Australian Mining February 2011

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SERVING THE MINING INDUSTRY SINCE 1908

VOLUME 103/2 – FEBRUARY 2011

www.miningaustralia.com.au

NO.1 FOR MINING TECHNOLOGY AND EQUIPMENT

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LAUNCH ISSUE 8th Annual Australian Mining Prospect Awards co-hosted by AIMEX

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COMMENT

Mining Australian

Copyright Reed Business Information Published 12 issues a year by Reed Business Information (ABN 80 132 719 861) Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Australia Tel: (02) 9422 2999 Fax: (02) 9422 2966 Editor – Cole Latimer Tel: (02) 9422 2352 Email: ozmining@reedbusiness.com.au Journalist – Jessica Burke Tel: (02) 9422 2909 Email: ozmining@reedbusiness.com.au Account Manager – Sarah Bateman Tel: (02) 9422 8994 Mob: 0408 991 585 Email: sarah.bateman@reedbusiness.com.au Account Manager – Tim Richards Tel: (02) 9422 2818 Mob: 0407 948 774 Email: tim.richards@reedbusiness.com.au WA Representative – Jamie Wade Mob: 0435 945 868 Email: jamie@wadebusiness.com.au QLD and SA Sales Manager – Sharon Amos Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mob: 0417 072 625 Email: sharon.amos@reedbusiness.com.au New Business – Alex Evans Tel: (02) 9422 2890 Email: alex.evans@reedbusiness.com.au RBI Manufacturing & Electronics Group: Associate Publisher – Michelle Graves Email: michelle.graves@reedbusiness.com.au Graphic Designer – Dave Ashley Production Co-ordinator – Mary Copland Tel: (02) 9422 2738 Fax: (02) 9422 2966 South Africa – Bob Stephen Stephen Marketing PO Box 75, Tarlton, Gauteng 1749, South Africa Tel: 27(011) 952 1721 Fax: 27(011) 952 1607 USA – Jonathan Sismey RBI 24th Floor, 125 Park Avenue, New York, NY 10017 Tel: (1) 212 370 7445 Fax: (1) 212 370 7441 Email: jsismey@ix.netcom.com Larry Arthur RBI Suite 203, 3700 Campus Drive, Newport Beach, CA 92660 Tel: (1) 949 756 1057 Fax: (1) 949 756 2514 Email: lharthur@ix.netcom.com Printed by GEON 20 Baker Street, Banksmeadow, NSW 2019 Tel: (02) 8333 6555

Playing our part As the mining industry actively helps the QLD recovery efforts, some just can’t resist playing politics.

W

hat a state we’re in.

First floods hit the West coast, inundating Carnarvon.

Then massive floods tragically devastate Queensland, and flood parts of New South Wales and South Australia.

This is soon followed by fires wreaking havoc once more in Western Australia.

Australia truly is a nation in turmoil at the moment, but at times like these we see how Australia really pulls together to support one another.

And the mining industry is playing a major part in the rebuild efforts across the nation.

Not just in providing monetary support and donations (although it is doing this in spades, with the major miners handing over millions to the

Comment Cole Latimer ozmining@reedbusiness.com.au Premier’s Relief Fund and various other charities), but also by allowing employees to receive full pay while working on disaster relief programs and clean ups, with out having to take annual leave.

I doubt many employers would take this course of action, in actively paying employees to do this.

So it is frustrating to see the industry taking an active part in recovery, only to have it besmirched by the hand of Greens leader Bob Brown.

Coming out and blaming the entire mining industry for the floods which have so rocked the state of Queensland, on the back of no evidence at all, after people have died, it’s just disgraceful.

Especially as he is essentially ignoring the major floods that happened in the same area over 100 years beforehand when there was no mining.

On top of this, the fact that Brisbane is built in a flood plain also contributed to its inundation.

And to see this as part of a backflip after previously blaming mining for the drought.

In a situation such as this, it is not the time to play point the finger politics.

Now is the time to band together, get the nation back on track and support those who have been affected.

After this, feel free to play the blame card Mr. Brown.

In the meantime, let the industry support their local communities in the relief effort, clean up, and start again.

Australian Mining’s heart goes out to all those who have been affected by the flooding and fires across the country, and we wish them all the best.

To donate to the Premier’s Disaster Relief Appeal, please call 1800 219 028.

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ON the front cover of the February edition, we’ve featured a tripper spreader at Rio Tinto’s latest coal mine – Clermont.

The mine, which has recently been effected by the devastating flooding that hit Queensland, was opened late last year and is set to slowly replace Rio’s nearby Blair Athol mine, which closes in 2016.

The open cut mine holds approximately 190 million tonnes of thermal grade coal and has an expected lifespan of 17 years with production predicted to peak at 12 million tonnes per annum of export coal and 100 000 tonnes for domestic use.

The mine will feature an in-pit crusher/conveyor system which will run over 13 kilometres.

AustralianMining

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Contents Features

February 2011 issue

A floody big problem

COAL MINING Powering away at the coal face Raising safety in underground mining ....... p12 These computers can cut it Heavy duty excavator computer systems ... p14 PERSONNEL Mining in lights Training staff is becoming easier ................. p16 In-house development Komatsu’s apprentice training program ...... p17 Violence reports a beat-up An investigation into reports of violence in mining communities ........................... p18-19 In the driver’s seat for safety Embracing vehicle simulators on site .......... p20 A fluid solution to a fluid problem Outsourcing our miners ............................. p22 MINERALS PROCESSING Get SET, Go! New thickener technologies are set to change processing ................................... p24-26 QUARRYING/CRUSHING/SCREENING Making an impact on site Impact crushers for damp conditions .......... p30 Your new crush Pre-assembled crushers preventing headaches ...................................................... p32 Bigger is better New Zealand develops the world’s largest cone crusher ................................................... p34 MINESITE VEHICLES In for the long haul CAT’s newly developed long haul trucks .... p36

4 February 2011

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Investigating the effects of the QLD floods...p10

Got you covered Leica creates a GPS that doesn’t fail in pits ................................................................. p38 ACE-ing it Hyundai launches new wheel loaders ......... p40 Pump it up Safer diesel transport and transfer on sites.................................................................. p40 Tired tyres?

Tyres with longer working lives ................... p41 PROSPECT AWARDS In this issue we launch the 8th Annual Australian Mining Prospect Awards, co-hosted by AIMEX .............................. p52-53

Regulars INDUSTRY COMMENT .................................. p6 NEWS ............................................................... p8 PRODUCT SHOWCASE ......................... p50-51 JOBS ............................................................... p54 EVENTS .......................................................... p55

Product Focus

Motors and Drives... p42-48

www.miningaustralia.com.au

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INDUSTRY COMMENT

Resourcing safety reform in WA Western Australia is in changing the face of mining safety in the state, the West Australian Department of Mines and Petroleum writes for Australian Mining.

T

he Western Australian Department of Mines Ridge said that this was a concern for everyand Petroleum is in the midst of one of its one involved in the resources industry in the State. largest recruitment campaigns in recent “Traditionally, it has been held that safety mining history. performance relies upon leadership from the top,” The goal is to ensure the Resources Safety Divi- Ridge said. sion has the resources to regulate Western Australia’s “It is now recognised that although this is expanding industry well into the future. undoubtedly the primary factor, it also requires Resources Safety executive director Malcolm that shop floor personnel, and particularly safety Russell said that this drive aimed to recruit the best and health representatives, are empowered to make possible people for the range of inspectorate posi- a difference too. tions available.

“Unless we harvest the knowl“These are technically and “In order to save lives we edge of our employees and workintellectually challenging posimates so we really understand need to make necessary tions and it is vital we have skilled, the issues in the workplace, it is passionate people to fill them,” cultural changes.” unlikely that our safety performRussell said. ance will improve, and highly “I think the nature of this campaign ensures likely that serious incidents will continue to occur. we are doing all we can to attract the right people.”

“Managers and supervisors should be seeking The campaign is a key part of reforms to safety out the “bad news” and engaging shop floor employregulation in WA. ees and their safety and health representatives in “In the mining sector, as for other industry sectors, meaningful dialogue to develop effective and targeted safety performance has been sitting on a plateau for programs that address the problems.” some time,” state mining engineer Simon Ridge said.

Russell said that in order to save lives and reduce “Our particular industry has struggled in recent injuries on site, industry, the regulator and employtimes to maintain an acceptable rate of improve- ees must work together to make the necessary ment and, in fact, has started to slide backwards cultural changes. in the fatal incidence rate.”

“The significant improvements we are seeking

Resources Safety Inspector Jock Watson at a Goldfields mine site in Western Australia.

in industry safety performance will only occur when every person working in the industry accepts personal responsibility for working safely, at all times,” Russell said.

Further information on the safety reform process and employment opportunities is available at www.dmp.wa.gov.au/safetyreform

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HEADLINES

The latest mining news and safety Australian Mining presents the latest news and safety affecting you from the boardroom to the mine and everywhere in between. www.miningaustralia.com.au is keeping you up to date with what is happening.

Katter slams “inconsistent”, “hypocritical” Greens Greens Senator Bob Brown continues to draw widespread criticism for accusing the mining industry of having a hand in the devastating floods across the country.

Bob Katter, member for the Queensland seat of Kennedy, is the latest to voice his objection to Brown’s comments, saying they are ridiculous and hypocritical.

Earlier in the week the Greens leader suggested the mining industry should foot the bill for the flood clean-up, because the industry is a major contributor to global warming.

But Katter says the argument shows inconsistency.

“There is a problem that will arise in the oceans that we should be cognisant of," he said.

“But Mr Brown, with all due respects, [has] the hide to say to the Australian people that it's causing massive flooding, when not a year ago and for the last 10 years, they've been telling us that it's been causing the drought on the Murray Darling.”

He’s also accused Brown of being insensitive to the devastation people across the flooded areas are suffering.

“I react with great anger,” he said.

Indigenous employment strategy slammed by Rio Tinto Rio Tinto has criticised the Federal Government’s Aboriginal employment strategy and says it does not provide opportunities for Indigenous Australians.

The miner said in a submission to the Government’s proposed economic strategy that companies are left with the responsibilities for Indigenous education and training.

It says all Governments need to work together with industry and local communities to provide solutions, because the current situation is unsustainable.

Rio increased its Indigenous employee numbers by 22 per cent last year, with 1500 employed in the second quarter, but says similar growth cannot be achieved throughout the industry until the government provides assistance.

The issues surrounding social issues and individual communities are complex, according to Rio, and the Western Australian mining lobby says the government should be taking more responsibility.

The lobby wants the government to provide Aboriginal employment, training and education programs.

8 February 2011

AustralianMining

Australian Mining gets the latest news every day, providing mining professionals with the up to the minute information on safety, news and technology for the Australian mining and resources industry.

Clive Palmer saves 60 with private helicopter One of Australia’s richest men, mining giant Clive Palmer has used his private helicopter to save up to 60 people from floodwaters in southeast Queensland.

“Thank goodness we have lost no one,” he said.

According to Sullivan, Palmer’s generosity saved about 60 people in the area, with emergency services stretched too thin to cope with the huge number seeking assistance.

Mining policy story is wrong: NSW Minerals Council The NSW Minerals Council says the reported “rewriting” of Coalition election policies by the mining industry is inaccurate and does not reflect their continuous and ongoing work with the farmers association and the Opposition.

Scott Keenan from the NSW Minerals Council says the report on the Sydney Morning Herald’s website was misinformed.

“The story is wrong,” he said.

“I don’t think they understood we have been in a room more than 50 times with the NSW Coalition and the farmers federation to discuss these matters.” www.miningaustralia.com.au

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COAL MINING

A floody

A

s the ‘once-in-a-lifetime’ floods pummelled Queensland, mining companies were among those brought to a standstill when rain came down.

And as the flood waters rose, companies including Rio Tinto, Vale, Cockatoo, BHP Billiton, Aquila Resources, Macarthur Coal, Wesfarmers and Xstrata closed their operations and were under full or partial force majeure, allowing companies to miss scheduled deadlines due to circumstances beyond their control.

Special reports on the impact of the floods by IbisWorld predict the loss of revenue for the mining industry to be $2.5 billion as a result of the floods.

The report said more than 15 million tonnes of coal that would have been shipped has been lost since the floods began in December and export losses will total $2 billion by the end of 2010-11.

The loss of exports from the State has been picked up by the US and has also placed NSW mines under pressure to fill the gap.

“There’s likely to be a big swing towards Newcastle for that additional supply. We’re already hearing of customers that are already rushing there for more coal,” Mark Pervan, from ANZ Commodity Research said.

While many are making predictions and estimating losses, the affects of the floods on mining will still not be known for some time.

“Once the pits are free of water, we'll have more coal exposed that can be processed and transported, but it is not possible to predict when we will return to a steady state of mining as that largely depends on any future rain,” Macarthur Coal chief executive Nicole Hollows said Federal Resources Minister, Martin Ferguson told Australian Mining the industry is trying its best to get back on its feet.

“Now that the waters are retreating companies are focus10 February 2011

AustralianMining

BIG PROBLEM

The floods have struck a serious blow for the industry, but it is not out for the count, Jessica Burke reports.

Companies were under full and partial force majeure due to the floods.

ed on doing priority assessments. Clearly ports are heading up stockpiles so the sooner they get it going the better,” he said.

With government departments only taking crisis calls and miners desperately trying to find ways to recover from the battering, they try to figure out the future of their companies and the State.

However, the mining industry has been one of the most generous donators to the flood relief, with Xstrata first to donate, contributing $1 million on 30 December.

Rio Tinto has given over two million dollars worth of donations, split between the

Premier’s Flood Relief Appeal, Emerald charities and organisations.

BHP Billiton added to the $300 000 donated by the BHP Billiton Mitsubishi Alliance (BMA) with another million dollars and has pledged to match donations made to their Matched Giving Program.

Rio Tinto chief executive Doug Richie said his company wants to help out in any way they can.

“We have all been shocked by the extraordinary flood events that have impacted much of our state,” Ritchie said.

“Queensland is home to many Rio operations and we have around 7,000 employ-

ees working and living in Queensland, some of whom have been directly impacted by the floods.

“In addition to this donation, Rio Tinto is helping in other ways during this time of need,” he said.

“This is why Rio has launched an employee volunteering programme which allows employees based in Brisbane to receive their usual salary and benefits while helping in the clean up, without having to take annual leave.”

Despite the assistance efforts from Australia’s major miners, it wasn’t long after the tragic floods hit before politics came into play.

Transporting resources became impossible, with railways under floodwaters.

Greens Leader Bob Brown attracted a barrage of criticism for declaring the mining industry partly to blame for the floods and should therefore pay for the clean up.

He wants half of a 40 per cent mineral resources rent tax quarantined in a fund to pay for future natural disasters.

Ferguson said Brown should consider the affects the floods have had not only on the mining companies, but also on the workers and their families.

“In the midst of this crisis, it is important to remember that it is not just the coal companies taking a hit,” he said.

“Workers in the coal industry, their families and their local communities are suffering. It is time for pulling together, not pointing the finger.”

As they try to get back on their feet following the devastating floods, there is still not a lot of light in the near future for the mining industry.

The skills shortage is only expected to worsen as mines need more staff to deal with the impacts of the tragedy, and more floods are expected across Queensland, according to long term forecaster Haydon Walker.

He says there is more heavy rain to come, with a second cyclone expected to form in late January and three more in late February and early March. www.miningaustralia.com.au

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COAL MINING

Powering away at the coal face An 11kV longwall system is raising the standard of underground coal mining.

H

eavy electrical equipment requires extremely high levels of safety precautions when operating in volatile underground mining environments.

These standards are even more important when dealing with high voltage machinery in coal mines.

The Ampcontrol Group has focused on designing equipment that excels in this dangerous environment.

The company has produced the world’s first 11kV Armoured Face Conveyor (AFC) longwall system for use in Zone 1 hazardous areas.

It was developed for Xstrata’s Blakefield South coal project in the Hunter Valley, who’s AFC needed three electric motors rated at 1.5MW. However, providing this much power at the industry standard voltage of 3.3kV would create a number of operational problems that are typically associated with starting large capacity motors on AFC’s at this voltage.

These issues include an excessive voltage drop, reduced motor starting torque, reduced motor efficiency, and

12 February 2011

AustralianMining

A longwall miner in operation at Lithgow’s Springvale coal mine.

an increase in short circuit currents as well as cable handling problems.

Ampcontrol devised an 11kV longwall system which is safe for explosive environments and can power three 1600MW AFC motors while addressing the voltage problem and at the

same time provided a step change in AFC capacity, allowing it to significantly increase production rates along with the potential for increasing coal face widths which were not realistic using only 3.3kV. Ampcontrol also created a new Intrinsically Safe (IS)

LED lighting system, an innovative 11kV protection scheme and a SIL-3 rated high integrity isolation system.

On top of this it incorporated individual outlet visible disconnect load break isolators and fault make earth switches into all load supply outlets.

Single point isolation control systems were used for the longwall face 11kV and 3.3kV drive systems, which allowed for maintenance without requiring high voltage isolations.

Its PLC was independently certified to a safety level equivalent of only one failure every 100 000 years.

For its innovative design, the 11kV electric system was awarded an Excellence in Engineering award by Engineers Australia.

During 2010, Ampcontrol’s subsidiary ATF Mining Electrics also completed the electrical systems for the first 55 tonne Petitto Mule Longwall Shield Retrievers imported into Australia.

• Ampcontrol 02 4961 9000 www.ampcontrolgroup.com

www.miningaustralia.com.au

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COAL MINING

These computers can cut it Computers designed to operate in open cut coal mines are improving efficiencies.

C

omputers are becoming a more frequent sight on mine sites.

It is unlikely that you can visit any site without seeing some form of computer controlled machinery improving efficiency.

However, not all computer technology is up to the job of working in harsh and unforgiving mines.

In coal mines, it’s vital to ensure that the computer technology is able to deliver crucial information, and Kontron’s CompactPCI systems are up to the task.

The system was utilised

by EWG automation GmbH at the Welzow South coal mine in Eastern Germany to renew its outdated diagnostic and visualisation systems for its open pit excavators.

When testing various systems, it required one that had to tick a large number of boxes.

It needed a system that could collect data and the excavator performance after which the excavation angle can be adapted to the hardness and geological composition of the coal and faults in the seam.

Additionally, it had to collate data regarding the motor currents and strains, and then send the flow rates from the measuring system directly over Ethernet connections to the excavator operator’s workstation.

While the visual systems required for information in the operator cabins, such as status/error messages of the motors, need only average performance rates for good graphics and moderate hard drive and memory capacity, the requirements for the diagnostics systems are completely different.

Processing the large amounts of data regarding diagnostics, analysis and optimisation of the individual technical processes, as well as the provision of fast status graphics based on complex data sources, requires a con14 February 2011

AustralianMining

The excavators on site required a heavy duty computer system to monitor operations.

tinually high level of computing performance.

On top of this, the user must have access to long term trends which in turn requires extensive database archives.

IO flexibility was also essential.

In order to guarantee maximum flexibility to the field operations, the system needed to support other interfaces such as RS232 ports of industrial IOs and field buses.

Hardware aside, the machinery software had to be extremely versatile.

Typically the computer systems on large excavators are run on different operating systems which are not always the latest versions.

Software diversity requires an open system structure that is capable of supporting all operating systems in different versions.

A software flexible system would also ensure that the migration to any newer operating system would be more convenient.

Due to the fact that investments in process automation systems are long term and the systems have to remain in use for several years or more, it is important that individual

components can be exchanged on a modular basis so that if a defect occurs, or an upgrade is necessary, entirely new systems do not have to be acquired and installed.

Obviously though, the best components are those which do not have to be replaced.

EWG needed hardware systems which could operate

reliably even under the harsh conditions of open cut mining.

Because of this, the systems had to be able to safely start in all operating situations and under all conditions.

The components would also be exposed to a high degree of pollution caused by small amounts of dust from the ventilation systems.

The work station.

Importantly, the computers had to be able to withstand a great deal of mechanical stress, including low frequency vibrations in the 5Hz range.

Non-directional impacts and shock loads must also be taken into account.

Given these pressures and the required availability, the systems had to be designed in an extremely robust fashion.

Lastly, it enforced the requirement that all components should come from one source and should be available as standard components.

Based on this long list of criteria, EWG chose Kontron’s CompactPCI due to its robust construction and the fact that it has a wide range of IOs. EWG’s configuration features a Kontron 3U CompactPCI rack system chassis.

An integrated CompactPCI switching power supply and an external UPS take care of the non-fluctuating power supply and protect the equipment from damage due to voltage changes.

A high performance 3U CompactPCI processor CP307 Intel Core 2 Duo processor with 2.16GHz, 667 MHz front side bus and up to 4 GByte of DDR2 SDRAM delivers the computing power needed for the measurement and visualisation systems.

In order to provide additional interfaces such as RS232 or PS/2, EWG opted for the expansion module.

As the processor and memory are both soldered, it is equipped to withstand the continuous effects of shocks and vibrations typically found in mining machinery.

Speaking to Kontron’s Australian marketing specialist Mike Schwaab, he said that the company has a number of specialist computer systems for the mining industry.

• Kontron Australia 02 9457 0047 info@kontron.com.au www.kontron.com.au www.miningaustralia.com.au

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PERSONNEL

Mining in LIGHTS W

hile a major focus of the mining industry is on retaining staff, there is also the issue of how to actually attract people in the first place.

While money is a large motivator for many, how can you ensure that you attract the people you want and keep them as well?

Production Hut’s creative director Damian Kent believes the Australian mining industry has revolutionised staff communication through using visual mediums.

“There are not many tools that allow you to really engage with, retain and train staff across multiple locations and departments.

“Video gives you the ability to showcase your company first hand, and capture the genuine sentiments of your existing staff and customers,” Kent said.

“It’s common in the mining industry for companies to undergo re-branding or to acquire smaller businesses, leaving them with the need to establish and reinforce the brand and its values to staff.”

According to Kent, the more successful and impacting staff videos typically feature current staff, not actors, and contain real quotes, not scripted voiceovers.

It recently shot a national staff video for Hanson Heidelberg at dozens of locations around Australia and featured actual Hanson staff talking unscripted about why they like their work.

“It was well received because people can identify and relate to genuine and truthful accounts from real life people,” he said.

The same rule applies for training videos, Kent explained.

“Whether you are teach-

Video training is making education of staff easier than ever.

Training videos are shot on site.

ing staff how to complete a task or educating them about company health and safety procedures, a video can give them a real life look at what they are in for.”

Kent went on to say “we advise companies to use existing staff to demonstrate procedures and tasks and we prefer to film training videos on site.”

For operating in multiple locations, companies can utilise the internet, which has allowed them to cut training and travel costs by uploading the video onto their own websites.

And with many Australian mining and services companies operating across a number of countries, this transnational approach has allowed compa-

nies to reach out to their furthest projects.

“More than 70 per cent of the videos we produced in 2010 were also compressed and uploaded to the clients’ website,” Kent said.

• Production Hut Damian Kent www.productionhut.com.au

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AustralianMining

www.miningaustralia.com.au

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PERSONNEL

In house development Komatsu has developed a program to train apprentices in the Komatsu style.

O

ne thing the industry will soon Due to the success of the program, be crying out for is young, Komatsu will being rolling the scheme trained, professional plant out across its Australian sites to all and heavy machinery technicians. new apprentices, Komatsu Australia’s A company that is seeking to national organisational development address this major staffing issue is manager Paul Richardson said.

Komatsu Australia.

“We’ve refined (the program) In 2011, the company is aiming somewhat, based on our experiences to nationally roll out its apprentice- with the 2009 intake, and made some ship training scheme, which aims to minor adjustments which are being not only give apprentices technical training they require, but to Apprentices doing the program also teach them ‘life skills’. were six months ahead of those Originally set up at Komatsu’s in traditional apprenticeships.

Hunter Valley sites during 2009 and 2010, the Apprentice Development System (ADS) is designed to applied to our Hunter Valley apprengive entrants to the industry not only tice intake for 2010,” he said. key trade skills, but also life and “It’s now at the stage where we personal responsibility and aware- feel confident about rolling it out ness, according to the company. nationally and it will be applied to In the first year of the program it our 2011 apprentice intake. We’ll have achieved measurable results, with appren- around 40 apprentices in Australia tices being six months ahead of their participating in this program this year, peers doing more traditional appren- and are aiming at a large increase in ticeships and are predicted to have a 2012 and every year after that.” minimum of a one year advantage at Currently Komatsu has a total of the completion of their training.

130 apprentices, both in house and

www.miningaustralia.com.au

employed via training providers.

Komatsu is also extending its partnership with TAFE NSW, which helped to develop the scheme, to include TAFE Queensland and TAFE Western Australia.

Overseeing this process will be Ian MacCowan, the newly appointed GM for regional operations, supply chain and apprentice development.

Previously most of its apprentices were trained through various training groups.

“In the past, we opted for group training providers, but now we recognise that if we are to develop people for the future, we need to lift their skill levels,” MacCowan said.

The company also sees the program as a way of retaining staff and “developing our own people through our own culture.”

• Komatsu Ian MacCowan 1300 566 287 info@komatsu.com.au www.komatsu.com.au

Komatsu Australia’s Ian MacCowan.

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Violence reports a beat-up Have reports of violence in mining camps been blown out of proportion by the media? Jessica Burke investigates.

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re mining communities’ alcohol and drug fuelled violence rings, overrun by workers who fly in to cause damage and leave again without a care for the community ? Or are they small towns desperately fighting against the pre-conceived notions of the industry?

Reports late last year on an investigation into mining camps said people living in mining communities are more than twice as likely as those who live in other areas to face violence and social unrest, mostly fuelled by alcohol and drugs.

Local police and mining industry bodies dismissed claims that violence in Western Australia’s mining areas is the worst in Australia following reports on the Queensland University of Technology’s study, entitled ‘Booze, Blokes and Brawls.

“In one WA mining community, which was surrounded by work camps housing about 8000 mostly male workers, the rate of violence was 2.3 times the state average,” the report said.

But police in the GoldfieldsEsperance district, which has eight mining campsites, say that there has actually been a decrease in alcohol-related violence in Kalgoorlie-Boulder.

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The mining industry has rubbished claims that work camps are filled with violence and drunkeness.

“Violence has definitely trended downward in the last 12 months,” Goldsfields-Esperance Inspector Craig Parkin explained.

He went on to say that non-domestic assaults in the district had gone down 12 per cent from last year and threatening behaviour had also dropped by 17 per cent.

Parkin has worked in policing in the mining community for eleven years, and says he hasn’t experienced the socalled “culture of violence” in his time there.

Even the author of the study, Professor Kerry Carring-

ton, says the conclusions were blown out of proportion.

She told Australian Mining that the media misinterpreted the findings, which they only “stumbled across” when conducting research into violence in regional communities, not necessarily just mining camps.

“We didn’t go there trying to find this information, but what we have discovered is that more needs to be done,” she said.

“The other thing is that those camps are not all bad.

We didn’t conclude that at all.

They are not all negative.

That’s one of the many things

the media has gotten wrong.”

Carrington does maintain that more work needs to be done to curb what she calls “organised drunkenness” in the mining communities.

“Camps had courtesy buses that would arrive at the end of shift and just drive them to the pubs.

“Police who we interviewed were working out of dongers and they couldn’t cope.”

But industry executives say workers are actually subjected to much stricter drug and alcohol screenings than the general population, and companies have no hesitation

sacking workers who breach their liquor restraints.

“Our members take their responsibilities very seriously and they are often the only employers which have mandatory alcohol and drug testing”, says Reg Howard-Smith, chief executive of the Chamber of Minerals and Energy (CMEWA).

The CMEWA has criticised the claims in the report, saying there is a lack of reliable data or statistics.

“The report used emotive language and relies heavily on anecdotes,” Howard-Smith said.

“We don’t know where the research was conducted, who was spoken to, or the circumstances of the incidents outlined.”

Carrington defends the secrecy surrounding the exact locations and sources used in the report, and says their complex methodology was approved by the university.

“We cannot name names because of the nature of these communities, but we spoke to mayors, doctors and nurses,” she told Australian Mining.

“But if you say, ‘we went to this town and spoke to a nurse’, well she might be one of only a few and could therefore be identified.

www.miningaustralia.com.au

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The study found ‘organised drunkeness’ a problem in towns.

“The same thing goes for mayors and councillors; we couldn’t provide details of the towns we were referring to because it would be obvious.”

But the findings have been criticised by the Opposition Spokesman for state development, Mark McGowan, who says they are the result of skewed data because the towns do not represent typical gender ratios.

“I think the report is a bit over the top and I’m not sure that it’s accurate, I think in a lot of communities where you get lots of men working toge-

www.miningaustralia.com.au

ther, of course there are going to be incidents,” he said.

Robert Hicks, CEO Goldfields-Esperance Development Commission (GEDM) told Australian Mining he disagrees with the findings and says mining communities cannot be all categorised as the same.

“Each mining town is quite distinct and different and has its own community and unique situations.

It’s quite improper, wrong, to generalise on mining towns, because what is a mining town?

Are we talking about Kalgoorlie-Boulder with

40 000 people or somewhere like Karartha with 1 500?”

He said the report does not take into account the dayto-day realities of mining communities.

Hicks fears the negative publicity caused by the reports will discourage families from considering relocating to mining communities.

“It bothers us that this sort of report may discourage people from considering to relocate to mining towns.”

There are calls to end the ‘blokey’ culture in the mining towns, by enticing families to relocate to the area and by employing women at the mines.

“The reality is there are a lot more women working in mining,” Hicks said.

“When I walk around I see an increase in women at the mines, and the accusations it is a male dominated industry are wrong.”

But the report’s author dismissed claims it has damaged the family-focused communities the mining industry are trying to develop.

“I think that’s a cheap point,” Carrington said.

The mining industry says it wants to encourage more families to work and to live in regional mining towns.

Carrington told Australian Mining that one of the biggest problems identified in the report are the FIFO workers.

“Studies of the social impact on adjacent communities needs to be done and council planning needs to take into consideration the affects these camps have on infrastructure because there’s a lot that goes unrecognised in the industry.

There are a whole lot of discussions that need to be had about whether it’s justified to have seventy to eighty per cent of workers non residents. These are debates mining

communities and industry and governments need to have.

Non-residents are not included in the census data so they’re not planned for.

Communities cannot have enough important institutions, or doctors, nurses, police and the like if they’re only providing for 30 per cent of those who access them,” she said.

Carrington says the media’s representation is “problematic. We’re not about bagging communities or pointing the finger, we’re about encouraging industry, workers and governments to work together.

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In the driver’s seat for safety An underground mining contractor is embracing vehicle simulator technology to drive improvements in unscheduled maintenance costs and operator safety and efficiencies. Jamie Wade writes for Australian Mining.

W

A-based underground mining contractor Barminco has its pedal to the metal.

With base metal prices shooting to record highs and gold prices hovering at near record levels the company is experiencing rapid growth, but that growth is not without its share of challenges.

With a workforce in excess of 1600 employees in Australia including more than 120 heavy vehicle truck drivers and 50 loader operators in underground operations, training new and existing operators to safely and effectively operate a heavy vehicle has become a critical factor.

To that end, Barminco has turned to vehicle simulator technology to boost training capacity and reinforce its approach to safety with the purchase of a UG360 Advanced Equipment Simulator from Immersive Technologies.

The acquisition includes a transportable UG360 simulator, three modular Conversion Kits - equipment modules – and a virtual Custom Mine Site training environment.

Barminco CEO Neil Warburton said the advanced operator training solution would support Barminco’s ‘Safety First – Safety Foremost’ commitment to its employees and drive improvements in unscheduled maintenance costs and operator efficiencies.

“This is a significant addition to our training capacity and we are looking forward to passing the benefits realised through this process onto our clients,” he said.

“Maintaining a high standard of training is vital for ensuring high safety standards across all of our projects. This is particularly important as we grow our presence in the international market and seek to maintain a strong position in the Australian market.”

Immersive Technologies’ chief executive officer Peter Salfinger said the company 20 February 2011

AustralianMining

The simulators allow for training on replicas of the operator’s actual underground worksites.

was proud to partner with Barminco to deliver a sustainable training solution that underpinned its proactive approach to safety management and to measured work performance.

“Immersive chose not to enter into the underground market until it was confident it could provide the industry's best simulator solution,” Salfinger said.

“The UG360 achieves that goal and we look forward to helping Barminco achieve its business goals."

The sale to Barminco continues Immersive Technologies' strong growth during 2010 which follows the company's launch of its next generation product range, the PRO3 for surface mining and the UG360 for underground mining in August 2010.

“We are pleased to see the level of positive interest from the mining industry to our new UG360 technology,” he said.

“In addition to partnering with Barminco, two underground mining customers in Australia have already acquired these simulators and have

since incorporated them into their operator training programs.

“These include a leading copper miner in northern Queensland and large nickel producer in Western Australia.

Globally, Immersive has a number of additional UG360 simulator deals underway.”

Immersive Technologies was appointed Barminco's preferred supplier for simulation technology following a rigorous international tender.

“Barminco demonstrated a commitment to partnering with their suppliers to develop and commercialise new technologies,” Salfinger said.

Immersive Technologies’ simulation expertise and track record in successfully integrating and supporting its technology to meet customers' long-term business objectives were noted as key success factors, together with Immersive’s strong exclusive OEM alliances, provided Barminco the confidence of a ‘futureproofed’ simulation platform.

In development for three years, the UG360 simulator is specifically designed for training in underground mining conditions.

It is said to deliver the highest level of fidelity through advanced display, feedback

The simulators provide a safe learning environment.

and measurement systems intended to provide a trainee with maximum skills transfer in a completely safe learning environment.

The first conversion kits to be made available for the UG360 are a range of Caterpillar underground trucks and Load Haul Dumps units.

The accuracy of these kits was made possible through Immersive Technologies’ exclusive technical information alliance with Caterpillar Inc. This sees CAT provide Immersive with access to its engineers and confidential technical information to develop the simulators.

“Given that Barminco has the largest underground fleet of Caterpillar loaders in the world, partnering with Immersive was very compelling,” Warburton told Australian Mining.

In addition to Caterpillar, Immersive Technologies has exclusive licensing and technical information alliances with leading Original Equipment Manufacturers including Hitachi, Komatsu, Liebherr and P&H MinePro. These alliances provide Immersive Technologies with exclusive access to confidential technical information that is required to properly simulate the OEM’s machines.

Warburton said the company’s investment was expected to pay off for Barminco and its clients.

“As many of our clients are paying a fixed sum for our equipment and senior staff to be onsite, they’re expecting the equipment to have a certain availability and performance.

I believe that having better trained operators will result in more efficient vehicle usage and, therefore, greater productivity – the financial benefits of which will go straight to the client’s bottom line,” he stated.

Barminco’s simulator will be commissioned in March this year. www.miningaustralia.com.au

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A fluid solution to a fluid problem A fluid workforce is damaging the mining industry, Jessica Burke reports.

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ompanies are failing to retain staff and skilled workers are being lured away by better jobs offers midway through other projects, leaving behind frustrated teams and difficult games of catch-up for new contractors brought in to pick up the pieces.

The largely fluid and unstable workforce in the mining and resources industries is well documented, and Kristine Berry, Director of engineering and ECPM (project management) recruitment firm, says the trend will cause serious disruptions if left unresolved.

“Key contractors leave before the completions of a project and then you have their replacements playing catch-up, resulting in frustration and burn out on the part of other team members.

A recent survey conducted among their database found that only a quarter of respondents are demonstrating loyalty to their current organization, and nearly half would seriously consider moving for the right opportunity.

These kinds of statistics are concerning for owners and managers, as the need for skilled workers increases and they scramble to keep up with their offers at other companies.

“Skilled workers realise they are in demand. They have the luxury of considering more attractive opportunities with other companies, and a very good chance of being successful due to the lack of overall candidate competition in the industry,” Berry said.

She adds that industry workers are “clued up” on alternate opportunities on the market.

“Companies are aware of this risk, and we are seeing a remarkable increase in salaried staff positions over contractual arrangements.”

Workers are lured away, often headhunted by larger companies, with the promise of better pay, travel agreements and other incentives.

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AustralianMining

High unemployment levels overseas means skilled foreign workers are willing to work in Australia.

Bernie Hogan, from Site Work Ready, says there is only so far companies can stretch to accommodate the demands of the workers.

“These guys are able to say ‘Yes, Big Company, hire me, I’ll work for you if you pick me up and drop me home for footy on Saturday’. I think they need to work on eliminating this. It becomes an arms race and it will become unattainable, as the demands get bigger and bigger.”

Site Work Ready describes themselves as a ‘one-stopshop’ for skilled industries including mining.

They say they have identified a hole in the market and are moving to solve the problems by providing skilled workers, who are trained according to Australian standards at their main training centre in the Philippines.

“What people do now is they go across the globe looking for staff. It’s like speed dating sometimes, they interview 200 people, get 100 to start work, which is a very risky venture.

We’re taking a pre-emptive step, telling the industry to think and understand how many people they are going to need in specific roles for a mining project.

“There’s been huge investment and growth in the mining industry in the last 12 years and there are cascading effects, as contractors need numbers, as do the maintenance teams.

Also it’s created a situation where people want FIFO’s or they want to work in maintenance based in capital cities so they can stay with their families and in the cities.

“We’re offering a workforce willing to go where you need them to.”

He told Australian Mining the workers are trained not only in skills they require, but must also successfully pass English tests and be aware of Australian culture, including slang and even sports like football and cricket.

“Our company has a different mentality to a lot of the companies who bring foreign workers over. We’re not going to graduate someone who can’t speak quality English and has the same qualities as

someone who companies train here,” Hogan said.

In December, mining giant Clive Palmer announced plans to have 10 per cent of workers at his $8 billion coal development in the Galilee Basin of central-west Queensland sourced from China.

“In Western Australia, at our projects there, we’ve had around 7000 workers and about seven or eight hundred Chinese engineers who are directing the work.”

He said it “would probably turn out something like that” at his Queensland site.

Moves to source miners from other countries have been met with widespread criticism, with concerns raised about the loss of local jobs in favour of cheap foreign workers.

Hogan counteracts these claims, saying the workers must be paid the same as Australians and therefore will not be providing companies with the same amount of work for less money.

“We’re talking about a 200 000 shortage of people in WA alone, across the different sectors. Going overseas won’t cure the problem completely but it will allow a guaranteed workforce for some of the roles,” Hogan said.

Experts say the lack of skilled workers needs to be addressed. www.miningaustralia.com.au

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Coates Hire can provide you with a totally reliable solution to help maximise productivity on any Mining project.

With more than 1.5 million items of equipment, plus over 200 branches nationwide, Coates Hire is the largest and most experienced hire company in Australia.

So talk to the experts at Coates Hire, they’ll make sure you get the right advice and right gear for your project.

coateshire.com.au

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MINERALS PROCESSING

Get

SET, Go!

New thickener technology is SET to change processing, Chad Loan and Ian Arbuthnot write*.

A

n effective thickener is indispensable in getting the most out of processing.

Inside most thickener tanks, there are several layers of varying aggregate compositions and suspension density exists.

To achieve an appropriate underflow density, the free settling, hindered and networked zones should remain largely undisturbed.

However as the pulp bed increases in depth it becomes increasingly difficult for released liquids to filter through the pulp.

Dewatering pickets attached to the rake arms assist in removal of the liquids and pickets are typically spaced at equal intervals to produce dewatering channels.

Rotation of the rake assembly with pickets increases the potential for pulp bed rotation, which is more commonly known as ‘donutting’ or ‘islands’.

Determined to push the processing sector forward, Outotec has developed a new technology – Shear

24 February 2011

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The shear rates applied to aggregates by a moving shearing element is generally expressed by: ?= k.ul / î ……..(1) where ? is the shear rate in s-1, ul is the linear velocity of the shearing element in ms-1, î is the distance between the shearing element and the aggregate in meters, and k is a constant, which is a function of the material properties of the pulp. ul = 2pv.l ………(2) where v is the rotational speed of the shaft in s-1; and l is the distance from the centre in meters.

Sedimentation zones differ as the aggregates flow through the tank.

Enhanced Thickening (SET) to address these problems.

The theory of SET Following previous studies of applying shear to the hindered settling zone

to increase both sedimentation rates and the compressive yield stress of the pulp bed, Outotec carried out further processing investigations and developed the Shear Enhanced Thickening (SET) technology.

Both the equations (1) and (2) indicate that as the distance from the axis of rotation increases, then linear velocity of the shearing element increases proportionally.

Continued on page 26

www.miningaustralia.com.au

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MINERALS PROCESSING

Continued from page 24

and ‘shear enhanced’ thickener conditions.

Angling the proportionTest ranged in flux rates ally spaced shearing elements from .5 to 2.0t/m 2h and a to the vertical plane will result rake rotational speed from 1 in a substantially uniform rpm, under both standard and cumulative shear being applied sheared conditions, and with to the aggregates by the time constant bed heights of they exit the shear zone.

500mm.

Following these tests, it Validation was clear that higher underOutotec’s test work units flow density for the same thick(94mm, 190mm and 1m pilot ener size could be achieved. scale) were modified to incorA 40m SET could be porate a SET mechanism to utilised to produce a paste provide a uniform cumula- like underflow of 62%w/w, tive shear to the hindered well above the 52%w/w from settling zones. a 57m high rate thickener.

The company carried out If a gold sample required one of its tests on gold tail- full scale underflow density ings, which aimed to evalu- of 52%w/w, a flux rate of ate the association between .5t/m2h would be needed using flux rate, uniform cumulative a high rate thickener. shear and underflow density.

If this plant were to treat The tests were carried out 1500 t/h of tailings, a 62m in the 94mm dynamic thick- diameter high rate thickener ener under ‘standard high rate’ would be required.

However, if SET technology is used, a flux rate of 2.0 t/m2h or higher could be selected and would result in a 31m diameter SET thickener.

Assuming this, it could be implied that to obtain an underflow density of 52%w/w with SET a flux rate of 3.0t/m2h could be employed.

At this flux rate, a SET thickener of only 25m Results of the pilot thickener tests.

Test worked showed a marked increase in underflow density for gold tailings.

diameter would be required versus the 62m high rate thickener without SET. Alternatively, a higher underflow density for the same thickener size could also be achieved.

For instance, a 44m SET thickener could be used to produce a paste like underflow of 62%w/w, a density that is well above that of 52%w/w from a 62m high rate thickener.

Conclusions Across all of the standard high rate thickening test work, the company found a drop in underflow density with increasing flux rates.

When uniform cumulative shear is applied, the underflow densities remain and also, in certain circumstances, increase significantly at up to three times the flux rate.

It found that the SET underflow densities are consid-

erably higher than those that are produced under normal conditions.

The implications on thickener design sizes are extremely significant.

For example, if this data was extrapolated and assuming a linear drop in density, it could be implied that to obtain an underflow density of 52%w/w with SET thickening a flux rate of 3.0t/m2h could be employed.

At this flux rate a SET thickener of only 25m diameter would be required, as opposed to a 62m high rate thickener.

Alternatively, paste like underflow could be produced at higher flux rates with Shear SET technology, without the need for deep sidewall paste thickeners.

Realisation After discovering these test results, the company is now

focused on full scale installations of the technology.

To date it has already retrofitted a SET mechanism to an existing 8m CCD thickener application.

The previous high rate thickener produced an underflow density of 45%w/w with a flux rate of 1.33t/m2h.

After SET was installed, the underflow increased to 54%w/w and the flux rate jumped 20% to 1.61t/m2h.

Outotec has also been commissioned for a greenfields installation this year. *Chad Loan is a thickening specialist with Outotec and Ian Arbuthnot is a director of special projects with the company.

• Outotec Chad Loan 02 9984 2500 chad.loan@outotec.com www.outotec.com

Safety first. Call us first.

Chandler Macleod’s innovative approach to workplace safety wasn’t developed by accident. It’s part of the range of effective workforce solutions we implement to unleash the potential of your business.

We understand today’s complex workforce structures and have specialist expertise in mining and energy. This means you can concentrate on running and growing your business, while relying on us to source, assess, develop and manage your workforce.

WORKFORCE

All our workforce operations are underpinned by integrated and innovative OH&S programs that have helped us to become one of Australia’s safest employers.

In fact, many of the region’s most highly regarded companies use our services to help them reduce workplace risk, while enhancing the efficiency of their human resources.

Visit www.chandlermacleod.com for details of the specialist mining and energy team closest to you.

RECRUITMENT

CONSULTING

www.chandlermacleod.com 26 February 2011

AustralianMining

www.miningaustralia.com.au

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BAC Modular Workplace and Storage Systems (P) 02 9832 2777 • 193 - 195 Power Street Glendenning NSW 2761 www.bacsystems.com.au

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MINERALS PROCESSING

Smart load sensors OMNI Instruments is distributing a smart load sensor called LoadSense, developed by Sensor Technology. The new development allows weighing processes to be fully integrated with handling operations. All live data is captured in real time and can be transferred to a database, stored and analysed. It allows users to know how much material has been transported, or for handling Captures data in real time. two or more materials simultaneously which need to be accounted individually. The development is an intelligent load sensor that can be integrated with a crane hook, fork lift or other handling device. It has an on-board single-chip computer for recording, analysing and archiving readings, and wireless communications capability which can transfer data in real time to a host computer. Internal batteries make LoadSense’s operation completely autonomous. Due to this it can be deployed with minimal disruption to operations, and will automatically begin transmitting data.

• Omni Instruments 02 8244 2363 info@omniinstruments.com.au www.omniinstruments.com.au

Temperature sensors Measure thermal dilation.

HBM has released the K-OTC sensor which gives automatic temperature compensation for optical strain gages. Optical strain gages are sensitive to temperature variations because of the sensitivity of the fibre Bragg grating that forms the strain gage and the thermal dilatation of the object being measured. This can be up to 30 µm/m/K, depending on the material involved but, in stress analysis, engineers are normally only interested in mechanical strain. It is based on an optical strain gage applied to an aluminium sensor body. It’s attached to the object under test and only measures the thermal dilatation of the aluminium and the temperature-dependent signal change of the fibre Bragg grating. This means that no mechanical strain is transferred.

• HBM Australia 02 9889 8070 www.hbm.com

Linear positioners PARKER Hannifin has released the PROmech precision linear positioners. The positioners are designed for industrial automation applications, and are matched to fit any application.

It features a miniature profile, optimal length to travel Comes fully assembled. ratio and the ability to travel between 5mm and 50mm. The linear positioner comes as a fully assembled package, including the motor, as a multi-axis platform. The PROmech LP28 is a packaged linear positioner whose completeness reduces OEM component selection and system design time. Further, PROmech positioners minimise re-engineering requirements because the positioner’s design is already fully tested. Building a linear motion axis from scratch requires the procurement, tracking, receiving, inventorying, kitting, assembly, and testing of about a dozen parts.

• Parker Hannifin www.parker.com

28 February 2011

AustralianMining

www.miningaustralia.com.au

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Process performance motor technology.

Meeting your mining demands.

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Cast iron motor technology is prepared to answer any reliability, availability and energy efficiency challenge, helping you to achieve the most reliable production applications. For more information visit: www.abb.com/motors

ABB Australia Pty Limited Phone: 1800 222 668 E-mail: motor.sales@au.abb.com

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QUARRYING/CRUSHING/SCREENING

Making an

IMPACT on site

Unique fines problems, unique solutions.

C

rushing ore in Tasmania is vastly different to crushing ore in the Pilbara region.

And operating in a part of the state where the weather is often wet, cold and miserable, Tasmania Mines encountered a number of unique problems when crushing its scheelite and magnetite iron ore.

It operates a tracked jaw crusher, tracked cone crusher and a tracked two deck screen to process the two ores as well as granite.

The magnetite and scheelite is supplied to the crushing plant in sizes of 500 mm and is then crushed down to 30 mm, and then fed into a ball mill for grinding.

Due to the damp operating conditions, the feed materials for the crushers consisted of ore mixed with wet fine material.

This damp material is a concern as it creates blockages in the feeders

The MR 122Z impact crusher crushing magnetite at the Kara Mine.

of the jaw and cone crushers resulting in a drop of crushing production of up to 50% to 75%.

In addition to this high moisture content, the feed materials also contained a wide range of product sizes; from miniscule fines through to large rocks with an ore density 30% to 50% greater than concrete and limestone applications where mobile crushers are typically used.

The miner had a serious problem.

So it approached Wirtgen Australia to devise a solution.

After testing the materials and reviewing the mine, the company came to a conclusion that a Kleeman Mobirex MR 122 Z Tracked Impact Crusher would be the most suitable for the task.

Following a trial of the crusher, Tasmania Mines saw production levels leap by 100% to 150% over the previous equipment’s output.

Wirtgen claimed this is due to the Mobirex’s independent double deck pre-screen, impact crusher and other attachments.

This independent double deck prescreen comes as standard on the machine and is designed to remove more fine materials than a conventional combined feed hopper-grizzly feed unit.

The double deck unit can be supplied with either a grizzly, punch plate or a blanking mat in the top deck and a mesh or blanking sheet for the lower deck.

The top deck allows all material

that falls within the required size to pass through the top deck and either bypasses the crusher or is then screened by the lower deck.

This lower deck removes fines from the material screened by the top deck via a side conveyor and passes the on-size material behind the crusher to rejoin the crushed material on the main conveyor belt after the crusher.

The Mobirex MR 122 Z Tracked Impact Crusher in service at the Tasmania Mines operation is fitted with a punch plate on the top deck and mesh in the lower deck.

The miner believes that that the pre-screen with the correct size punch plate and mesh was the key to dealing with the wet clumping feed material.

In addition to this, a heavy duty construction which accommodated the heavier denser material, and electric drive concept which allows for future external power supply as well as an increase in fuel efficiency.

• Wirtgen Australia Andrew Gotley 02 4735 2699 www.wirtgen-aust.com.au

An independent double deck pre-screen unit.

30 February 2011

AustralianMining

www.miningaustralia.com.au

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QUARRYING/CRUSHING/SCREENING

Your new crush Pre-assembled crushers are saving time and money on site.

A

new crusher that will save time and improve safety has hit the scene and is being welcomed by mining operators.

Metso says it has made assembled crushers attractive to customers by changing the way they are delivered and operated and making it simpler to use and source the crushers.

Neil Rackham, project manager at Metso’s Perth office says the new crushers, which arrive at the mine site already assembled, could save company’s “time, money and logistical headaches”.

“Crushers are typically supplied in various pieces, sourced from around the world, and assembled on site,” Rackham explains.

The crushers are being used to great success at the Karara Iron Ore Project in Western Australia.

“In this case we consolidated the parts in Geraldton on the west coast of Australia so that the crushers could be pre-assembled, and then delivered to the mine site in assembled form.”

In addition to delivering the machine, Metso also says they offer maintenance service and ultimately provide value to the project.

Karara is being developed

by Gindalbie Metals Ltd, an independent Australian ore company based in Perth, through a fifty-fifty joint

32 February 2011

AustralianMining

Metso say their new pre-assembled crusher will save time and importantly ‘logistical headaches.’

venture with AnSteel, one of China’s leading steel and iron ore companies.

An integral part of the Karara operation is the use of the three MP1000 secondary core crushers that were supplied by Metso.

It delivered the crushers fully assembled and to the site, which is made possible because there are no logistical restrictions.

Rackham says there are many benefits that the customer derives from this process.

“First and foremost, there is the element of safety. Assem-

bly work is safer in a workshop environment where workers have better control of their surroundings and potential local hazards.

And obviously they have all the necessary equipment for assembling the parts which need to be assembled free of harmful dust.”

The work carried is carried out by one of Metso’s partners,” Rackham said.

“We have a long-established relationship with them and we can easily address any issues, such as identifying and locating parts, with no impact

on the customer’s installation schedule.”

The company says their approach to crusher delivery will save costs through the elimination of expensive onsite labour costs, as well as the travel and lodging expenses of putting together an assembly crew at the concentrator.

“It can take up to four months to assemble a crusher onsite with our assistance,” he said.

“But with the pre-assembly it only takes a day or two to position the crusher once it’s delivered.

“Plus, many of the typical hazards of assembling on a site are eliminated.”

Once the crusher is assembled, the job of transporting the 157 metric tonne machine then becomes the challenge, but Metso already has experience with this, having delivered five assembled crushers to other sites in Western Australia.

“Our method is quite simple, but it is very elegant,” Rackham said.

The process doesn’t require a crane and takes only a few hours to complete.

When speaking of the customer’s reason for choosing Metso, Rackham notes that it was largely the crusher’s reputation and Metso’s experience that made the sale.

“We’ve been in the business for a long time,” he says, “and we care about what we do and how.

We have the most experience with these types of large crushers.

He goes on to point out that the customer was also influenced by the company’s ability to deliver a pre-assembled machine.

“Knowing that any issues would be handled directly by Metso was an important consideration for the customer,” he said.

• Metso Mining and Construction Technology www.metso.com

www.miningaustralia.com.au

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QUARRYING/CRUSHING/SCREENING

Bigger is better The development of a gargantuan cone crusher is taking the sector in a new direction.

F

or crushing, the industry is always looking at processing higher rates ever faster.

And a New Zealand mining company, Screening and Crushing Solutions (SCS), is definitely leading the way with the development of the world’s largest mobile cone crusher.

Operating out of the Delta Group’s Sunshine plant in Melbourne, the brand new 140 tonne monster is capable of filling the equivalent of an Olympic size swimming pool with aggregate every four hours.

The chief executive of the Brightwater Group which owns SCS, Warren Arthur, said that getting to this point has taken a number of years, and the knowledge gained from over 15 years of making crushers has allowed it to ‘think bigger.’

“In the crushing industry, big is better, and the potential volume of throughput from this machine is huge.”

The size of this machine will enable it to generate approximately 1000 tonnes of crushed rock per hour.

This capacity, combined with its mobility is what really gives the TC1885 its edge,” he said.

And its ability to tram around a site is what sets it apart, Arthur explaining that a “mobile crushing unit can be placed right at the rock face where it is needed.

“The TC1885 can be moved around mining operations depending on where it required, which helps to

34 February 2011

AustralianMining

The massive mobile cone crusher can tear through rock at rate of 1000 tonnes every hour.

eliminate costly double handling of any material.”

By processing at the rock face, it will save miners money on fuel and equipment costs, lowering the cost of production per tonne.

Arthur stated that this crusher is the product of years of development ensuring that the machine is capable of undertaking the massive stresses involved with such an enormous cone.

The crusher itself is powered by a 27 litre 880 HP, twin turbo, V12 Caterpillar engine.

It contains over six tonnes of liquid when fully fuelled and all

hydraulic systems are fully charged.

The crushing cone alone weighs in at 65 tonnes.

The TC1885’s close side setting can vary from 65mm down to 15mm.

Four concave options are available offering feed openings of 500, 360, 240 and 180mm.

SCS believes the potential for the crusher across different applications is high, as the global mining industry looks to increased efficiency and higher production rates.

“The mining industry is looking for ways of consolidating production costs while still increasing production

capability to satisfy future demand,” Arthur said.

Delta’s managing director Con Petropoulos said the acquisition of the TC1885 “gives us a very high capacity mobile solution for a number of campaign crushing applications in mining, quarrying, civil construction and demolition.”

SCS has put manufacturing time for each TC1885 at approximately four months.

• Screening and Crushing Solutions 03 9311 8558 www.scsnz.co.nz

www.miningaustralia.com.au

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MINESITE VEHICLES

In for the LONG HAUL Cat has stepped in a new direction – unveiling brand new on-road haul trucks.

A

n enormous Cat haul truck making its way across the mine is a common sight.

However, while it is a major player in these haul trucks, it has never stepped foot into the on road truck space – until now.

Caterpillar has unveiled its brand new CT610 and CT630 on road trucks in the Northern Territory.

Developed by NC2, a joint venture between Navistar and Caterpillar, the two new vehicles answer the need for large on-road haul vehicles in the mining industry.

The conventional prime movers are available in both day-cab and extended cab options.

According to NC2’s general manager for sales and marketing, Jeff Tyzack, the “CT610 and CT630 are designed to address Australian customers needs.”

The CT610 is powered by a 350kW Cat C13 engine, and has a capacity of up to 57 tonnes.

It has a bumper to back of cab (BBC) measurement of 2.72 metres and is targeted to 19 metre industrial applications.

The larger CT630 is driven by a 409kW Cat C15 engine and has a BBC measurement of 3.10 metres.

This truck can be used for B-double on-highway roadtrain applications and comes in either a 72 tonne or 90 tonne model.

In developing these trucks, the focus was on the growing market place demand for significantly improved fuel efficiency.

36 February 2011

AustralianMining

The CT 630 truck can be used for B-double on highway road train applications.

The development also looked at a more styled body.

Both trucks have sculpted fenders, sloped hoods, a streamlined cabside shaping and a much more overall aerodynamic shape that reduces wind resistance, providing additional fuel efficiency.

The sleek economic design of the trucks was achieved using computational fluid dynamics, a computerised application used to optimise design in the early stages of inception; a 1/8 scale wind tunnel for testing of basic shapes; and finally

The CT610, powered by a 350kW Cat C13 engine.

testing in a full scale wind tunnel.

Additionally, “we’ve chosen a chassis package to support high loads; adding stronger cross members, thicker frame rails, higher capacity axles and suspensions, better routing and clipping of all hoses and wires in the chassis, and finally, stronger suspension and cab supports,” Tyzack explained.

Designers also focused on creating a more comfortable air conditioned cab, which features instrument panel gauges and steering wheel based controls and actively reduce what Cat termed as ‘cognitive demand’ on drivers, allowing them to focus more on the road ahead.

• NC2 Global Glen Sharman 0417 827 194 www.nc2.com

www.miningaustralia.com.au

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MINESITE VEHICLES

Got you covered Leica Geosystems has found a way to provide complete coverage and accurate positioning in open cut mines.

W

ith a number of vehicles constantly traversing a mine site, it is difficult to always keep a track of what equipment is where, and when.

And with the increase of vehicle automation, knowing precisely where the vehicle is, where it is going and how fast is crucial.

The use of Global Positioning Systems (GPS) has made this task easier than ever before, however it is not completely foolproof.

GPS is a system of satellites maintained by the United States air force, which can be received by anyone with a GPS device, and works in a similar way to someone using a prominent landmark such as a tall building to get their bearings.

The landmarks used by GPS systems are very tall – with about 31 active GPS satellites across the sky, orbiting about 20 000km above Earth.

The satellites' orbits are arranged so that, at any time, there are at least four satellites above the horizon anywhere in the world and the receiver then calculates the distance between to each satellite.

It then uses at least three ‘landmarks’ to give your location.

The more satellites in view, the more accurate your positioning.

GPS availability and accuracy is crucial for accurate positioning inside mines, but open cut mines can present challenges for satellite based positioning as the pit becomes deeper and the walls of the pit continually get higher, causing what is known as ‘blackout’ Speaking to Australian Mining, Leica Geosystems sales and marketing executive Geoff Roberts said “this problem of coverage blackout often

38 February 2011

AustralianMining

Leica’s ground based system works independently of satellites to fill gaps in traditional GPS coverage for open cut mines and pits.

occurs next to high pit walls due to the obstruction of the positioning satellite.”

Leica Geostystems have launched the GPS Augmentation Network, which they say will provide optimal fleet productivity by delivering total positioning across sites and diminish

this coverage problem within pits.

The Network incorporates exclusive technology developed by Locata Corporation, which ensures a 24/7 positioning coverage in adverse GPS situations.

To ensure consistent and accurate positioning, Leica’s GPS augmenta-

tion network fills holes in coverage where the “sky view” is further reduced by machinery being in close proximity to pit wall.

The ground base system “doesn’t rely on GPS and can work independently of satellites,” he said.

“You point it where you know you’ve got a hole in your coverage.”

Leica embarked on a partnership with Locata to develop the Jigsaw360, the first fleet management system with the ability to replicate the GPS satellite constellation from the ground.

They say the “ground breaking technology” enables a level of control and flexibility which is not possible from the satellite GPS network.

The development is a significant advancement in the availability of consistent positioning signals and the company says the efficiency and productivity benefits of total positioning coverage make a serious impact on overall productivity.

The company say the technology is also a “significant step” forwards in other areas, including GPS collision avoidance systems and automated mining developments, which depend on constant and accurate positioning. Roberts explained that this system can also be integrated into over site fleet management.

He told Australian Mining that “it will lead to longer terms benefits in the full automation of vehicles within pits, but in the shorter term it is likely to help with the continued development of proximity awareness technologies.”

• Leica Geosystems 07 3891 9772 www.leica-geosystems.com/mining

www.miningaustralia.com.au

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AM.FEB11.PG040.pdf

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MINESITE VEHICLES

Pump it up

ACE-ing it

A new compact diesel tank and transfer unit is safer on site.

S

ilvan Australia has launched a new 200 litre capacity Dieselpak fuel tank and diesel transfer unit.

Designed to be carried on the tray of a ute or in a four wheel drive, it incorporates a number of new features.

These additions include a Piusi BP3000 12 volt diesel pump with a flow rate of up to 45 litres per minute at 1.5 bar.

The compact squat unit is also fitted with a lockable filler cap to reduce the risk of any theft of its contents.

A longer 5 metre diesel delivery hose plus an auto shut-off delivery gun with a hose swivel is also included to make fuel transfer easier.

Impact resistant and U.V stabilised, the tank has a calibrated fill mark and four brass inserts moulded onto the base of the tank to allow it to be permanently secured to the tray of a vehicle with bolts.

It also features an earthing strap.

The compact lower profile tank design can be carried safely on the rear of the vehicle without restricting the view through the rear view mirror or window.

Comes with a longer five metre delivery hose.

• Silvan 1300 745 826

info@silvan.com.au www.silvan.com.au

40 February 2011

AustralianMining

A new addition to the Hyundai Dash 9 wheel loader series is about to hit Australia.

Set to launch at the Australian Construction Equipment exhibition later this month, these latest wheel loaders build on Hyundai’s 7/7A series.

In developing this latest model, the focus was on the wheel loader’s safety and maintenance aspects.

It also has been designed with a range of new features that include a load sensing hydraulic system with more efficient variable volume pump technology.

The wheel loader is driven by the latest Cummins Tier III environmentally friendly fuel efficient engine and incorporates fully automatic power shift transmission comprising of variable stage control as well as multistage clutch cut off.

Additional features of the new Dash 9 wheel loaders are a HI-Mate RMS remote monitoring system as well as an integrated cluster control system and integrated cluster payload management system.

Depending on the model of the loader, it comes with an auto greasing system as standard.

Attention has also been paid to the operator’s cab, which is now larger and comes with improved visibility, climate control and a hydraulic air ride seat for more comfortable operation.

The cab’s access ladders have been fabricated with large steps providing a 20º angle of incline for safer access into the cab.

Inside the cab there is also joystick steering and an integrated rear view backup safety camera.

This latest loader has a larger capacity bucket.

www.miningaustralia.com.au

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MINESITE VEHICLES

Tired tyres?

Bearcat has designed tyres with longer working lives.

W

hat really keeps everything moving on site? Tyres.

And if vehicles on site do not have the best quality tyres things will eventually grind to a standstill.

Servicing the mining industry’s constant need for a better tyre, Bearcat has unleashed its upgraded radial OTR tyres.

Bearcat OTR manager Glen Wolfenden believes that local testing and intense development of the second generation Duratough tyres will aid in more efficient mining.

The company has focused on tread design and depth in their latest tyres.

In particular, Duratough has looked at loader tyres.

The company supplied a set of four 23.5R25 ETLDD2 cut resistant tyres with extra deep tread to a mine to test their performance in typical harsh mining applications.

Heat release channels.

Testing revealed a maximum potential tyre life of 6500 hours.

During the testing period, an emphasis was placed on effective tyre maintenance and management, ensuring correct usage and proper inflation.

Following this trial period, the company found that all

four tyres achieved a full tread life span and retained casing integrity with an overall average hour life of 6210 hours.

In the case of rigid dump truck tyres, six 24.00R35 ETDT E4 tyres were tested

on a Terex TR60 dump truck used in quarrying applications – predominantly cement.

While the tread depth remained at the industry standard, initial testing and continued design improvements were

created, including a heat release and a ‘star’ shaped tread block which assisted in maximising the tread, and therefore ensure tyre life.

On top of this, a heavy dead design was also implemented for the tyres.

As the testing and updating of the tyres drew to a close, it was noted that all six ETDT2 tyres achieved a maximum of 6500 hours.

Three of the tyres situated on the rear of the rigid dump truck continued service after the trial.

This improvement on tread life has increased the tons/kilometres per hour rating from 410 up to 432 tons/kilometers per hour. • Bearcat Tyres Glen Wolfenden 03 9931 0237 glen@bearcat.com.au www.bearcat.com.au

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www.qmw.com.au www.miningaustralia.com.au

AustralianMining

February 2011

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PRODUCT FOCUS: MOTORS & DRIVES

VSD filters

Speed controllers

WESTEK is launching Schaffner’s FN 5040/3045 output filters for variable speed drives.

The basic topology of the Schaffner filters is a series of line inductors and filtering capacitors arranged in either star form or delta-wired, depending on the exact variation chosen as well as Provides sinusoidal line voltages. current rating.

The filters are suitable for inverters with switching frequency selection ranges from 2 kHz to 4 kHz. The Schaffner FN 5040/5045 filters provide a smooth sinusoidal set of line voltages so that irrespective of cable length to a large degree, voltage build-up due to pulse reflection is avoided.

For PWM frequencies of 2 kHz, cable length can be as high as 2000 metres.

These filters are suitable for line voltages to 500 volts, motor frequencies to 70 Hz, and to 200 Hz with suitable derating (50% at 200 Hz).

Rated motor current filters are available from 4.5 amps to 1200 amps.

The Schaffner FN 5040 series has an IP rating of IP00 and the FN 5045 series, a rating of IP20.

• Westek Electronics 1300 937 835 info@westek.com.au www.westek.com.au

LIN Engineering has introduced its BL 100 brushless DC speed controller which can be utilised with a large majority of BLDC motors. The controller operates voltage of up to +48VDC and up to 10 amps of continuous current, with 20 amps at its peak.

In addition it also features closed loop control with adjustable P and I values for finer tuning, according to Lin Engineering. The BL 100 can be used in either analog or digital modes.

According to the company, the analog mode allows users to adjust speed and direction via the on-board potentiometer or external potentiometer for higher resolution. The digital mode allows for communication via RS485 and comes with a complimentary Graphical User Interface, says Lin Engineering.

• Switches Plus Components 03 9587 4044 sales@switchesplus.com.au www.switchesplus.com.au

Mill drives SIEMENS has created updated drives for SAG mills. Equipped with new control and automation technology, the drives were commissioned by Rio Tinto for its three copper ore crushing mills at the Kennecott copper mine.

The new system is based on Simatic S7 for the general control of the mill and a Sinamics DCM convertor for the drive specific control of the rectifier.

Siemens will implement a modernised design where the power section of the existing rectifier remains in operation. It will use the Simatic PCS7as the central system for all visualisation and diagnostic tasks for the three mills.

The scope of supply also includes an additional diagnostic system for enhanced diagnostics, as well as operating data acquisition and remote service features. This enables shutdowns to largely be avoided and maintenance costs to be reduced.

The project will begin in early 2011 and finish at the start of the following year.

• Siemens www.siemens.com

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Email sales@brevini.com.au

AustralianMining

www.brevini.com.au www.miningaustralia.com.au

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PRODUCT FOCUS: MOTORS & DRIVES

Another one bites the dust Motor covers can save costs and improve the life of motors, Margaret Tra writes.

T

he performance and longevity of motors can often be affected by surrounding debris.

Debris such as dust can be a serious problem for mining and minerals processing operations, by damaging plant and equipment, in addition to harming an operator’s health.

Kinder & Co has come up with a solution to tackle the issue with its K-MotorShield motor cover.

It developed the cover, particularly in coal preparation and minerals processing plants, to minimise dust exposure on electric motors.

The motor covers are NEMA specified with different size electric motor housings, from 143/145 to 447/449.

According to the company dust can result in breakdown of electric motor drives in bulk handling and process operations in general.

“Dust impedes the flow of air over electric motors and the cooling fan ,” explains Neil Kinder, managing director Kinder & Co. “The motor fails because the bearing heats up. The whole mechanism

Studies showed that a motor with a protective cover and clean air intake had a 130.4% higher average air flow than those motors without the covers.

runs at the specified temperature that the motor is designed to.

“That’s why there are cooling fans there,” Kinder said.

“Dust is a hazardous to machinery, particularly electric motors. It leads to more maintenance, it involves pulling motors out, and it’s not just the cost of replacing the motor.”

“Motors are not that expensive.

The expense is in the labour. You need a fitter and an operator. One fitter can’t work by himself, there also has to be someone who can manage the paperwork to do all the tag outs. You also need an electrician on-site to assist the fitter. So, the bottom line is if you maintain your machinery properly and protect it from dust exposure, you won’t have the motor problem.”

The covers are a formfitting and do not require clamps or fittings to

be affixed to a motor housing and can be easily removed.

The K-MotorShield differs from what is already on the market because it is standard stock; whereas everything else on the market is made to order and therefore expensive, according to Kinder.

“The motor shield is made from fibreglass, all others are generally metal, therefore very heavy, whereas this is very light.”

According to Kinder, studies by the Institute of Electrical and Electronics Engineers (IEEE) have indicated that K-MotorShield has been effective in simplifying cleaning and maintenance from the outset.

The report also indicated a motor with a protective cover and a clean air intake area enjoyed a 130.4 per cent higher average air flow than a motor without the cover.

The average temperature rise in the winding end turns of a motor with a cover was 1.8 degrees (Celsius) lower (about 69.5°C) than the average temperature rise without a cover.

The K-MotorShield covers will guard against fine powder, slurry and spillage particles, also the natural enemies of electric motors in bulk handling and process operations, according to Kinder.

The cover has been used by mining companies such as Xstrata, Iluka and BHP Billiton.

• Kinder & Co. Neil Kinder 03 9587 9244 www.kinder.com.au

The covers are formfitting and are easily attached to the motors.

44 February 2011

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www.miningaustralia.com.au

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PRODUCT FOCUS: MOTORS & DRIVES

Driving your data Drives are ensuring information access and integration for the future. Schneider Electric’s Paul Cooper speaks to Australian Mining.

Y

ou can’t run a modern mine site without power. And with the remoteness of so many sites in Australia, saving energy and monitoring its usage is a critical factor.

Not to mention actually getting power to a site and controlling it in the first place.

Speaking to Australian Mining, Paul Cooper from Schneider Electric explained that there is a massive focus on “optimisation and getting more out of your site” and how drives are integral in saving energy, keeping everything moving on automated sites and also tracking and monitoring how it is working both on and off site.

“Energy saving is definitely something that will become more important as time continues and there is a greater push for efficiency and ‘greener’ site management, as we are seeing more of a desire to invest in drives which will aid in this, “ Cooper said.

A major part of this is the demand for more specialised turnkey implementations of drives.

Variable speed drives allow for massive power savings and environmental management on site as compared to installing dampers.

He explained that at low and medium voltage levels Schneider does a standard installation, but once you

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46 February 2011

AustralianMining

W: www.globalrewinds.com.au Fax: (08) 9434 9955

get to the mid tier level then “we don’t really consider the drives as a product, instead it is best to look at it more as a solution approach due to taking a specified approach.

“Putting a specialised variable speed drive (VSD) in place allows for massive power savings as compared to a damper.”

It also allows for more effective mitigation of a lot of typical energy and motor problems that sites faces, such as harmonics or ensuring the constant flow of power and diagnostic data to machinery.

Even more importantly though, is the role that drives are set to play in allowing for total site automation, Cooper explained.

“There is a real push from remote operations and management levels to get a greater view right across the mining chain.”

Part of this push is the integration of the variable speed drives, which allows for a greater inflow of diagnostic information.

“This gives a manager the ability to use information straight from the plant floor to make more strategic decisions.”

Cooper told Australian Mining that additionally “Schneider’s EcoStruxture allows for greater management as it integrates all these information and data flows into a single control off site that is entirely web based.

“This remote diagnostics capacity aids in off site management” and importantly, EcoStruxture aids in guaranteeing compatibility between the management of power, processes, and machines.

He went on to say that with more diagnostic data from a site’s processes coming in, it also provides the information needed to carry out preventative maintenance.

Drives play an important role in this as their connectivity is piece of the puzzle that creates a higher visibility of the entire access chain in terms of data.

“They are becoming more process critical as the info they have for day today operations is high, and the costs of actually installing the drives is going down so we are seeing more and more being deployed onsite.”

Integration of many different data streams into a single manageable and remotely accessed tool is a key function drives are set to play in the future.

“Drives are going to play a major part in the automation and off site management of mining operations,” Cooper said.

And with the common target of total site automation in the future across the entire mining industry, drives are only set to grow in importance.

• Schneider Electric 1300 369 233 www.schneider-electric.com.au

VSD provides greater diagnostic data. www.miningaustralia.com.au

AD_AMTOSJUN_10.pdf

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TOSHIBA INTERNATIONAL CORPORATION PTY LTD NSW/SYDNEY - Registered Of ce Toshiba International Corporation Pty Ltd 2 Morton Street, Parramatta NSW 2150 Tel: +61 2 9768 6600 Fax: +61 2 9890 7546 NSW/MAITLAND Toshiba International Corporation Pty Ltd Unit 1, 18 Kinta Drive, Beres eld NSW 2322 Ph: +61 2 4966 8124 Fax: +61 2 4966 8147 QUEENSLAND Toshiba International Corporation Pty Ltd Unit 4-20 Smallwood Place, Murarrie QLD 4172 Ph: +61 7 3902 7888 Fax: +61 7 3902 7878

VICTORIA Toshiba International Corporation Pty Ltd 411 Ferntree Gully Rd, Mount Waverley, VIC 3149 Tel: +61 3 8541 7960 Fax: +61 3 8541 7970 WESTERN AUSTRALIA Toshiba International Corporation Pty Ltd 10 Anderson Place, Perth International Airport, WA 6105 Tel: +61 8 6272 5600 Fax: +61 8 6272 5601 www.toshiba.com.au Toshiba International Corporation Pty Ltd ABN: 29 001 555 068

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PRODUCT FOCUS: MOTORS & DRIVES

Remote site power POWER Equipment has installed innovative generators at remote Kimberley locations. It needed a generator set that could power Leopold Downs station, and turned to the JCB 444 model as the solution. This four cylinder 4.4 litre engine has four valves per cylinder with high torque at constant speed settings. It is rated at 100kWm at 1500 rpm. The entire system protected by Power Equipment’s EC-150 engine management system. It protects the engine in a range of adverse conditions such as low oil pressure, low cooling water level, high cooling water temperature or fan belt breakage. The EC-150 system also comes fitted with a battery voltage indicator, hour meter, tachometer, 99hr engine timer and high and low pump pressure shutdown.

• Power Equipment Noel Heritage 03 9709 8500 noel.heritage@powerequipment.com.au www.powerequipment.com.au

Has four valves per cylinder.

Drive power range

New 450kW drives.

ROCKWELL Automation has expanded the power range of its Allen Bradley PowerFlex 755 AC drives to 450kW. Featuring advanced diagnostics and a roll out design, the drives are suited for motor control applications in mining and materials handling. A key feature of the PowerFlex 755 extended power range drive is its roll-out capability, which allows easy access to the drive for fast installation and maintenance. The drive’s modular design simplifies replacement of drive components, such as cooling fans, circuit boards and major subassemblies. This modularity also allows the drive’s converter and control pod to remain in the unit while the inverter is rolled out, so control wiring can remain connected. It also has the capacity for the control pod in this drive to be mounted remotely for easy access to low voltage control and diagnostics. Advanced diagnostic capabilities include indication of blown fuses and blown surge protectors. The PowerFlex 755 drive comes equipped with an embedded Ethernet port and five option slots that allow users to tailor the drive.

• Rockwell Automation 03 9896 0300 www.rockwellautomation.com.au

Next gen generators CATERPILLAR has unveiled its next generation of Olympian diesel generator sets. The new generator sets are rated 26 to 200kVA (at 50Hz) and 27 to 175kW (at 60Hz). Improvements on the sets include more robust construction, increase accessibility and greater performance in hotter climates. A major focus of their redesign was the enclosure, which is built from galvanized steel with powder coated paint. It is designed to withstand harsh environments, be more rust resistant and less prone to weathering. To prevent water ingress, it 3dBA quieter than previous models. features a single piece roof and rain caps fitted with compression seals. The new enclosure is up to 3 dBA quieter than previous models, as a result of the incorporation of sound absorbent materials and modifications to the airflow and exhaust systems. To allow for easier installation, the configurations were standardized, with less variation between models when it comes to access panels and option connection points. In addition, a lifting eye – capable of lifting the entire weight of the generator set (including fuel) – was integrated into the design. Additional basetank drag points were also added for convenience. The base frame has been extended past the enclosure to protect the enclosure from impact. In the event of any damage to the exterior, the surface is divided into modular panels. Resilient corner posts were added to prevent denting when in motion or while stationary. With the new package, both the fuel line and fuel transfer system entry points are located on the same side to simplify installation and also improve maintenance efficiency. Better cooling efficiencies were achieved through radiator improvements and new air flow designs that reduce restrictions. To ensure a clean operating environment, a drip tray was incorporated to hold engine fluids. For easier operation and service, access points have been oversized without compromising sound attenuation or security. The doors are larger and have lift off side hinges (removable at 45 degrees). A key upgrade affecting the day-to-day operation was co-location of the controller and electrical connection box, centralising all electrical equipment.

• Caterpillar www.cat.com

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www.miningaustralia.com.au

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THE NEXT GENERATION UNDERGROUND ADVANCED EQUIPMENT SIMULATORS

Designed for Underground Mining

Unique 360° Visual Display

Accurate Motion Platform

The UG360 Advanced Equipment Simulator has been specifically designed for Underground Mining and delivers cutting-edge technology not previously seen in the mining industry. This ensures our customers’ receive the world’s leading simulation solution to drive operator optimisation and business improvement.

Recognising the distinct operating conditions of the underground mining environment, the UG360 has been developed with an entirely new display system allowing the trainee to see in all directions, including the high viewing angles necessary to learn key underground equipment operating techniques. This advanced display system sets a new standard in underground simulators, delivering a higher level of training engagement and learning retention.

With the very latest in motion platform technology, the UG360 delivers the optimum level of feedback required to accurately simulate the operation of all underground mining equipment.

Contact Immersive Technologies today for more information on the UG360.

Enquiries@ImmersiveTechnologies.com | Tel. (08) 9347 9000

www.ImmersiveTechnologies.com/NextGeneration

From rapid jolts, feelings of acceleration or the fine-tuned sensitivity necessary for LHD operation, the UG360 delivers unrivalled tactile feedback to the trainee.

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PRODUCT SHOWCASE

Amber safety glasses SPERIAN has released its latest protective eyewear.

Named the A700 Amber, this new addition features an amber coloured scratch resistant hardcoat lens. It is designed to absorb the blue and ultraviolet light typically associated with Reduces hazy light conditions. hazy light conditions such as at dawn and dusk, as well as foggy days.

Transmitting approximately 90% of available light and significantly reducing the haze associated with blue light, the A700 provides wearers with clearer perception and brighter vision, improving safety overall while protecting the wearer’s eyes.

The glasses feature a lightweight wrap around base lens design, universal nose bridge and soft temples.

In addition to the amber hardcoat lens, the A700 series also are available in clear and grey, hardcoat and anti-fog lens, for both indoor and outdoor work applications.

• Sperian 1300 139 166 www.sperian.com

Safety air guns COMPRESSED Air Australia (CAA) has released EXAIR’s new Precision Safety Air Gun. The lightweight air produces a highly focused, forceful blast of airflow for a range of industrial work applications.

With a small diameter nozzle and extension to fit in tight space, it uses a nano super air nozzle which has been designed to maximise entrainment of room air while minimising compressed air consumption.

The nano super air nozzle is available in a rugged Type 316 Stainless Steel or PEEK plastic to provide non-marring protection should the nozzle come in contact with other surfaces.

The PEEK nozzle is resistant to chemicals, fatigue and temperatures of up to 160°C. • Compressed Air Australia 1300 787 688 info@caasafety.com.au http://caa.exair.com

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Has a small diameter nozzle.

Level gauge safety HONEYWELL has enhanced its FlexLine level gauges which are used with tanks to prevent spillage.

Approved by the TÜV for use in Safety Integrity Level-2 (SIL-2) rated loops, allowing industrial facilities to use the device in applications that require stringent certifications and safety measures.

FlexLine is used in overfill protection loops to prevent spillage and mitigate the likelihood of an accident, effectively stopping overfill before it happens.

Key enhancements to the FlexLine gauges include an improved safe failure fraction of more than 90 percent, which will permit uses in SIL-2 safety loops.

Diagnostics within the gauges have also been improved, which extends the safety proof-test interval to four years to mitigate operational costs and strengthen reliability, depending on the safety requirements on the loop.

Additional safety functions in the gauge make use of a dual redundancy which automatically detects failures in the safety circuitry, isolates and reports those failures, and still allows the gauge to continue to function as a safety device without interrupting the process.

• Honeywell 02 9353 7000 www.honeywell.com

www.miningaustralia.com.au

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PRODUCT SHOWCASE

Handling Bulk Powders and Granules?

Worklights WORKING in dark and dangerous mining conditions requires illumination you can rely upon for quality and durability. Designed to provide high performance for 10 years or more of normal use, the HEMIPRO incorporated NiMH 2500 milliAmp hour battery has a life expectancy of three hours under normal use. The 2 LED HEMIPRO can be used up to up to five hours between charges and the 3 LED for three. For added reliability and durability in tough conditions, they both have non-slip grip and shockproof housing, as well as a lens shield with a 360 degree swivel hook which can be replaced. HEMIPRO work lights have high power LEDs in a light but rugged casing originally designed for the demands of the automotive repair market, and using 2 LED and 3LED work lights provides powerful beams which equal or exceed the intensity of a 60W or 75W beam, according to Gary Oborne, from GO Distribution. The lights also feature engineered hemispherical lens design, which refracts the LEDs into a clean, bright and wide beam. The highly modified lens design captures and transfers the powerful LED light into a super-wide 70 degree beam, while also eliminating hot spots, dull areas or irritating halo rings.

• GO Distribution Gary Oborne 02 6026 4886 goborne@bigpond.net.au www.cliplight.com.au

We are System Designers, Suppliers and Integrators.

Dense Phase Pneumatic Conveying for efficient powder transfer Microveyor shown under a bulkbag discharge station

low-rate economical MicroveyorTM models 100kg to 10 te/hr

high-rate ‘KT’ series, rates of 5 to 500 te/hr

Secondary belt cleaners FLEXCO has launched secondary belt cleaners with slide out cartridges. It has released the Mineline MHS Secondary cleaner with service advantage cartridges. The cleaner only needs Equipped with carbide tipped blades. one operator to remove the cartridge, which they can do from one side of the conveyor or the chute wall. Following the removal of a pin, the cartridge slides out easily with the use of a cartridge removal tool, which stores in the pole for easy access. Replacement can be completed in a matter of minutes and multiple cartridges can be replaced during the same maintenance period. The slide-out service makes this cleaner ideal for use in tight spaces, enhancing safety by deterring operators from crawling under the conveyor or getting into dangerous spaces. During maintenance, the cartridge’s interface with the pole is minimal – reducing the possibility of corrosion and fusing with the pole. The cartridge is equipped with hard-wearing carbide-tipped blades for use with mechanical belt splices. V-tips are also available for use with vulcanised belts.

• Flexco 02 9680 3322 www.flexco.com.au

Compact pumps GAAM Emergency Products is introducing two new Spechtenhauser specialty pumps.

Lightweight and compact for easy mobility and handling, the ‘Woody’ pump has a three-phase 400V/50Hz motor and a capacity of up to 2200 l/min. Designed for de-watering and moving large quantities of water around, the pump is blockage-free for solids up to 80mm in size and can operate continuously when used with 6.5kVA generators. At 53kg, it has a carrying frame with four folding handles and abseiling eyelet, making it easy to carry around and simple to handle. The pump is dry run safe because of its impeller cooling system, has a slurping operation and is capable of low level pumping down to a few millimetres depth due to its patented flat intake socket. Offering further versatility is the Mini Woody pump, which can be fitted with either an ac 230V/50Hz motor or three-phase 400V/50Hz motor. The pump’s capacity reaches up to 1400 l/min with continuous operation possible using 3kVA generators (B1000 version) or 5kVA generators (all other versions). It comes with a central carrying handle and abseiling eyelet as well as a carrying frame with an integrated cable rewind.

• GAAM Emergency Products 03 9466 1244 www.gaam.com.au www.miningaustralia.com.au

Discharge of powder products to silos from containers.

We offer a range of solutions, and rates of transfer.

The ‘Original’...

For Handling Powders - Very heavy duty -

Valve Closed

Fill and empty Bulk Bags and Automated packaging systems.

Recent products handled: Magnesia, Lime, Zn oxide, Flocculents, Ni concentrate, Cement, Rutile, Alumina, Sand, Perlite, Ti02, Barytes, Flyash, Bentonite, Limestone.

The autoinflating seal.

Models to 7 bar pressure, andoto 480 C.

Valve Open

Single Products .. to total Turn-key Installations.

The Professionals in Powder Handling Systems and MA1112

CONTROL AUTOMATION

Head Office VIC - Tel: (03) 9457 8277 Fax: (03) 9457 7695

Enquiries: sales@kockumsbulk.com.au

www.kockumsbulk.com.au AustralianMining

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8TH ANNUAL AUSTRALIAN MINING PROSPECT AWARDS

Entries now open for 8th Annual Australian Mining Prospect Awards, co-hosted by AIMEX

The event brings together those in the mining industry who have gone above and beyond.

F

Growing in size every year, 2010 saw close to 300 attendees.

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or close to a decade the Prospect Awards have highlighted the talent and advances that the mining industry has consistently made.

The awards aim to recognise the best, brightest and most innovative in the industry, a vision that is shared by the largest mining exhibition in Asia Pacific, the Asia-Pacific International Mining Exhibition (AIMEX).

Held only once every four years, AIMEX is an internationally recognised platform for Australian and global suppliers of mining technology, equipment and services, and one of

PROSPECT AWARD CATEGORIES Australian Mine of the Year Contribution to Mining Mine Manager of the Year Coal Mine of the Year Hard Rock Mine of the Year Minerals Processing of the Year Contract Miner of the Year Employer of Choice

the highest attended mining events in the world.

These two events are working together in 2011 to present the Australian Mining’s 8th Annual Prospect Awards

Excellence in Mine OH&S Innovative Mining Solutions Explorer of the Year Excellence in Environmental Management Young Achiever of the Year Mining’s Female of the Year Community Interaction of the Year

co-hosted by AIMEX. In line with the enormous size of the exhibition, the awards have also increased in range, adding three categories to the list.

www.miningaustralia.com.au

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8TH ANNUAL AUSTRALIAN MINING PROSPECT AWARDS

Northparkes swept the awards night in 2010.

Bringing back the coveted Young Achiever of the Year award, Australian Mining has also added, for the first time ever, an award for exceptional Community Interaction and for Mining’s Female of the Year.

These two new awards highlight sides of the mining industry that are often ignored within Australia.

For the Community Interaction of the Year award, the event will look at those who have made a real difference to their local region and are seen as an integral part of their community.

www.miningaustralia.com.au

Despite being seen as a completely male dominated industry, women have always played an important role in keeping mining on track and moving forward.

Mining’s Female of the Year award highlights those women who make an impact in the mining industry every day and showcase the sector’s fair go attitude.

These latest awards underscore the growth of mining within Australia and the many different ways in which the industry is supporting the nation.

This exciting event is being held on the second night of AIMEX, with transport provided to and from the venue.

Nominations and seating Nominating your company or a person within your company is a great way to recognise and reward superior performance.

Nominations will be accepted from individuals, companies, contractors and technology suppliers who are associated with the Australian mining industry.

The entries should outline how a mine or a person has

The finalists issue will be available at the exhibition with winners featured in the September edition and a follow up in the October edition.

Deadline

The relaxing night allows the wide spread mining industry to come together.

improved productivity or has reached notable milestones using new technology, innovative processes or techniques.

Get in quick as well to ensure that you are able to secure seating to the event To get a ticket to the night please contact Alex Evans at 02 9422 2890.

Winners A panel of judges with expertise in the Australian mining industry will first determine the finalists in each category.

After further consideration, the panel will then select

a winner for each category, based on the specific criteria outlined in the Australian Mining Prospect Awards entry forms.

In addition to a trophy, all winners and finalists will receive extensive editorial coverage and publicity in Australian Mining, www.miningaustralia.com.au and other media outlets.

The winners will be presented with their awards at a gala presentation ceremony held on the second night of AIMEX event, on the 7th of September.

All entries must be submitted electronically, via email or CD, to Australian Mining no later than 30 June.

The entry form contains information on what should be submitted as part of your nomination.

It can be downloaded from www.miningaustralia.com.au.

Entry is FREE.

WHERE TO SEND NOMINATIONS Email your entries to: ozmining@reedbusiness.com.au Post your entries to: Australian Mining Prospect Awards Attn: Editor – Australian Mining Tower 2, 475 Victoria Avenue Chatswood NSW 2067

TO BOOK A TABLE Call Alex Evans on 02 9422 2890 or email him at alex.evans@reedbusiness.com.au

AustralianMining

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MINING JOBS To advertise a new job contact Hussein Azzan at 02 9422 2851

To see the latest jobs available visit www.miningaustralia.com.au, which is updated daily.

GEOTECHNICAL ENGINEER – UNDERGROUND Location – Launceston & North East, Tasmania Company – EMS Pty Description: If you are looking to make an investment into your future, then this deposit will challenge your potential while expanding your geotechnical and mining skills. The role will be tailored to the experience level of the candidate, so we can look at candidates with as little as 3 years experience, but we would also like to hear from candidates that would be ready to move into a senior role within 12 -18 months.

The position reports to the Senior Geotechnical Engineer, and you should possess a recognised tertiary qualification in Geotechnical or Mining Engineering or Geology with 3-5 years experience in underground geotechnical engineering. Some Experience with numerical modeling, preferably Map 3D and with mine design software will be very advantageous, but enthusiasm and a good workethic with excellent verbal and written communication skills will be even more valued.

If your emphasis is on safety and getting it right first time, then this role will offer you the financial and lifestyle benefits that you will be hard pressed to find anywhere else.

Please contact Dianne on 08 9443 0400 or diane@emsjobs.com.au in strict confidence or to apply for this role, please visit www.miningaustralia.com.au

GEOLOGISTS Location – Bendigo, Heathcote Company – Mandalay Resources Description: Mandalay Resources creates shareholder value through the acquisition of advanced or producing mineral resource properties at deep discounts. Mandalay are growing a critical mass of producing properties within three years that will contain extensive, self-funding organic growth opportunities and generate substantial free cash flow to support further acquisitions or dividends. Mandalay Resources has two fantastic opportunities for an Exploration Geologist and a Graduate Exploration Geologist to join the Costerfield Project near Heathcote, Victoria.

Reporting to a Senior Geologist, both of these roles will work alongside a range of staff and contractors on-site, ensuring optimal productivity out of the respective drilling crews under their supervision.

In return for your hard work and dedication, you will be rewarded with an attractive remuneration circa $60,000-$80,000 (commensurate with skills and experience) plus super and salary sacrificing options. You will be part of a large, social team offering an excellent work/life balance in this exciting and varied role.

To apply for this role, please visit www.miningaustralia.com.au MAINTENANCE PLANNER Location – Adelaide Company – EMS Pty Description: We are looking for a top notch Maintenance Planner that is looking for a long term and rewarding role. Be appreciated for what you do and recognised financially!

You can rest assured that the $$$ and benefits here are right up there amongst the best!: On offer with this great FIFO role will be some excellent remuneration and perks. These guys know the benefits of keeping their staff well rewarded for what they do and provide the training opportunities and benefits to ensure just that.

A strong trade background will form the foundations of your experience ideally and with that we also want you to come to us with a good three years prior experience in a maintenance planning role. A well rounded understanding of relevant software will also be essential here. A commitment to continuous improvement of the maintenance and performance and equipment would be good too.

Please contact Nikki on 08 9443 0400 or nikki@emsjobs.com.au in strict confidence or to apply for this role, please visit www.miningaustralia.com.au

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www.miningaustralia.com.au

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EVENTS

Conferences, seminars and workshops Event submissions can be emailed to ozmining@reedbusiness.com.au MineSafe Summit 2011

OZMINE 2011

15-16 February Hyatt Regency, Perth

29-30 March Jakarta

The importance of safety in mines is crucial both to the health and safety of the workers and the continual running of mining operations. With the increase, both nationally and internationally, of mining accidents and fatalities taking place: many mining companies are feeling the added pressure to ensure their operations are safe and the health of their workers is guaranteed.

As a result of the incredible growth in the mining industry there is no time to be complacent on issues of safety as no compromises can be made. Implementing a safe working culture is therefore essential at any mine site as the nature of the job is high risk. The detrimental effects of poor safety practices are huge and not only in the cost of lives but also potentially costing millions of dollars for the company.

As current national and international events have shown, safety and health issues are exceedingly in the news and MineSafe Summit 2011 will be an opportunity to hear from leading international and national speakers address pertinent issues and topics relating to mine safety.

• Chilli IQ 02 9818 6566 www.chilliiq.com.au/upcoming

This premier industry event consists of a twoday joint exhibition and conference, showcasing the capabilities of Australian companies serving the mining industry in Indonesia.

In 2010, over 85 Australian mining equipment, technology, consumables and service companies exhibited at OZMINE. In 2011 it is anticipated this figure will reach 100 exhibitors with more than 2000 visitors anticipated. The event also draws regional industry players and in 2010 will include members of Austrade ASEAN Mining Team and their buyer delegations.

• Austrade 13 28 78 info@austrade.gov.au www.austrade.gov.au

Mine Site Automation and Communication 2011 15-16 March Chifley on Lennons, Brisbane Automation and communication is the future of mining operations in Australia, however as you know these new technologies represent a substantial investment and determining the right technologies for your mine site is a challenging process.

Developed in extensive consultation with your industry peers, Mine Site Automation and Communication features industry case studies showcasing best practice in capitalising on these innovative new technologies and maximising return on investment.

In addition to practical case studies from some of Australia’s leading mine sites, the conference will feature keynote presentations from international thought leaders to keep you up to date with industry trends.

• IQPC 02 9223 2700 info@iqpc.com.au www.iqpc.com.au www.miningaustralia.com.au

Coal Processing Optimisation 2011 29-30 March Brisbane, QLD With the demand for coal soaring over the past 12 months, the need for optimising coal processing is at an all-time high as companies seek ways to maintain and increase the highest levels of throughput.

The Coal Processing Optimisation Conference 2011 is the only event in Australia focusing purely on coal processing within CHPPs. Such optimisation at your plant could have a substantial impact on your company’s bottomline.

Mining IQ’s Coal Processing Optimisation Conference serves as the meeting point for industry professionals to learn effective strategies and find out about the latest developments in the industry, such as new tailing reprocessing methods, innovative control systems, the latest in monitoring equipment and the use of Reflux Classifiers and large DMC’s in the field.

You will hear from experts on technical developments, peers presenting industry case studies, and witness presentations on new technologies.

There will also be workshops on the hottest topics in which you will be able to have questions answered that pertain specifically to your company or CHPP. • IQPC 02 9223 2700 info@iqpc.com.au www.iqpc.com.au AustralianMining

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REDA

ELECTRICAL SUBMERSIBLE PUMPING SYSTEMS

*Mark of Schlumberger. Measurable Impact is a mark of Schlumberger. © 2010 Schlumberger. 10-AL-0066

High-Pressure Pumps for Mining Reliable Operational Performance

Maximize Uptime with REDA High-Pressure Pumps REDA* electric submersible pumps offer efficient mine dewatering and can be customized as required.

REDA ESPs have been running continuously for more than 4 years in two mines in Queensland, Australia—reducing downtime and operator costs. Engineered for best-in-class reliability, Schlumberger REDA high-pressure submersible bore pumps and underground booster pumps provide a single lift to the surface.

www.slb.com/espmining

Global Expertise | Innovative Technology | Measurable Impact