produce an instant, albeit tiny, gold vein. However, there can be hundreds of thousands of tiny earthquakes (fault movements) every year in a single fault system. Over hundreds of thousands of years there is the potential to precipitate very large quantities of gold.

Theoretically, typical rates of seismicity along the San Andreas Fault zone could generate a spider’s web of gold containing almost 100 tonnes of gold in less than 100,000 years.

For the exploration geologist, it is not about where the plate boundaries are now – it’s about where they were hundreds of millions of years ago. Knowing the location of ancient plate boundary faults helps geologists predict where regional mineralisation may occur today.

No amount of gold can make up for the loss of life, pain and suffering caused by earthquakes. However, the more scientists learn about earthquakes and the more seismic-aware society becomes, the better prepared people will be to minimise the effects of an earthquake. •

A

t 5.12am Pacific time on 18 April, 1906, an earthquake with a Modified Mercalli Intensity (MMI) scale of VII to IX swept throughout the entire San Francisco Bay area. The earthquake was felt over an area of nearly 321,000 square kilometres – from southern Oregon to south of Los Angeles and inland as far as central Nevada.

Survivor P Barrett recalled: It was as if the earth was slipping gently from under our feet. Then came the sickening swaying of the earth that threw us flat upon our faces. We struggled in the street. We could not get on our feet. Then it seemed as though my head were split with the roar that crashed into my ears. Big buildings were crumbling as one might crush a biscuit in one’s hand. Ahead of me a great cornice crushed a man as if he were a maggot – a labourer in overalls on his way to the Union Iron Works with a dinner pail on his arm.

Fires broke out in the city almost immediately and burned for days, incinerating buildings across more than 500 blocks in the heart of the city. It is estimated more than 3000 deaths were caused directly or indirectly by the catastrophe, and in

50

Quarry April 2019

excess of 28,000 buildings were destroyed.

In ancient times, earthquakes were believed to be the work of gods, specifically Poseidon, the Olympian deity of the sea, earthquakes, storms and horses. Today we know better.

The current prevailing theory, in a nutshell, is that an earthquake is caused by a sudden slip along a geologic fault. Stresses in the earth’s crust push the sides of a fault together. Stress builds up and the rocks slip past one another. Energy is released in waves that travel through the crust and cause the shaking felt during an earthquake.

There is no doubt earthquakes can cause tremendous damage and loss of life.

Ironically, earthquakes also create a major source of wealth – namely, gold.

Small cavities exist along fault zones deep within the earth’s crust. These cavities are filled with super-heated fluids rich in dissolved quartz, other minerals and metals.

As rocks along a fault slip during a major earthquake, these tiny cavities expand, resulting in a rapid pressure drop.

The pressure drop is sufficiently large that super-heated liquid in the cavities instantly vaporises. The quartz, other associated

Bill Langer is a consultant geologist.

Email bill_langer@hotmail.com or visit researchgeologist.com

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