Australian Mining October 2012 by Prime Creative Media

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VOLUME 104/10 – OCTOBER 2012

Australian Mining

SERVING THE MINING INDUSTRY SINCE 1908

www.miningaustralia.com.au

NO.1 FOR MINING TECHNOLOGY AND EQUIPMENT Mapping

The automated mine site Robots and remote control machinery

SURVEYING YOUR SITE Knowing your mine

P.18

Dust & Ventilation

DEFEATING DUST Breathing easy

P.30

Minerals Processing

METALS AND MINERALS More processing power

The Technology Edition

Print Post Approved PP255003/00535

October 2012

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P.50

GME Preview

GOLDFIELDS MINING WA’s exhibition

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WHEREVER THERE’S COAL AND COPPER, SILVER AND GOLD, IRON AND BAUXITE. WE’RE THERE.

technologies to support all types of mining operations, with the infrastructure and support network to serve every mining region in the world.

WHEREVER THERE’S MINING.

M I N I N G . C AT. C O M

© 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” and the “Power Edge“ trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Cat and Caterpillar are registered trademarks of Caterpillar Inc., 100 N.E. Adams, Peoria IL 61629.

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COMMENT

Mining Take the good with the bad 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

Associate Publisher – Martin Sinclair Email: martin.sinclair@reedbusiness.com.au Editor – Cole Latimer Tel: (02) 9422 2352 Email: ozmining@reedbusiness.com.au Journalist – Andrew Duffy Tel: (02) 9422 2884 Email: ozmining@reedbusiness.com.au Key Account Manager – Tim Richards Tel: (02) 9422 2818 Mob: 0420 550 770 Email: tim.richards@reedbusiness.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 WA Representative – Jamie Wade Mob: 0435 945 868 Email: jamie@wadebusiness.com.au RBI Manufacturing & Electronics Group: Production Co-ordinator – Tracy Engle Tel: (02) 9422 2707 Fax: (02) 9422 2966 Graphic Designer – Dave Ashley 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

Mining has always been a rollercoaster ride of highs and lows.

his year is in a spiral. While we hate to be the bearer of bad news for the mining industry, we can’t pretend that the last few months have not been rough. Around 600 job have been cut at Xstrata; Rinehart’s Roy Hill has pared back on its workforce; contractor numbers have been reduced across BHP Billiton’s operations; Rio is slashing jobs globally in an effort to reduce expenditure by 10 per cent; and to top it all off BMA has closed the its second mine in the space of a year – the open cut operations at its Gregory Crinum coal mine. Fortescue has also been hit particularly hard, being forced to put major expansions on hold, sell off assets and dramatically trim its workforce. Not to mention the iron ore price dropping sharply,

Comment Cole Latimer ozmining@reedbusiness.com.au and watching Fortescue’s share price drop nearly 14 per cent on single day. It has been a rough few weeks. Especially for thermal coal, although this may change soon, as Europe and China will head into winter in only a few months time, which is likely to bring the price of coal up again. But despite this apparent light at the end of the tunnel, it has been a rough, and very volatile few months for the industry, and I’m sorry to say, it is unlikely to get better any time soon.

At least Fortescue has had a slight upturn and managed to get back on its feet to a degree, with much of the market speculation apparently fueled by certain bankers. Still, why the doom and gloom? Because it’s time to be realistic. Mining has been through some hard times before, and the commodity prices then were not anywhere near the current ‘floors’ we are experiencing, and even the ‘low’ prices today are still historically high. Yet despite uncertain

futures, it is still an industry that has always managed to dig itself out of a hole – literally and figuratively. It has happened before and will happen again. With the carbon tax and mining tax imposing penalties, states taking advantage by raising mining royalties – and the government trying to get out of its commitment to reimburse miners, and commodity prices falling through the floor, now is the time for the industry to rally together. Mining is a cyclical industry; we faced hard times during the GFC, great times after it, and now hard times again, so it is only a matter of time until prices are stable once more. As always, mining will come through the other side – maybe not unscathed but always smarter.

FRONT COVER All rights reserved. No part of the publication may be reproduced or copied in any form or by any means without the written permission of the publisher. SSn 0004-976X Reader Services – 1300 360 126 Subscription Rates – Australia (surface mail) $140.00 (incl GST) New Zealand A$148.00 Overseas A$156.00

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On the front cover of this edition of Australian Mining we’ve featured an underground mining LHD, which are at the forefront of automation in underground mining. In this technology-focused issue we’ve looked at the latest developments in automation and remote control technology, software and hardware, minerals processing, and process control and instrumentation. We’ve also examined the current state of the mining industry, and where analysts, the government, and miners themselves think the sector may go as our historically high prices begin a slow decline and eventually plateau. This edition is also the Goldfields Mining and Engineering (GME) Exhibition Preview, where we highlight some of the coming attractions A Mwho is showcasing their latest equipment. and

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Contents Features MINING’S FUTURE

Light at the end of the tunnel Analyst point to mining’s slow demise ..p12-13 Getting over Olympic Dam It’s not all over for the massive mine .......... p16

October 2012 issue

Cutting coal tragedies

Satellite start up

Stopping coal dust explosions....p30

Train tracking and controlling....p41

MAPPING & SURVEYING

A simpler stockpile Tracking stockpiles in 3D........................... p18 Mapping from a high Continent wide mineral maps..................... p20 What you see is what you get 3D modelling ............................................. p22 Uncovering Australia’s potential Unlocking the nation’s minerals ................. p24 Varying variograms Automatic mapping tools ........................... p25

CHINA

Cutting coal deaths .................................... p26

GAS

The future of gas ...................................p28-29

DUST & VENTILATION

Uncovering the issue Coal train dust and the community ............ p32 Understanding the dusty trail Mine dust academies .............................p34-35

CEOS UNDER THE SPOTLIGHT

The Rich Vs. the Rest ................................. p36 FORTESCUE The fight is on for Fortescue....................... p38

AUTOMATION & REMOTE CONTROL

Going truckless Vale set new automation standards ............ p40 Monitor in real time A D _ maintenance A MK R C J A N_ 1 0 . p d f P p42 a ge Remote ..................................

October 2012

AustralianMining

Increasing uptime Automated maintenance............................. p44 Automated and accurate Payload monitoring and control ................. p46 Bringing out the benefits Arguing for automation integration ......p48-49

COMMUNICATIONS

MINERALS PROCESSING

Risky work in WA Fatalities aren’t slowing down in the West... p81 Saving our miners Understanding the future, after injury ........ p82 Safety Conference Australian Mining helps you to work safer .. p84

Taking the coal out of dirt Recovering coal .......................................... p50 Super sized flotation Growing cell size ........................................ p52 Down to the grain The CSIRO and BASF work to cut lost fines.. p54 What’s driving milling Plant and mill motors ............................p56-58 Compressor control Powering your processing......................p60-62

SOFTWARE & HARDWARE

Increasing mining’s ICT The turn towards information technology .. p64 Stability simulations Simulation programs to harness coal .....p66-67 Now for the NBN Mining is seeing the allure of the NBN....... p69 Fighting the flame war 1The1spectre 2 / 1 1of/ viruses 0 9 , and 9 :hackers 5 4 A M ............. p70

In the loop Communicating underground .................... p72 Keeping connected Fibre optics on site ..................................... p74

SAFETY

GME PREVIEW ...................................p86-108

Regulars INDUSTRY COMMENT ................................ p6 NEWS .......................................................... p8 MINING FAMILY MATTERS....................... p10 PRODUCT FOCUS: Process Control & Instrumentation.....................................p76-78 PRODUCT SHOWCASE ....................p110-112 PROSPECT AWARDS .............................. p114 JOBS ........................................................ p116 EVENTS ................................................... p118

www.miningaustralia.com.au

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INDUSTRY COMMENT

What happened to Rio Tinto’s plan to fill 6,000 mining jobs in four months? Rio had plans to dramatically increase its workforce, yet in only four months it has instead cut 3,000 roles, The Dirt asks what happened?

arlier this year Rio Tinto announced, to much fanfare, a plan to fill 6,000 mining jobs in four months. It planned to use part of this massive new workforce to aid it in its planned 333 Pilbara expansion, which looked to take advantage of the historically high iron ore prices. Since the recruitment drive was launched in April, instead some 3,000 jobs have been cut from the coal industry and serious doubts have been raised about China’s demand for coal and iron ore. Over the past few months Rio Tinto itself has made sweeping The wellspring of Rio Tinto jobs in the Pilbara has apparently dried up. white collar layoffs nationwide and cut its contractor workforce in the questions it can on whether it’s man- sector, which hasn’t seen as much Bowen Basin and Hunter Valley. aged to hire an extra 6,000 work- doom and gloom as the coal indusNow that the four month time- ers. When it initially announced the try over the past few months. frame recruitment iron ore has not A D _for A MitsT R E F E B _ 1drive 2 . pisd f ambitious P a g e plan 1 Rio 5 / said 0 1 most / 1 2of, the3 : 2 9Nevertheless PM over, RioTread-AustralianHorizontal1-2pg2Page Tinto is dodging all the jobs 1would focus 1:15:13 on theAMiron ore been immune to the downturn, with 12/19/11

Fortescue Metals Group announcing significant layoffs of its own earlier this month. And while iron ore prices are now on the rise again mid to long term demand for the commodity is looking increasingly volatile. Back in April The West Australian reported two thirds of Rio’s 6,000 new jobs would be located on its West Australian iron ore sites, which leaves another third to fill unknown positions around the country. But five months on, just how many out of the original 6,000 Rio Tinto’s managed to hire, who they are, and where they’ve gone, remains a mystery. The company refuses to field any questions on the topic, leaving open the option its initiative has been shelved as the coal industry continues to bleed jobs.

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HEADLINES

Latest mining news Australian Mining presents the latest news affecting you from the boardroom to the mine and everywhere in between. Visit www.miningaustralia.com to keep up to date with what’s happening Koala rescued from mine A group of university students have managed to rescue a koala from an abandoned mine shaft in Victoria. After stumbling across the koala in Lal Lal State Forest, students lowered a tree branch into the shaft to help the trapped marsupial scramble to safety. But after climbing to the top of the shaft on its first attempt the koala misjudged a leap of faith and fell almost seven metres back to the bottom of the shaft. Unharmed and undeterred, the koala reached ground level on its second attempt and climbed to safety in a nearby tree.

Newmont cuts workers Newmont has announced that it will begin cutting workers today at its operations around the world, reducing its Australian workforce by 50 positions. In a statement Newmont’s Waihi Gold said job cuts at its mine “are part of a wider package of job cuts across all Newmont sites globally. “Staff at Newmont’s four mines and regional headquarters in Australia have also been notified likely redundancies.” Speaking to Australian Mining, Newmont Asia Pacific spokesperson Sharon Iannello said the Australian workforce has been reduced by 50 positions following a recent cost A D“While _ A Mredundancies A B L O Cwere T_ 1 review. offset by reductions in budgeted

vacant positions and natural attrition, there have been job losses largely in support service areas from the Subiaco regional office and in Boddington,” she said. The company is today beginning the process of consulting with staff and contractors about changes in the workforce, which are likely to include a number of redundancies. However it did state that “where possible the company will be seeking to offer changes of jobs rather than redundancies, and some staff are in the process of being offered jobs at other Newmont sites globally.”

Xstrata to slash 600 jobs

Australian Mining gets the latest news every day, providing up Xstrata has announced it will be to the minute information on cutting 600 jobs across its Australia coal operations. According to the safety, news and technology miner it is part of a wider ongoing for the Australian mining and Australian business review. resources industry. It stated that it is “undertaking a planned restructuring to respond to Xstrata explaining that “although we industry-wide pressures including are not breaking down the reductions low coal prices and high input costs” by individual site, the restructure is Speaking to Xstrata spokesperson focused on scaling back high cost Francis De Rosa, he told Australian production at some of our mines”. Mining that the company is It will also axe jobs at its Sydney “currently dealing with a very headquarters and at some of its challenging market and a high Queensland based offices, De Rosa Australian dollar, so Xstrata has had added to act to ensure the ongoing health Despite the cutbacks Xstrata does of the business. not expect its production levels to “This [restructing] is part of an drop significantly. ongoing review.” This restructuring will see the BMA close Gregory mine 2 company . p d f cut 600 P ajobs g eacross 1 all of 1 3 / 0BHP 9 Billiton / 1 2 has , announced 1 0 : 4it 4will A M its Australian coal operations, with shut down its Gregory coal mine.

According to the miner its joint venture operation BMA will cease production at Gregory Crinum’s open cut operations from 10 October this year. BHP explained that this “decision follows a continuing operational review of the Gregory Crinum operations, which determined that the Gregory open-cut mine production was no longer profitable in the current economic environment of falling prices, high costs and a strong Australian dollar”. BMA asset president Stephen Dumble said production costs for the Gregory open cut operation currently exceeded revenue from its sales and “therefore the only option available to the company was to cease production”.

BHP dumps 3 coal mines BHP Billiton has canned plans to build the massive Red Hill and Saraji East coal developments in Queensland, citing a “challenging external environment” for the cutback. Study on the two expansions has been shelved and BMA has withdrawn the projects from the Federal Government’s environmental approvals process. The move follows a blanket statement in the company’s profit announcement earlier this year that no major projects would be approved in 2012-13. BMA previously said the Red Hill project would employ 3,000

contractors during peak construction and up to 1,500 workers and contractors during peak operations. It slated a further 2,500 contractors for peak construction of the Saraji East project, and around 1,400 workers for the development during peak operations.

Glory days are over: BHP BHP Billiton has put a freeze on executive salaries and warned that recent highs in some parts of the mining sector are unlikely to be repeated. In the company’s annual report BHP chairman Jac Nasser marked economic instability in Europe and the US and softening growth in China as key pressure points for the industry. BHP CEO Marius Kloppers also said lower commodity prices and higher costs and currency rates were also causing headaches for the company. Outlining future supply and demand BHP said iron ore production was expected to meet the demand and “the scarcity pricing seen in recent years is unlikely to be repeated”. But the company said demand for raw materials was positive in the long term as the developing world industrialised, and copper was tipped to be a key growth point. BHP said copper production was unlikely to meet demand through to 2015 and beyond, and prices were expected to be high enough to support the development of new mines in the future.

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MINING FAMILY MATTERS

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October 2012

AustralianMining

Couples on the same mine site

– can it work?

Can mining couples deal with the 24/7 pressures of the industry, and each other?

o, you’ve decided to coordinate your rosters so you can live and work together on the same mine site? Great for maximising precious time together. Not so great when you’re forced to share a teeny tiny donga! We all have our little quirks: how tidy we are; how much TV we watch; how much sleep we need. Normally, couples have the space to be themselves without really bothering each other. In a donga, even small differences (like keeping the TV on) can make for major relationship stress. Couples with differing habits need to compromise and stick to clear ground rules (even rotating nights when the TV is on or off). Another pitfall is allowing work to dominate your thinking and conversations. If your partner wasn’t on site, there’s no way they would listen to endless complaints about work and colleagues, so try limiting these conversations to 10 minutes. A third cause of disharmony relates to time off. Because you work away together, friends and family might assume you don’t need time together when you’re home. Just remind them that you haven’t been on holiday; you’ve been working hard on long shifts. It’s OK to say ‘no’ sometimes, or introduce set times for catching up. It’s important that you spend down time together as a couple.

Remember, too, that couples who spend a lot of time together don’t necessarily communicate better. In fact, there is a real danger of complacency, with both of you assuming you are close and connected just because you are physically together. No matter how much time we spend with someone, they can’t read our minds. Here’s an example: you get ‘home’ to the donga, exhausted and not in the mood to talk. If your partner was 1000km away, you’d send a text, explain your mood, tell them you love them, and leave it at that. BUT, if your partner is with you in the donga, you’re more likely to assume they know you’re grumpy and not bother with the niceties. That’s not fair! Some couples use a code word like “pina colada” as shorthand for saying “I’ve had a bad day, I’m grumpy and don’t want to talk to you. I love you very much though.” Try it. As with any major decision, weigh up the pros and cons beforehand. Problem-solve any potential problems in advance, and give yourself a realistic settling-in period before you reassess. You’ll find loads more relationship advice for mining couples on the Mining Family Matters website www.miningfm.com.au or in the new book Mining Families Rock. www.miningaustralia.com.au

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BIS SHRAPNEL

Light at the end of the tunnel

A Legend in the Making

Despite predictions of mining’s demise, it still has some way to go.

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October 2012

his magazine has never really like the term mining boom. Because if there is a boom, it implies there will always be a bust, and soon. Yet many people have called this the boom to end all booms. But has it really been that high? Yes and no. In terms of iron ore the metal has never seen commodity prices like those following the global financial crisis. From a measly twenty odd dollars per tonne in 2002 it shot up to $186 in both February 2011 and February 2012. It’s amazing how high the price has risen, how volatile it has become compared to its rather inglorious history. All this was driven by the growth of China and its demand for steel, and to a lesser degree that new rising Asian powerhouse India. Coal has also been seen as one of the main drivers of the apparent boom, but is this really the case? Thermal coal hit its price peak at just over $200 per tonne – in 2008. Since that time the highest the commodity has reached is only $142 per tonne, back in January 2011, and has since been on

AustralianMining

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a slow yet steady decline. During this apparent boom the mining industry copped flack from other Australian industries, they laid the blame for their dwindling productivity and economic hardships at mining’s door – unfairly so in many cases. In fact much of the slow down across the economy was blamed squarely on mining’s rise. So what is the future for these minerals and the economy; have we seen the peak and actually begun the slide off the boom before it was even recognised as such? According to BIS Shrapnel mining investment will continue to propel the economy ahead for the next few years, but will soon be overtaken by other sectors as the primary driver of Australia’s growth. This will “soften the impact as the mining investment boom runs its course,” BIS says. However “don’t panic, mining investment will continue to grow, albeit more slowly, for a few years yet,” BIS Shrapnel’s chief economist Frank Gelber said. Gelber explained that “now people have finally realised that the investment mining boom won’t last forever, they are likely to overreact on the pessimistic

side”, resulting in many overzealous predictions regarding the industry’s demise. In BIS Shrapnel’s recently released Long Term Forecast report it predicted a mid-decade downturn in mining investments, adding that “it’s the magnitude of the eventual downturn in mining investment that will determine the severity of the impact on the rest of the economy”. It explained that as mining investments peaks in around two years time, and then starts its gradual decline, non-mining investment will stabilise and begin to pick up, taking over as the nation’s economic engine. And while this decline will see the end of what is an apparent golden age for mining – one not likely to be repeated any time soon – the industry will not be in as dire straits as many, particularly those in government, are predicting. The industry still has legs. “Despite any weakening in investment, mining remains extremely profitable, with strong production in prospect,” Gelber said. He went on to outline that the LNG boom is still coming, and would bring along with it a boom in construction and associated services. www.miningaustralia.com.au

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BIS SHRAPNEL

“The current discussion is about resources investment, which is stimulating investment-related activity in design, construction, equipment, and business services, [which is] adding significantly to our capacity to produce commodities. “On our forecast of continued high commodity prices, the Australian dollar will remain high for a few more years yet; this will keep pressure on other trade exposed industries [such as manufacturing] that are already suffering from structural change,” he said. However he added that most of the economy is sheltered from the impact of the economy. Gelber stated that despite the growth of mining being the apparent cause of failure for many other Australian industries, it has not driven all of them into the ground. “Health services have gone through the mining boom and high dollar episode growing strongly,” he said, adding that “they will continue to do so”. The report states that parts of business and financial services have picked up the benefit from serving strong mining investment; other parts have languished along with the rest of the economy and the weakness of other A Dbusiness _ A M F investment L E O C T _– 1that 2 .may pd change as mining-related business sof-

Mining investment is predicted to slow down over the coming decade as commodity prices drop.

tens, and strengthening of the broader ment is still rising, Gelber stated, economy will drive growth.” and “that means overall investment BIS Shrapnel’s report added that in the construction industry should f thePbuilding a g e industry 1 1 8will / 0also 9 / recover. 1 2 , 1 grow 0 : 5 strongly 7 A M over the next year,” “And remember, mining invest- although he did state that employ-

AA-0910_MiningAd_091412_Layout 1 9/14/12 11:05 AM Page 1

ment will remain subdued. Gelber added that there will be steady transition for Australia’s economy as the mining boom runs its course.

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AustralianMining

October 2012

AM.OCT12.PG014.pdf

Page

25/09/12,

2:26

END OF THE BOOM?

Rethinking mining’s PESSIMISM I t’s now official, according to Federal resources minister Martin Ferguson. The mining boom is over. But that doesn’t mean all is lost. In a speech last month Ferguson told a Canberra audience that modeling by the Bureau of Resources and Energy Economics had confirmed “the high prices associated with the mining boom are over”. “We have seen this moderation in prices unfold gradually over the course of the year,” he said. Linking the recent job losses with falling commodity prices and the weakening economic market, Ferguson said the mining industry would be facing tougher times. But far from ruling out a decline in the sector Ferguson said there was still promise for the industry. “Although this is not good news, it is by no means a death knell for the Australian resources industry,” he said. “It is useful to remember that the commodity prices experienced since last year were record-breakers. “And although it’s difficult to say when or if we might scale to those exceptional heights once more, BREE expects a rebound in some commodity prices in 2013, should global growth pick up as expected by the International Monetary Fund.”

While the sky high prices have come down, it doesn’t mean the end of mining.

advanced stage of planning, with FerWilliams said BP’s 2012 review guson adding that this was a 12 per of world energy showed global coal cent increase in value from October consumption grew by 5.4 per cent in 2011 and a 34 per cent increase from 2011. April 2011”. “These numbers are impressive, He also said exploration in min- and as an industry we support the erals and energy was worth $7.1 view that the long-term demand outbillion in 2011-12, twelve per cent look for coal remains strong,” Wilhigher than 2010-11 levels. liams stated. But while Ferguson’s facts are But what she left out was BP important perspective, they may be has also released research showing The outlook looking too far into the past. a dramatic drop in market share for Pointing to another BREE study Most drillers and miners don’t oil and coal globally, with gas and from April this year, Ferguson said share Ferguson’s optimism and whe- renewables strongly on the rise. it was important to keep a wider ther we’re still in a lag period with Like Ferguson, Williams has an picture of the mining industry in much grimmer statistics to come re- interest in talking up coal and cherry mind when talking about its decline. mains to be seen. picking the facts, but by the same toThe BREE report points to around But at the same conference last ken she represents one of the largest $270 billion worth of resources projects month Australian Coal Association industry bodies in the nation, and _ A M E Nstage WO of C Tdevelopment, _ 1 2 . p d f CEO P aNikki g e Williams 1 6 / 0also 9 / talked 1 2 , up1 : her 4 4 views P Mare likely to be shared by in A anDadvanced with almost 300 more projects in a less the industry. the majority of the sector.

October 2012

AustralianMining

What’s to come?

The focus for both Williams and Ferguson, and indeed the wider resources industry, is now less on the doom and gloom and more on finding new solutions. Marking increases to productivity, production, and innovation, both industry leaders said there were still opportunities to take advantage of. “While we can’t escape the fact that some of the heat has gone out of the commodities market, I reiterate that there is still cause for Australian optimism at present,” Ferguson said. “By taking the necessary steps to build infrastructure, train workers and improve our productivity we can sustain the benefits of the boom for many years to come.”

www.miningaustralia.com.au

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AM.OCT12.PG016.pdf

Page

17/09/12,

9:21

OLYMPIC DAM

GETTING OVER Olympic Dam While BHP has shelved expansion plans for Olympic Dam, it’s not all over for the project.

HP Billiton’s Olympic Dam expansion was one of the first dominos to fall this year in the mining industry. And at $US20 billion it was also one of the biggest. Blaming weak commodity prices and spiraling costs BHP Billiton CEO Marius Kloppers said the company’s decision to shelve expansion plans reflected the weakening mining market. Amid investor concerns that the company was acting too riskily, Kloppers said shelving Olympic Dam was a “prudent and disciplined course of action”. “As we finalised all the details of the project in the context of current market conditions, out strategy and capital management priorities, it became clear that the right decision for the company and its shareholders was to continue studies to develop a less capital intensive option to replace the underground mine at Olympic Dam,” he said. But whilst the company 16

October 2012

AustralianMining

has gone back to the drawing board it hasn’t axed plans for the mine completely. At the time of the announcement Kloppers said BHP was still looking to expand its South Australian centerpiece but it would look toward a plan “involving new technologies” that would make the project cheaper. “Olympic Dam is a resource of enormous potential and we will continue to work on technological and design alternatives that have the potential to substantially improve the economics of the expansion, while also completing some early stage site works,” he said.

Seen it coming

Before the official announcement many pundits predicted Olympic Dam may form part of a range of cutbacks proposed by the global miner. In May BHP chairman Jacques Nasser said himself that the company was under more pressure than it looked, and was starting to reconsider its expansions.

After BHP uranium president Dean Dalla Valle said BHP was “copping it from some major shareholders” analysts saw even more reason to tip a setback at Olympic Dam. In the lead-up to the announcement JP Morgan analysts also said the expansion may be three or four years away and even warned “Olympic Dam may not happen”.

Wider view

Outside the Olympic Dam expansion BHP added to its South Australian cutbacks by dumping plans to buy a swathe of exploration licences around the mine from Tasman Resources. In a tight lipped statement Tasman said the sale had been terminated by BHP but neither company provided any reason for the fallout. Earlier this year BHP made a number of deals to pick up exploration tenements around Olmypic Dam amid rumours it was searching for “dominant control”

over the Stuart Shelf region surrounding the mine. At the time BHP said some of the developments were “believed to be deep and relatively high risk” and it comes as no surprise they looked to offload them as uncertainty rose.

Get over it

Once the dust had settled the head of SA’s economic development board said businesses needed to “get over” BHP’s decision and start looking toward encouraging new growth in the sector. Despite the board previously hyping the benefit the project would bring to the state, it said there was much more to the mining industry than Olympic Dam. And despite his initial pessimism about the industry resources minister Martin Ferguson told ABC Radio there was still some chance the Olympic Dam expansion would get off the ground in the future. “This is a 100 year life potential mine. It’s not lost,” he said.

“Our requirement now is to continue to work together in partnership with South Australian and Australian Governments, and with BHP, to actually get this project in place.” While that’s easier said than done many miners and analysts still rate the uranium sector a strong industry moving forward. In a paper last month Uranium SA chairman Alice McCleary said the rise of nuclear power would be tied to a future clean economy, and demand for uranium would rise as new nuclear power plants came online. “Nuclear power currently provides ~30 per cent of world base load power, and if carbon emissions are to be curtailed and reduced this contribution will have to increase,” she said. “It is this reality that is driving countries to continue to operate and plan for the construction of new nuclear plants – a trend that is particularly evident in the developing world.” www.miningaustralia.com.au

AD_AMHEN2OCT_12.pdf

Page

14/09/12,

2:45

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AM.OCT12.PG018.pdf

Page

21/09/12,

9:26

MAPPING & SURVEYING

STOCKPILE

A simpler S

tockpiles represent the the velocity of the conveyor culmination of most pushing the material off the of a company’s time, belt determines where that technology, and effort. ore is going to be projected But while they look to,” Honeywell officials told simple from the outside or- Australian Mining. ganising and shuffling ore “We know based on the through these systems and angle of repose and the denonto ships can be a compli- sity of the material it will fall cated affair. a particular way, it’s called a At simple operations it’s rolling algorithm. hard enough but at large ports “One of our clients gets things are even more difficult. a lot of value out of this by Responding to feedback being able to take material from its customers Honey- from different parts of the well has developed software stockyard and break it up to help businesses visualise for the customer so the qualand organise stockpiles. ity is right.” With the computer doing Using the image of the the work the software makes stockpile users can rotate and an accurate representation of cut through the stockpile, and a stockpile on a screen and see the different quality of ore allows users to rotate, cut, throughout the entire stack. and demarcate ore as they Most often targeted at see fit. the coal industry, Honeywell “The principle behind officials said the software it is that stacker/reclaimer AD _ Aa M B A U A U G _ 1 2 could . p d fhelpP track a g e a number 1 1 6 / moves up and down, and of different measures.

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October 2012

AustralianMining

Honeywell’s helping companies keep track of their ore with its 3D stockpile software. “There are a couple of things we can have a look at. We might want to look at ash or sulphur, moisture, or which company owns it,” they said. But beyond this miners can also use the software to track which mine and which pit or seam the ore came from. 0 7 “When / 1 2 , we1track 0 : 0the 0 maAM terial we break every move-

ment into a batch, and we can follow every batch from the mine site,” officials said. “If you know that a stockpile is getting out of specification ranges you can trace back where it came from, what seam it actually came from.” Based on the principle that the first cart out of the mine will be the first one in, Honeywell admitted this

tracing ability was not watertight. “It’s going to be a little bit inaccurate, but for what you want to do, it’s accurate enough,” they said. Already at use in one of the ports on Australia’s east cost, Honeywell said a mining company had also taken to using the product on site to simulate blending that would occur at the port.

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AD_AMSCASEP_12.pdf

Page

20/08/12,

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AM.OCT12.PG020.pdf

Page

12/09/12,

2:53

MAPPING & SURVEYING

Mapping from a high Australia has taken a massive step forward and produced the world’s first continent wide mineral maps.

ustralia is still an un explored wilderness. Despite the nation driving the mining boom, it is still focused on well known mineralised zones, and has barely even entered the na tion’s vast interior. Only last year Gold Road Resources announced that it had uncovered a new poten tial gold greenstone belt, the Yamarna Belt, which lies just north of the recently discov ered massive Tropicana de posit. The Northern Territory is also woefully underexplored, with only 30 per cent actively explored to date. Much of this lack of headway is due to Australia’s harsh interior, particularly in the Northern Territory. However in August one miner, Kentor Gold, made a surprising announcement. It had uncovered several previously unknown copper gold zones at its Jervois cop per silver gold project in the Territory. So what made this dis covery unusual? It was uncovered using the recently released satellite ASTER (advanced Space borne Thermal Emission and Reflection Radiometer) mineral maps over Austra lia that were created by the CSIRO’s Minerals Down Under Flagship in collabo ration with Australian geo science agencies. These ASTER maps are the world’s first continental scale satellite derived miner al maps and represent more than a decade of planning and development, according to the CSIRO’s CEO Megan Clark and Geoscience Aus tralia chief Chris Pigram. ASTER maps represent a collaboration involving sci entists from Japan, the USA, and Australia. According to the CSIRO “the new suite of mineral maps will enable mining companies to increase the efficiency and viability of 20

October 2012

AustralianMining

had its information trans formed into maps of land surface mineral information of Australia.

Mapping from a high

Surveying and exploration has historically been a labour intensive task.

their exploration efforts”. The information for these maps “was generated from a tenyear archive of raw Ad vanced Spaceborne Thermal Emission and Reflection data collected by NASA and the Japanese Government’s Ja pan Space Systems.

“They are already chang ing the way that geoscientists look for mineral deposits by providing more accurate and detailed information than ever before,” it stated. CSIRO scientists also developed the software that changed the data into con

These maps will increase the viability of exploration in Australia.

tinentwide mineral maps which show rock and soil mineral components and provide the ability to view images from thousands of kilometres wide to just a few kilometres.

One small step

Until now there have not been global scale mineral maps of the Earth’s surface. And while individual states have made major steps forward, such as Tasmania’s project which saw it produce 3D mineral maps of nearly the entire region, nothing on this scale has been attempted before. And definitely nothing from space. To date the only ‘geo science tuned’ satellite system that can even provide this in formation is the ASTER sen sor, which was launched in 1999 and has only now, 12 years after its initial launch,

The technology itself works via the use of reflectance and emission spectroscopy data collected from satellite, air borne, field, and drill cores and “is a noncontact and nondestructive method that measures electromagnetic ra diation from different parts of the wavelength spectrum, from the visible to where we can sense heat. “This naturally reflected or emitted radiation pen etrates only the top few mi crons of geologic materials; importantly the wavelength range also spans diagnostic absorptions of a wide range of materials.” While the laboratory hy perspectral equipment has been around for years, the abil ity to combine it with satellite and other logging systems is only now becoming available. These hyperspectral satel lites are also reportedly gener ating mineral maps of Mars, which are being used to find suitable sites for landers.

A team effort

The CSIRO has been working towards developing the meth ods and software to properly “transform these raw ASTER images into seamless, conti nent wide mosaics of mineral information, and then mak ing these web available for use in standard GIS systems for explorers”. Data access and software development was coordi nated by CSIRO through the Western Australian Centre of Excellence for 3D Mineral Mapping and involved Geo science Australia, state and territory Geological Surveys, AuScope, iVEC, NCI, JSS, NASA and the USGS. These maps are freely available to the public and miners to help improve the nation’s prospectively. www.miningaustralia.com.au

AD_AMBACMAR_12.pdf

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17/02/12,

11:53

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AM.OCT12.PG022.pdf

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21/09/12,

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MAPPING & SURVEYING

What you see is what you get Whilst not traditionally focused on the mining industry, 3D modeling is helping mining companies detect wear more accurately, writes Andrew Duffy.

onitoring wear and tear is an everpresent concern for mining companies, and technology has long been used to help solve the problem. Whilst most often focused on predicting downtime, software developers are also helping miners spot wear when conducting regular maintenance checks. Using 3D modeling WYSIWYG 3D, short for what you see is what you get, aims to help companies identify wear by comparing before and after scans of equipment and machinery. WYSIWYG officials told Australian Mining the software was most often used to make a scan of machinery when it was brand new, and compare later scans to the perfect model. “You have a model that is a nominal model. It could be the model that was scanned on the day of installation so you know what it was actually made as,” they said. “Once it’s installed you can come back three months later on a maintenance check-up and compare it to that previous computer model.” “Companies can gauge distances and deviations, where the2 .most, AD_ A M Pit’s O Swearing OCT _ 1 p d fthings P a like ge that.”

The WYSIWYG can model fine details to track even slight changes to equipment.

How long before a second scan is made for comparison is an inexact art, and depends on the operation, equipment, and where it’s going. follow-up 1 But 2 1 /most 0 9 often / 1 2 the , 1 2 : 0 8 scan P M is made during a regular maintenance check.

Whilst it’s used in a range of industries outside mining as well, WYSIWYG told Australian Mining the software was most often used by support companies in the sector. “It can be used on a whole range of sites, but more so in the mining suppliers,” they said. Casting companies and businesses that create the actual wear material are the best fits for WYSIWYG, as are companies manufacturing equipment for the mining industry. “Often people are scanning catalogues against a new casting off the production line because it could distort or bend and they want to make sure that each part is close to design specifications before they send it to the next stage of processing,” officials said. “If it doesn’t meet specifications they’ll actually send equipment back to remelt straight away, so you can reduce waste and machining time.” Used for reverse engineering and wear analysis, WYSIWYG’s 3D modeling is just making a start in the mining industry, but the company has been making a strong presence at trade shows around the country and looks keen on expanding its reach into mining.

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AD_AMHELOCT_12.pdf

Page

6/09/12,

4:51

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AM.OCT12.PG024.pdf

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12/09/12,

2:55

MAPPING & SURVEYING

Uncovering Australia’s potential Geoscientists gathered in Brisbane in August to discuss how to unlock the nation’s minerals.

t is no secret that despite Australia’s mining boom, we’re still yet to even uncover the vast majority of our resources. According to the Australian Academy of Science’s secretary for science policy, Bob Williamson, “Australia’s resources industry is [still] based on research conducted in the late 19th and 20th centuries but around 80 per cent of Australia still remains underexplored”. Considering the sheer scale of the nation’s mining industry, and its often remote work locations, many may find it surprising that so much of Australia is still unmapped, and its metal and mineral deposits unknown. However when Australia’s vast, uninhabited interior is taken into account, this discrepancy begins to make sense. So with the high value of the country’s existing mineral wealth, it only makes sense that there is still massive deposits just waiting to be uncovered. “[These under explored regions] represent an enormous opportunity for Australia,” Williamson said. But the question remains – how do you unlock this potential? At the 34th International Geological Congress in August, the questions of how to uncover these deposits, and use the latest digital technology in doing so, were the main focus.

sources minister Martin Ferguson, the project “arose from the Academy’s 2010 Theo Murphy High Flyers Think Tank. “It brought together scientists from government research institutes, universities, and industry in an unprecedented level of collaboration to address [this] national challenge.” He went on to say that UNCOVER aims to combine knowledge and use the latest technology to explore Australia. “Traditionally we’ve seen cover as a barrier that masks the signature of buried mineral systems,” UNCOVER group member Mike McWilliams stated. “However cover can also disperse the geochemical signals of a large mineral system, expanding the potential geographic footprint of a buried resource to make it more discoverable. “We want to turn cover into an exploration opportunity, not an impediment.” McWilliams added that it will also have broader implications than mineral exploration as “the knowledge and data generated by col-

laborators will enhance our understanding of Australia’s mineral, energy, and groundwater resources”. While scientists are coming together to discuss the future direction of exploration and mapping Australia, it is the technology that will really move it forward, in particular the explosion of digital technology in the geo-surveying space.

‘The information explosion’

The Congress also saw a presentation on “the digital revolution and explosion of information” and how it is shaping earth sciences. Australia’s Tom Cudahy, along with Germany’s Kristine Asch and New Zealand’s Ken Gledhill explained how “advances in technology are creating new insights into geological processes and at the same time allowing optimum use of an expanding array of digital geoscience information”. In the last few months the world has seen the first public release of country and continent scale minerals maps generated by airborne imagery, a massive leap for-

Uncovering potential

One of the major developments unveiled at the event was UNCOVER: Searching the deep earth, a project “designed to unlock Australia’s enormous potential wealth”, Williamson explained. Launched by Federal re24

October 2012

AustralianMining

Supercomputers are set to reduce the risk of mining exploration.

Australia still relies on surveying from the 19th and 20th century.

ward considering only last year Tasmania created the first 3D state-wide minerals map for Australia. One of the major developments was the Advanced Spaceborne Thermal Emission and Reflection (ASTER) Geoscience Map of Australia, which also uses field and drill core systems to build 3D mineralogy maps of the earth. Another has been the collaboration of Geoscience Australia and the National Computational Infrastructure (NCI) Facility. The two have come together to use NCI’s super computer to develop high resolution 3D images of sub-surface geology, which solves some of the degraded resolution and scale issues in models built with low power computers. Geologist James Goodwin expressed how this super computer is changing geological mapping. “High resolution models covering an area of 240 square kilometres and containing

6.48 million cells can now take as little as 30 minutes to process,” Goodwin said. “Models have already been built successfully for offshore and onshore areas in Western Australia, with the onshore model supporting interpretation of deep seismic survey data identifying features separating the Pilbara, Capricorn, and Yilgarn geological regions. “The improved data quality will allow minerals and energy resource explorers and mining companies to more accurately identify specific areas with resource potential.” Andy Barnicoat, the head of Geoscience Australia’s Minerals and Natural Hazards division, added that these models “remove the effect of anomalies outside the specific area of interest [and] will greatly reduce the exploration risk for mining and exploration companies”. Cudahy stated that “this new generation of remote and proximal technologies [is creating] opportunities for more efficient exploration”. www.miningaustralia.com.au

AM.OCT12.PG025.pdf

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MAPPING & SURVEYING

Varying variograms Automatic variogram fitting tools are one of the new developments in mapping software.

utomation is working its way through all aspects of mining. And now it has become part of the geologists’ sector with the release of Geovariances’ Isatis 2012 software, which features an advanced automatic variogram fitting tool. Laurent Wagner, Isatis’ product manager, explained that “this tool is unique in the world of geostatistics software as it is the only one that handles complex variography and allows quick and high quality fitting of multivariate, multi-directional and multi-structure variograms. “The user just has to select a set of basic combinations of structures and the program is able to compute the best fit of the variogram model against the input experimental variograms,” Wagner stated. It works off of quadratic optimisation methods. “Its strength lies in the fact that it is able to identify anisotropies and to Aoptimise D _ _ 1 variogram 0 . p d f ranges, P a g esills,1 and other involved parameters for

www.miningaustralia.com.au

The program can handle complex variography.

each basic structure, each sample of cross-variogram, in all directions of the space simultaneously. “The important benefit of this under 1 6 / of 0 3feature / 1 0 ,is that, 3 : when 1 4 comPM bined with batch procedures, it al-

lows the set up of efficient automatic estimation workflows,” he said, adding that “it makes the update of resource models with new data easy and fast, and improves the users’ productivity.”

The geomapping software also features Flumy, a new geological modeller for meandering channelised systems. It provides a way for operators to model sedimentary deposits due to its combination of process-based and stochastic approaches. “It is unique in modelling the reservoir inner geometry with a high ‘geological reality’,” Geovariances R&D manager Francois Geffroy said. The model is based on evolution in time of the channel by migration, cut-off, and avulsion, and on the deposition of sedimentary bodies. “It is able to generate various fluvial deposit elements such as point bars, crevasse splays, overbank alluvium, sand and mud plugs.” Isatis 2012 also has the ability to compute grade tonnage curves from block simulations computed on selective mining units or on panel grids. The existing grade tonnage cruves, which develops curves from kriging results, has also been enhanced with the ability to handle 2D block models with a given thickness and irregular block models.

AustralianMining

October 2012

AM.OCT12.PG026.pdf

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25/09/12,

8:41

CHINA COAL

Cutting coal DEATHS W

hilst Australia has seen its fair share of mine closures over the past few months, they’re nothing in comparison to the recent cutbacks in China. Last month the Chinese Government announced it would shut more than 600 coal mines across the country, a move that sent shockwaves through the industry. But while mines in Australia have been hit by tough economic conditions most Chinese sites are closing down for different reasons. According to local Chinese media most of the 600 mine closures are aimed at ensuring a safer local industry. China has one of the worst coal mining safety records in the world, with around 35 workers killed forAevery D _ A100 M Pmillion O R O Ctonnes T_ 1 2 of coal.

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AustralianMining

Last year more than 2,000 miners died in Chinese coal mines but the industry and Government is slowly but surely making inroads into improving the sector’s safety. Part of the trouble with China’s industry is that illegal and unlicenced mining is rife, with many operators dodging regulations. The Chinese Government hopes consolidating and closing unsafe mines will help improve the industry’s record, but the move is sure to slow domestic production. Chinese officials have already warned turning to stricter safety measures will mean a reduction in output in some areas, and according to Government documents published earlier this year China has set a 2015 target to reduce coal mining deaths by cent.2 1 / . pmore d f than P a 28 g eper 1 In what could be seen

The Chinese Government has big plans to improve its lackluster safety record.

as a win-win for Australian producers and the global industry China’s improvements will see the creation of a safer industry for Chinese workers and will see imports of international ore rise. pre0 9 Areas / 1 2 ,of China 4 : 3 that 5 P M viously sourced coal from

unsafe domestic mines will be forced to look overseas for their product, which is good news for countries like Australia. But so far the closures don’t seem to have made a material impact on commodity prices, with coal miners

still closing mines and shelving expansions due to a lack of profitability. Nevertheless increasing demand for international coal and an improving safety record in China are positive developments for the wider industry.

www.miningaustralia.com.au

MM2002_PRODUCT_SUBS.pdf

Page

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Terms & Conditions Your subscription may be tax deductible, ask your accountant. ABN 80 132 719 861. Please note RBI has a no refund policy, contact Customer Service for details on 130 360 126. *Based on previous $99 annual subscription price. All prices are quoted in Australian Dollars and GST inclusive. We are committed to handling your personal information in accordance with the Privacy Act www.reedbusiness.com.au/privacy.asp

AM.OCT12.PG028.pdf

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GAS

The FUTURE of gas While the gas market is ripe for development community opposition is also rising, writes Andrew Duffy.

ith energy prices rising across Australia, on and offshore gas developers are heralding their projects as a solution for businesses and ordinary consumers. Spruiking jobs, taxes, and lower gas prices, they’re expanding rapidly. Western Australia’s North West Shelf and the onshore assets through Queensland and New South Wales are the hotspots, but with the advent of onshore gas there’s exploration almost everywhere. But compared to the offshore rigs in WA, coal seam gas and shale gas has had a hard time winning approval from both governments and communities. While developers acknowledge the issues they’re adamant they’re only short term hurdles. But many in the community, and in politics, aren’t so sure. The call for a moratorium on coal seam gas along the east coast has grown stronger as the months progressed, with protests locking down exploration projects every other week. Nevertheless the industry and most state governments remain bullish, albeit cautious, about expanding natural gas projects across Australia. Industry advocates claim it’s their pragmatism that’s driving the expan28

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sion, filling a shortfall in energy supply that can’t be made up any other way. But in the era of man-made climate change, protestors are wondering whether we can’t fill the gap with clean energy instead, whilst avoiding the health and environmental risks posed by the gas industry. This month Australian Mining got the lowdown from some of the industry’s biggest figures on the future of this burgeoning industry, including Santos CEO David Knox, Shell’s Ann Pickard, and Commonwealth Department of Resources and Energy secretary Drew Clarke.

Stay in control

One of the strongest themes emerging from the Shell, Santos, and Commonwealth leaders at the GE at Work Conference was the need for strict regulation of the industry. Pickard, who Fortune Magazine previously titled ‘the bravest woman in oil,’ told the panel strict rules needed to govern gas projects to ensure weak operators didn’t tarnish the industry. “We need a very good and strong regulator, it doesn’t matter whether it’s unconventional gas or offshore,” she said. “Because if a company misperforms, like with what happened in

the Gulf of Mexico some time ago, nobody remembers which company did it, they’re just going to know it was the oil industry, so we’re all tarred by the same brush.” Whilst marking the cost of heavy regulation a concern, Pickard said most developers were happy to accept it if it meant creating a stable business environment. The commitment to regulation should come as welcome news to concerned community members along the east coast of Australia, but many still claim the rules don’t go far enough. Most recently the Victorian Government enacted a ban on fracking until better regulation was drawn up, joining NSW in keeping a close watch on the coal seam gas industry. Whilst a token gesture unlikely to have any impact on developers, the Australian Petroleum Production and Exploration Alliance has still voiced opposition to the ruling. Long arguing the gas industry is one of the heaviest regulated sectors in Australia, the APPEA has urged state governments to look toward QLD as a model regulator. QLD has long housed coal seam gas production wells and has the most advanced industry in Australia, which the industry says has an impressive health and environmental record.

But unsurprisingly many protestors claim otherwise, and claim they can point to many QLD examples where land and health is already starting to erode as the gas industry expands. To try and settle the matter once and for all the APPEA is helping draft national best practice guidelines which it says will help clear up confusion and fear about the current state-based approach, which has caused headaches for companies and stakeholders with its varied and at times opaque approach.

National approach

Helping maintain the energy picture from the national level, Clarke was able to provide important insight into how this new national framework would be played out. And his approach was decidedly pro-business. “The best policy is to let the market make the investment decisions,” he told the panel. “There are inevitable and proper roles for government in this area, but the primary policy setting we aspire to is to keep those at the appropriate level and let the market make the choice of where to invest and what to build and what to do with their gas.” Clarke said the Government had aimed to encourage gas development www.miningaustralia.com.au

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GAS

because if projects were not supported their investment, jobs, and economic benefit would go elsewhere. It was a sentiment echoed by both Knox and Pickard, who said rising costs downunder meant Australia was already struggling to compete with provinces like East Africa and North America.

They also said such complaints could be heard from most onshore gas regions in NSW, and that companies had a long way to go before they gained the trust of the community.

What’s next

Risk factor

Outside the cost of doing business, both Shell and Santos said community consultation, and keeping the licence to operate, was one of the biggest concerns for gas developers in Australia. Knox said keeping the community informed was particularly important with onshore gas because of its proximity to built-up areas. “We’ve got to tell our story, because when I and a lot of other gas professionals were brought up, we basically worked on platforms offshore, out of sight out of mind.” “What’s happening with shale gas in the United States and what’s happening here in Australia is we’re coming on people’s farms and people’s backyards.” Knox said this consultation revolved around convincing the community A D _ the A Mindustry F L E O Cknew T _ 1 what 2 . pitd was doing.

Community opposition has grown as gas operations become more visible.

“We’ve got to do a tremendously good job in explaining what we do, why we believe we can do it safely, and why we can be responsible. “I think that’s one of our biggest challenges, not just in Australia, but worldwide.” Pickard also said Shell was taking its time and talking to the community before expanding with its QLD developments. “We need to take our time and make sure our stakeholders, farmers, and people out there understand f what P awe’re g e trying 1 1 to / do 0 6and / 1 that 2 , we5 can coexist.”

FRAS approved cartridge precleaner cuts replacement downtime

But she was confident the consultation would not be a major roadblock for the company. “Everybody’s saying we’re slowing down. We’re not slowing down we just want to make sure we get the stakeholder side right,” she said. But despite the commitment of both companies, many landholders say they can speak from firsthand experience about the lack of consultation before development. One owner told Australian Mining companies were guilty of “misrepresenting information, inadequate : notification, 1 9 P M and refusal to acknowledge valid concerns”.

Despite rising opposition to the onshore gas industry it’s showing no sign of slowing down. The senior management from all companies are determined to keep things moving, and while some state governments are more allowing than others, no major government is yet to voice opposition to the sector’s advance. While there’s no doubt some politicians are urging for more restrained growth, the industry as a whole faces little opposition. Nevertheless community backlash remains a significant wildcard and there’s no doubt shale gas protestors have had significant success at slowing developments, particularly in NSW. How long this opposition will last, and how high the stakes will rise remains to be seen. But if the industry’s current performance is anything to measure the future against, gas will have a bright future in Australia.

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October 2012

AM.OCT12.PG030.pdf

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DUST & VENTILATION

Cutting coal TRAGEDIES C

oal mining tragedies stantaneous automatic water often dominate the spraying to suppress a spread news, with scenes of such an explosion. such as Pike River’s huge onResearch has also been going explosions, the blasts undertaken in the civil tunregularly seen across Chinese nelling sector on similar coal mines, and events such anti-explosion systems, alas Nymbodia grabbing every- though this has obviously one’s attention. not been in respect of coal The cause of these awful dust events which can spread events is often linked directly right throughout a mine’s to leaking, and subsequent underground workings with ignition of methane gas in- the potential to cause wideside the mines. spread loss of life – not only But what many non-coal from the effects of an explominers don’t realise is that the sion itself but from toxic gasreal killer explosions, which es and lack of oxygen which tragically can sometimes cause result. major death and destruction BMT WBM, an Austrain underground coal mines, lian subsidiary of UK headare only triggered by an igni- quartered BMT Group, and tion of methane gas. SkillPro Services, also from The main lethal element Australia, have just announcis a subsequent coal dust ex- ed that they have successfully plosion set off by the meth- suppressed a coal dust exploane ignition which itself can sion using their Active Barbe relatively small and of rier prototype system in the short duration. CSIR’s experimental tunnel Traditionally the prevent- in Kloppersbos, South Africa. ative measure employed by The companies say that many coal mines is to use this system could play an instone dust barriers where the tegral role in enhancing the stone dust mixes with coal future safety of coal miners. dust and mitigates, or preHistorically, coal dust exvents altogether, a subsequent plosions have been the number coal dust explosion but this one cause of fatalities within has proved not always to be underground coal mines and 100 per cent effective in stop- even today, despite the use of ing these events. various passive countermeasConsequently much re- ures, these explosions cause search has been undertaken many fatalities worldwide. over the years to come up David Proud, business dewith a system which is more velopment manager for BMT efficient in suppressing such WBM’s Machinery group exA D explosions _ A M Q U I much A U G _of 1 2 plained . p d f that P a“using g e a1 sensor 2 0 / dust which revolves around in- to detect the approaching coal

October 2012

AustralianMining

Two Australian companies are trialling technology to cut coal dust explosions, Lawrence Williams writes.

dust deflagration, the Active Barrier system successfully injected 120 litres of water within 250 milliseconds in order to suppress the explosion, as was predicted by BMT WBM’s computational fluid dynamics (CFD) modelling. This is a ground breaking development – one which could help to mitigate the risks of coal dust explosions occurring in underground coal mines.” BMT WBM and SkillPro have been involved in this R&D project for several years with the financial support of the Australian coal industry research body, ACARP. 0 7 BMT / 1 2 , WBM 1 2 :has 2 0 been PM modelling the physics and

chemistry involved in the entrainment, devolatilisation and combustion of the coal dust particles and the injection and vaporisation of the suppressant. CFD was also used to simulate a range of designs for the prototype suppression device, in order to arrive at a practical and reliable experimental unit. SkillPro designed the final test apparatus and managed the test programme. The ACARP Underground R&D committee has recently awarded the SkillPro/ BMT WBM team an excellence award for the research and development undertaken on the Active Barrier project.

David Humphreys, SkillPro’s manager of the Active Barrier project stated that “a zero harm approach remains top priority for mining companies and SkillPro and BMT WBM are committed to helping their customers achieve this through the development of a range of innovative systems such as the Active Barrier. “The success of this test programme is another huge leap forward and we hope that we can continue our R&D work to further develop this pioneering product.” This article originally appeared in full on Mineweb.

www.miningaustralia.com.au

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AM.OCT12.PG032.pdf

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DUST & VENTILATION

Uncovering the issues Uncovered coal trains have got communities around coal rail networks fuming, Cole Latimer writes.

ith the coal price dropping, miners have to make sure they can move every bit of product they can. However when transporting and transferring it miners run into an entirely new set of problems, particularly when moving it via train through suburban areas. Not only do they lose a percentage of the coal as dust and fines flying off the loads, they also incur the wrath of communities located around transport routes, whose homes are subjected to clouds of coal dust that have also affected their health. This has been the cause of a massive backlash, not only from green and environmental groups, but also community interest groups. Most recently Queensland Rail announced that it will carry out a series of tests to measure coal dust levels across Brisbane suburbs. It came as a massive investigation is held into the current coal dust levels across Newcastle and across the Illawarra region. In Newcastle the Greens are leading the ‘Great Cover Up” campaign to force coal trains to cover their loads to minimise the amount of coal dust thrown into the air during transport. Supported by the local media, the campaign has begun to gain legs and turned more of the community against the coal industry, The Illawarra region quickly followed in the Hunter Valley’s footsteps, with the local Greens pushing to also have trains in the region covered. “There is growing community support in the Hunter ... to require all coal trains to be covered,” Wollongong councillor Jill Merrin said. “Residents of Wollongong are also being subject to the health risks of coal dust by the transport of opentopped coal trains through 32

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Campaigns have begun in the Hunter Valley to force coal trains to cover their wagons.

their neighbourhoods. “We now know that the fine dust particles from coal have the potential to cause serious lung diseases.” Merrin added that there are wildly different approaches to how coal is handled depending on the transport method. “Trucks which transport coal are currently required to have their loads covered, so we want to know why the same standards are not applied to coal trains,” she said. Now Queensland is following suit, with state transport minister Scott Emerson stating that QR will conduct testing in conjunction with the state government. Emerson said it has been nearly a decade since levels were last tested. “Ten years ago when that monitoring was done it showed that levels were safe in terms of coal dust,” Emerson said. “But I do think it is appropriate for some more monitoring to be done and QR National is in negotiations with QR Limited to do some additional monitoring to see what the current situation is.”

A group called “Stop Brisbane Coal Trains” is attempting raise awareness of the issue in the city and halt transportation of coal through Brisbane entirely. This group has even labelled these as “death trains, due to their serious local and global impacts”. The coal dust also presents additional problems

for transport as it coats the rails themselves, causing a friction problem for the trains and corroding the rails as well. With all these negatives, it makes sense to not only try and protect your product from dissipation, but also community backlash. Speaking to Spraying Systems, they told Austral-

Veneers have been viewed as one solution to coal dust.

ian Mining that covering the coal with a chemical veneer, rather than covering all of the carriages themselves individually works. “We’re putting veneers over the coal, and what we’re doing isn’t new, but the way in which we’re doing it is,” they said. It uses a fully automated spraying system that works above the rails, so that the train can continue running while the veneer is applied. This system also uses monitors to detect the difference between the locomotive and the carriages, so that it doesn’t spray the train, and can also detect the differing volumes of coal. “It can pick up whether the carriage is loaded or empty,” Spraying systems told Australian Mining. “Veneers have been in Queensland for ages, we’ve been doing it since 2000; we’re surprised there isn’t a system like this in New South Wales” considering the backlash faced, especially as it “protects both communities and the product”. According to Spraying Systems it can cut loss by between .5 and 1 per cent. www.miningaustralia.com.au

AD_AMHENOCT_12.pdf

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Enough said.

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AM.OCT12.PG034.pdf

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DUST & VENTILATION

Understanding the dusty trail A new training academy is teaching miners how to deal with dust.

A D _ A ML U H O C T _ 1 2 . p d f Pa ge Dust is an inescapable part of the mining business.

1 3 / 0 9 / 1 2 ,

ust is an ever present, but variable issue on all mines. It will never be fully eliminated, but understanding how it moves, what moves it, and how it affects air quality is something that can be controlled. To aid in understanding how dust operates, Australian company ATMOS Global has launched its revolutionary Air Quality and Climate Change Academy. According to the company the academy is a highly specialised and workplace specific air quality and climate change training and learning portal. Atmos Global’s chief Orestes Valianatos explained that the program provides its “industrial clients, with operations located anywhere 1 in 0 the : 5 world, 5 A Mand an opportunity to keep up to date with leading edge

concepts and practices associated with addressing air quality management, dust management and climate change related challenges important to the mining, manufacturing and energy industries He added that “Atmos Australia is also trading nationally and internationally as the Air Quality and Climate Change Academy”. The radical transformation of the world and current workplace diversity and mobility trends have led to an increased demand for ‘learning by doing’ training services that meet the learners’ needs for flexibility by providing direct access to information relevant to their work environment when they need it in real life situations. Valianatos said that this new “Air Quality and Climate Change Academy aims to be a leader in the ‘Digital

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AM.OCT12.PG035.pdf

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DUST & VENTILATION

A D _ A MB O G O C T _ 1 2 . p d f By knowing how dust operates, better processes can be introduced rather than blanketing the mine site in water.

Education Revolution’, a new concept of learning that helps our clients deal with the current far-reaching changes in our economic and technological landscapes. It shifts the learning and development paradigm to a performance improvement process. “While responding to our clients’ need for profound practical understanding of the key contemporary air quality management, dust management and climate change challenges surrounding their operations, ATMOS’ Air Quality and Climate Change Academy also opens the door to an optimal learning structure that closes the learning-doing gap by providing our clients with a handson approach to understanding and mastering the use of the world’s first advanced air quality management and dust management platforms ATMOS-5D, ATMOS-5D+, DustAlert and DustAlert+, which operate in the forecasting service framework provided by the company’s existing Centre for Global and Site Specific Dust Impact Forecasting, Management and Control,” he explained. The recently created Air and Climate Change Academy is an ’addon’ to the company’s air quality management, air quality forecasting, dust management, dust impact forewww.miningaustralia.com.au

casting and climate change services. ATMOS Global’s Air Quality and Climate Change Academy is an instructional platform for delivering information and knowledge using training architecture that integrates formal and informal learning and uses technology to deliver timely and engaging learning solutions and provide real-time answers to employees’ work-related enquiries. The academy’s workplace training in air quality services have already been used for Western Areas’s Spotted Quoll open cut nickel project. After utilising its training the miner has nominated as a finalist for the Golden Gecko Awards for Environmental Excellence. Valianatos told Australian Mining that “in the new world order, employees need to utilise the training and development opportunities offered by their organisations aimed at motivating and enhancing their performance and provide them with the skills required before they undertake a new task. Employees are not only seeking to work for companies like Western Areas that provide novel training opportunities, they are staying there because of these systematic and ongoing development opportunities”.

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October 2012

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AM.OCT12.PG036.pdf

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CEOS UNDER THE SPOTLIGHT

The RICH Vs the REST Mining bosses are calling on the rest of Australia to work harder, but it’s not proving a popular strategy.

s the pressure mounts on our mining companies to stay profitable more industry leaders are demanding others pull their own weight. It’s a perennial theme running through most industries but in mining the campaign to raise respect for entrepreneurs has gained more momentum than usual, led by several big names. Late last year MMG CEO Andrew Michelmore kicked off the fracas by saying Australia was suffering from “rich country’s disease”. He said unless we rediscovered our hunger for work we risked “pissing away” our economic strength. Part of Michelmore’s plan for increasing participation was reintroducing older workers into the industry and upping the number of female workers. “We need to get the grey hairs back into the industry and working; we need to get more women involved in work,” he said. He also said people “can’t be bothered” moving to find work, and this attitude needed to change if Australia was to keep growing. This last fact was certainly up for challenge, and the Construction, Forestry, Mining and Energy Union claimed if companies looked hard enough, and provided enough training, it wouldn’t be difficult to find workers willing to travel. Michelmore’s comments were left to stew for months before Atlas Iron boss David Flanagan and mining magnate Gina Rinehart reignited A D _ AChanneling M P R I M AMichelmore R_ 1 1 . p the debate. but adding their own flavour, both of

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AustralianMining

Rinehart said more working, and less socialising and drinking, would change Australia’s fortunes. Image: Fairfax Media/Jim Rice

the iron ore magnates Rinehart and tax, Flanagan said too much attenFlanagan called on workers to up tion had centred on taxing busitheir effort. nesses. Flanagan said hard work was With his sights set on the Federal no longer celebrated in Australia Government, he said too many peoand overinflated mining wages had ple were focused on gaining “free spurred too many into a “feeling of this and free that” and governments entitlement”. were using high taxes and subsidies “The concept where people need to encourage the behavior. to work really hard and take risk and But while Michelmore and Flansave to build something, it’s kind agan’s comments were inflammaof not celebrated the way it used to tory by far the biggest backlash was d be f inP Australian a g e 1 culture,” 4 / 0 2 /he1 said. 1 , 1 saved 1 : 1 for 8 Rinehart. AM A longstanding critic of the mining In a strongly worded opinion piece in Australian Resources and Investment magazine Rinehart called on her critics to start working harder. “If you’re jealous of those with more money, don’t just sit there and complain,” she said. “Do something to make more money yourself – spend less time drinking or smoking and socialising, and more time working.” But that wasn’t the end of it. Less than a month after her opinion piece hit the press Rinehart made an address to the Sydney Mining Club where she argued Australia was losing the battle to stay competitive against global markets.

“What was too readily argued as the self-interested complaints of a greedy few is now becoming the accepted truth, and more ominously, is showing up in incontrovertible data,” she said. While most of her argument centred on economics Rinehart said the high wages earned by workers in Australia were a significant roadblock to helping companies establish projects. In a parallel that drew the ire of most people, Rinehart said Australian miners had to compete with the wages of illegal immigrants in the Gulf of Mexico and Africans earning $2 a day. Whilst most of the arguments had some truth to them, the way they were presented ensured the message was obscured. Nevertheless it’s fair to say Rinehart and an increasing number of mining bosses are starting to campaign on raising work ethic and raise respect for entrepreneurship. It’d be a stretch to link these comments with the industry’s weakening finances, but there’s no doubt the criticism seems to be part of a rising tide in Australia. www.miningaustralia.com.au

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AM.OCT12.PG038.pdf

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FORTESCUE

The fight is on for FORTESCUE F

or most of the year Pilbara powerhouse Fortescue Metals Group had been one of the few large mining companies not to take the axe to their workforce and bottom line. But all that changed in a hurry last month, with the company slicing hundreds of jobs and $4.6 billion off forecast spending for FY2013. Over the space of two days the company announced the cutbacks, which it said were minor changes aimed at riding out instability in the market. Currently Pilbara miners are on edge over iron ore prices, which have dropped around 30 per cent in the last 4-5 months. Whether we can take the optimism spouted by most miners at face value remains to be seen, but Last month Fortescue Metals Group for now the facts are still worrying for most of these businesses. proved it wasn’t immune to weakness Wary of a credit rating downhurting most of our miners. grade from Moody’s, FMG has drawn the bulk of its $4.6 billion A D _ A ML A N J U N _ 1 2 . p d f Pa ge 1 1 5 / 0 5 / 1 2 , 3 : 4 8 PM in savings from deferring comple-

tion of a fourth berth at Herb Elliott Port and delaying development at the Kings deposit. Staff and operating cost cutbacks will also focus on the Cloudbreak mine while the company aims to complete the expansion of its Christmas Creek mine and commission the Firetail deposit at the Solomon mine. FMG CEO Nev Power said the cutbacks would allow the company to stay flexible and it would resume the delayed expansions when “iron ore prices return to more sustainable levels”. “We are confident that the underlying fundamentals of the Chinese economy are strong and we believe iron ore prices will rebound in the medium term,” he said. “However, we have moved quickly to strengthen the balance sheet.” In a separate annoucement a day later FMG also confirmed it had sold the power station at its Solomon mine in the Pilbara to a subsidiary of TransAlta for $US300 million. Power said the sale was “consistent with the company’s focus on core infrastructure” and represented a key step in its Pilbara expansions. “It was always our intention to divest the Solomon power station to 38

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an established owner and operator of power generation assets,” he said. Currently FMG is loaded with over $9 billion in debt, and with much higher operating costs than its Pilbara competitors BHP Billiton and Rio Tinto, its profit margins are looking increasingly thin. Without a rebound in iron ore prices the company may be stretched close to breaking point and investors are becoming increasingly wary of pouring money into the miner. FMG’s cost pressures group it with most Pilbara companies outside BHP and Rio, with China’s shaky economic performance putting downward pressure on most of the industry. Nevertheless WA mines minister Norman Moore has voiced confidence in FMG and the rest of the sector returning to strong growth over the coming months. Marking the current weakness in the market a temporary concern, Moore says he expects the iron ore industry to return to the strength it showed several months ago. But just like FMG and the rest of the iron ore industry, Moore and the Government have a direct interest in talking up the mining sector. Finding out whether their rhetoric corresponds with reality is now a matter of time. www.miningaustralia.com.au

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UNRESERVED PUBLIC AUCTION

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AM.OCT12.PG040.pdf

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AUTOMATION & REMOTE CONTROL

Going

TRUCKLESS

With the help of automation expert ABB, Vale is getting rid of trucks on its largest iron ore mine.

hile there’s plenty of talk of automated trucks taking over the future of Australian mines, Brazilian giant Vale is opting for a different approach. With the help of automation expert ABB, Vale is working to make its Carajas Serra Sul S11D iron ore mine automated by replacing trucks with conveyor belts. ABB’s new $140 million contract will see it install shiftable conveyor belts to move ore around the site instead of dump trucks. “This is the first time a ‘truckless’ solution will be used on a large scale at an iron ore mine,” Vale said. Highlighting the environmental benefit of cutting back the use of trucks, Vale said the conveyor system would help cut costs at the mine and reduce its environmental footprint. “If the S11D mine were to be operated A D _ Ausing M R Ctrucks T O CitT would _ 1 2 .need pd around 100 trucks and consume 77

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AustralianMining

per cent more diesel per year,” it said. In a statement ABB process automation leader Veli-Matti Reinikkala said the conveyor project with Vale was “unprecedented” in the industry and would create a new benchmark for sustainability and productivity on mines. “This project will also allow Vale to increase production by approximately 90 million tonnes, while reducing emissions and improving operational efficiency and process duction,” it said, with ABB adding safety,” he said. that “it also enables the automatic Under the plan ABB said it would recovery and piling of iron ore by provide the automation and electrifi- controlling and positioning equipcation to transport ore from the mine ment through satellite signal and via to the processing plant at S11D. GPS, and by using 3D scanning for All plant processes will also be field screening.” automated under the plan. As well as new control systems “The order includes a centralised ABB will also provide Vale with elec800xA control system for processing trical infrastructure for the mine’s operations, so that personnel can be new processing plant. includes medium and f located P a g away e 1 from 1 4the / 0site, 9 / for 1 2 im, 3 : 2The 7 delivery PM proved safety and continued pro- low voltage motors for use with fre-

quency convertors, the primary power transmission stations, duplication of the telecom system for the railroad, and 37 secondary substations in self contained electrical houses. The new developments place Vale at the forefront of automation and research in the iron ore sector. But with rivals Rio Tinto and BHP Billiton making their own headway on this front iron ore automation will be an interesting field to watch over the next 12 months.

www.miningaustralia.com.au

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AUTOMATION & REMOTE CONTROL

Satellite start up Rio Tinto and BHP Billiton are no longer the only automated mining players in the Pilbara.

hile most of the Pilbara’s automation focus centres on BHP Billiton and Rio Tinto, innovation on this front isn’t confined to those mining companies alone. Hancock Prospecting’s Roy Hill has plans to use autonomous trains on its fledgling mine and earlier this year Fortescue Metals Group announced it would be introducing satellite technology to help monitor its train movements in the Pilbara. Working with Norfolk Group and GE Transportation the $56 million contract will help install a new rail-based signaling system on the company’s track between Port Hedland and the Christmas Creek mine. It will include the installation of two control hubs, providing FMG with the ability to track trains and control signaling from headquarters in either Perth or Port Hedland. This ability for remote operations fits into a wider strategy in the region, with all companies looking to move work from the mine or track in question to more central locations. And while FMG is still behind Rio and BHP in developing remote operations this new rail play will fit easily within its future plans. According to Norfolk the new system will be the first of its kind in the Pilbara and use satellites to help track train movements along the A D _ A MF O U O C T _ 1 2 . p d 294km stretch of rail.

www.miningaustralia.com.au

Fortescue is installing satellite train tracking and control for its Pilbara rail ops.

“It will enable greater efficiency Indeed improving rail efficiency and flexibility on the track, signifi- is one of the key concerns for BHP cantly increasing annual tonnage and FMG, with both companies joscapacity,” the company said in a tling to export more tonnes out of statement. the increasingly cramped port. With tonnage allocations at Port Almost all of the work for Hedland getting tighter and tighter, FMG’s system will be completed by and port officials looking at intro- Norfolk and GE, including partial ducing a ‘use it or lose it’ strategy, design, fabrication, construction this increased efficiency will form and testing, and commissioning supa key part of FMG’s production port. In a statement Norfolk said f Pa ge 1 1 4 / 0 9 / 1 2 , 3 : 2 2 PM growth. the Fortescue Metals Group remote

control contract built on its existing relationship with GE, with both companies having worked together on a number of large mining and rail contracts. More than 150 Norfolk staff will work on the project from a range of different divisions, including design, factory, construction, logistics, testing, and administration. The contract marks a well needed win for the Pilbara and FMG, sparking another flurry of work in a region many pundits fear may be winding down. Indeed rumours are rife that many FMG contractors have been laid off over the last few months, with some contractors struggling to find work for staff as the miner shelves expansions. In a statement Norfolk said the contract win positioned it well to secure more work off FMG, including possible extension work on a new rail spur for the Solomon mine. But it will be a waiting game as to whether such work will be forthcoming from FMG, which is struggling to convince the market its finances are still watertight. Work on the satellite system has already begun and is expected to be completed by December this year. And while the might be uncertainty on the horizon regarding future expansions for Pilbara miners, there’s no doubt the focus on new technologies will continue.

AustralianMining

October 2012

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AUTOMATION & REMOTE CONTROL

Monitor in real time New software is helping keep machinery maintenance up to speed.

key pillar in moving toward building au tomated mine sites isn’t just introducing new equipment. Keeping track of this machinery and finding new ways to manage wear and tear is also important. Focusing the bulk of their efforts on this front into a single product, developers at Honeywell have put togeth er their Mobile Equipment Monitor (MEM) software to help monitor the performance of equipment in real time. Honeywell officials told Australian Mining the focus for the software was helping companies get a live insight into the performance of their machinery. They said while there were already a number of products in place to make such mea surements, the retrieval of the data was often too slow to help influence a change in practice. “One of the major dis advantages of mining in the mobile world is getting that data back to a second sys tem for everyone to look at,” they said. “Typically it’s done ad hoc, so if something breaks they’ll get it in and fix it, or if something comes in for maintenance, they’ll do that analysis of what went wrong after the fact. “What we’re doing now is getting that data in real time.” With the MEM Honey well said mining companies were able to gather perform ance statistics on their equip ment as it happened. One of the key benefits of such analysis is having the ability to push back scheduled maintenance if the equipment does not require it. Conversely companies can bring machinery in im mediately if something needs fixing. “When something does go wrong you can pick up on it straight away so you’re 42

October 2012

AustralianMining

The software allows remote operators to get a live insight into the machine’s condition and performance.

not waiting that extended period for it to come in,” Honeywell officials said. The MEM software col lects its data from existing sensors on equipment and uses a wireless connection to send analytics back in real time. Using the data both op erators and other staff at the mine can see at any time whether equipment is doing fine or whether it’s on the verge of failure. “On board a lot of the heavy mining machinery there’s already inbuilt sen sors collecting information, so we’ll be connecting to that and getting it off in real time rather than waiting for it to be downloaded manu ally,” Honeywell said. Being able to make main tenance decisions with more

accuracy means companies can choose the right point to take equipment offline. All of this will mean less maintenance, less equip ment replacement, and less wasted time doing check ups that aren’t needed. “Really where it’s head ing towards is predictive analysis, so you can stop things from breaking down and extend the equipment life,” Honeywell said. “Typically miners will bring equipment in, for ex ample, every 1,000 hours for maintenance regardless of whether it’s broken or not. “We’re looking at really extending that with this soft ware so instead of waiting 1,000 hours you might be able to do 1,500 or 2,000.” Whilst certainly a step in the right direction for

the rock breaking side of mining, Honeywell told Australian Mining many of the principles behind MEM had been in place in mining plants for a long time. “The base software that we’ve built it atop of has been around in the plant for around 20 years now,” they said. “Mining has just started to come up to speed with all of this stuff over the last few years.” And with commodity prices falling and costs, par ticularly for labour, on the rise, Honeywell said the fo cus on cutting maintenance costs was set to continue. “Mining companies have typically just been happy to fix something when it breaks, but now things are getting more costly,” they said.

But outside the business benefits of such software workers and unions have raised protests about real time equipment monitoring. Part of the goal of real time monitoring is that it can identify operator abuse much faster, and while these analyt ics can be useful for helping train new and existing em ployees unions are worried it could also lead to some work ers being singled out. If companies are to in troduce the software work ers need to be made aware that their performance is be ing monitored at all times. And if the software’s in troduction isn’t transparent miners risk sparking what could be another lengthy and costly war with the Con struction, Forestry, Mining, and Energy Union. www.miningaustralia.com.au

AD_AMGRUJUL_12.pdf

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AM.OCT12.PG044.pdf

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AUTOMATION & REMOTE CONTROL

Increasing uptime Remote automated monitoring is cutting maintenace costs.

t costs miners thousand every second a truck is in the workshop instead of working on site. So the ability to check a truck’s operating condition remotely, rather than pulling it off site, can make a huge difference. Volvo Trucks has developed a new GSM-based system that allows the workshop to check a truck’s condition remotely – increasing uptime and cutting maintenance costs. The new remote services are run off the latest version of in-truck Telematics Gateway – TGW, which allows a workshop to monitor the vehicle’s wear and condition and also read trouble codes remotely, using the GSM network. “With these new communication facilities on board the trucks, the workshop receives continuous information about wear in a number of components,” Christian Gustavsson, head of service at Volvo Trucks, explained. The new system allows the workshop’s service technicians to check

Wear and maintenance schedules can be remotely monitored.

how much mileage the truck has covered and how quickly the various components are being worn out. After this, the workshop can plan the servicing according to the individual vehicle’s actual needs. “This will increase uptime and minimise the risk of unplanned stop-

pages by the roadside,” he added. With different drivers and varying conditions vehicles may wear at differing rates than planned, and the service intervals may end up being too frequent or too far apart. When the workshop receives data about the actual wear rate, it can adjust

service intervals to suit the truck’s actual needs. “Many of the parameters are difficult to calculate. A truck driven in tougher than average conditions wears out certain components more quickly, while a truck operating in calmer conditions may still have a lot of wear left in the same components when the scheduled replacement date arrives. This in turn means uncertainty for the workshop,” Gustavsson said. He added that if the truck is used in a way that differs from the use that was planned for in the original service schedule, the workshop receives information about this. “For example, the workshop can be alerted to brake pad wear. As a result the worn parts are replaced in time, they don’t give up when you’re out on a long-distance trip. Gustavsson went on to say “it’s a win-win situation. It’s far more efficient both for the company and the workshop if it’s possible to avoid unplanned workshop visits”.

AustralianMining

October 2012

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25/08/11,

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AM.OCT12.PG046.pdf

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AUTOMATION & REMOTE CONTROL

Automated and accurate Automated systems for payload data collection is ensuring higher mine efficiency.

survey of some of Australia’s most senior mine managers, geologists, planners and engineers has revealed that a number of mines have been collecting payload data manually, either with handwritten logs or information typed into spreadsheets. “As the management style for mines continues to evolve from one of maximising production regardless of cost to one more closely resembling a factory-based ‘just in time’ system, it’s incredible that so many mines are still relying on data that may be incorrect,” Elliot Chisholm, Loadrite’s global product manager, said. The slow uptake of automated measurement and reporting systems is due to lack Over or underfilling trucks can cost thousands in lost output and machinery wear and tear. of awareness of what’s available and concerns about the and then analysing the data der filled which is important The content and the forlongevity of technology solu- through a variety of reports for safety and cost efficiency. mat of the reports can be tions in the physically tough has far reaching benefits. At the next level, informa- customised on the system to mining environment. At the basic level an au- tion sent from each individual best suit the mine’s individu“The value of this infor- tomated system installed in loader to a central software al operations. mation is huge and it’s easy an excavator or wheel loader system can track how much Reports are delivered to a to implement an automated can act as a gauge for the op- material is moving on site, central computer using USB system that completely re- erator, and indicate exactly and monitor the achievement data module, radio modem, moves the need for handwrit- how much material has been of planned throughput. WiFi, or cellular technology. ten logs or manual spread- moved, how much is in the This data can be used in Once loaded it is exportsheets,” Chisholm added. bucket, and how much is in number of ways to ensure ed into various formats enaAccording to Chisholm the truck ahead. that the mine is working as bling the data to be viewed automated measuring of the This will ensure that productively and efficiently as and dissected across various A D _ A MS E I J U N _ 1 2 . p d f a ge 1 8 / 5 / 1 2 , 1 1 : 0 4 AM amount of material moved, trucks are Pnever over or un- possible, Chisholm explained. software platforms.

October 2012

AustralianMining

Another survey by Loadrite found that the majority of mines did their reconciliations monthly, as generating reports from handwritten logs were time consuming. With an automated system these reports can be run daily or even hourly to help prevent losses. This will aid mine managers track the target productivity levels and create more accurate reports. “There is a new wave of thinking regarding mine management and it involves getting as much information as possible in as close to real time as possible. Managers want to know what’s really happening so they can plan workflow more effectively and control costs while increasing production,” Chisholm said. The systems can be used for entry-level through to advanced functionality options depending on the whether the requirement is of basic weighing information for a small loader, or greater accuracy and data capture capabilities for production-sized equipment. “Better efficiency across mines can be achieved with automated payload monitoring and reporting.”

www.miningaustralia.com.au

AD_AMGREOCT_12.pdf

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Whether W hether you are operating a mo m mobile obile g generator, a flee generator fleet of generators, or a complete power station, ComApâ&#x20AC;&#x2122;s new InternetBridge NT allows you to monitor and control them via the internet, using a computer, tablet or any web connected smartphone. There are even applications in the iTunes and Google Play App Stores, which provide increased functionality for users of iOS and Android devices. The unit is compatible with any of the ComAp generator controllers, including the InteliGen and InteliSys ranges. The InternetBridge NT also has inbuilt connections for ethernet, CAN, RS232, USB, has an inbuilt cellular modem (with SIM slot) and has GPS functionality.

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AM.OCT12.PG048.pdf

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Bringing out the benefits A new whitepaper has argued automated rail systems need to be integrated into the wider company structure.

hilst the move towards au tomation forms a key pillar of the future nation’s min ing industry, innovation on this front needs to be supported by develop ment in other parts of the sector. And according to analysts at Ajilon, unless the rest of a mining company is tailored to support auto mation then much of its benefits will be lost. With respect to rail networks in particular Ajilon says automation can’t be considered in isolation. Instead it needs to be thought of in respect to the wider rail system, and it needs to be integrated into lo gistics and scheduling. “In order to achieve these benefits, the automation must be effectively integrated into logistics scheduling,” Ajilon said in a recent whitepaper. “This requires subsequent auto mation projects to enhance the infor mation systems that can now support new behaviours.” In other words, as mining compa nies introduce automated equipment other parts of the business will have to change. “Organisation boundaries may need to change to accommodate these new behavoiurs,” Ajilon added. “It should be expected that this will be an ongoing process, but that each project will deliver a step change to the business if a holistic approach is employed.”

New measures

According to Ajilon new metrics are needed to measure the performance of automated rail projects. “Automation is the first step to support new ways of operating, and should not be considered as a means to make old ways more efficient,” the company said. And as workers are no longer driv ing the trains, Ajilon said new KPIs should be developed to help measure performance. In addition to this the company said as automated rail systems become larger, more information will need to be fed into scheduling systems. This information will need to be “more ac curate,” according to analysts, and will 48

October 2012

AustralianMining

need to come from both port and mine operations. “The dependency of this new in formation will drive further automa tion projects, as these boundaries are where the most benefit for driverless trains can be obtained,” Ajilon said.

The benefits

Ajilon said introducing automated rail systems would quickly bring a number of obvious benefits to mining companies. Many of the opportunities revolved around flexibility of labour. With automated trains Ajilon said companies were able to hold back or green light trains without concern over how these decisions impacted employee shifts. It also said with computers con trolling the equipment the departure and arrival of trains would be more reliable, which would improve sched uling right down the supply chain. This benefit was underlined by Ajilon analysts, as it represented a key example of automation running right through a company instead of in isola tion. “Automation can be incorporat ed into a larger system to leverage ad ditional business change,” they said. “For example, the removal of one of the constraints to train running provides additional flexibility to the associated logistics scheduling pro cesses.”

Staying on track

Track maintenance is one part of the business that’s also expected to bene fit from this accuracy, with crews better able to work around departure and arrival times. Ajilon said there were also bene fits in having train schedules run over the top of employee shift changes. The company said complexities around maintaining driver qualifica tions were also reduced when com puters were in charge of the system. From all the benefits, the work arounds with respect to the availabil ity of workers were often highlighted as the big benefit. Such analysis puts Ajilon at odds with the rhetoric of many specialists www.miningaustralia.com.au

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AUTOMATION & REMOTE CONTROL

and mining companies, which argue the move toward automation does not revolve around workforce concerns.

To each their own

While the above benefits and initiatives are relevant to the broader industry, Ajilon said it was important to note there was no â&#x20AC;&#x2DC;one size fits allâ&#x20AC;&#x2122; approach to rail automation. Targeting operations in the Pilbara in particular, where most of the headway on automated rail is taking place, the company said that each project had its own goals that needed solving. Rio Tinto has already seen a massive backlash from its plans to automate its iron ore rail networks, with unions stating that it will see job cuts across the board for drivers. And as each company is at different stages in development Ajilon said development needed to be considered and level pegged. â&#x20AC;&#x153;Each company is coming from a different starting place and needs to consider which automation choices will drive efficient rail operations and increase throughput,â&#x20AC;? it said. Nevertheless rail automation represents an exciting new development the Pilbara, A Din _ A MS O U A Uand G _ itâ&#x20AC;&#x2122;s 1 2 likely . pdf Pa ge 1 1 1 / 0 7 / 1 2 , 1 1 : 1 2 AM Many operators, such as Rio Tinto, have to weigh up the benefits of automation against the eventual backlash. weâ&#x20AC;&#x2122;ll hear more of it in the future.

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October 2012

AustralianMining

Taking the COAL out of dirt A new processing method is recovering more product by using dirt to wash coal.

he drop in the commodity prices has hurt all Australian miners. It has forced coal giants such as Rio Tinto, Xstrata, and the BHP Billiton Mitsubishi Alliance to lay off workers and cut costs just to stay afloat. With so many coal miners barely making margins as the commodity price drops, many are trying to get all they can out of their coal. Some are turning to their tailings, to try and recover the remainder of their processed coal. Others are turning to ways to process coal that was previously too difficult, and simply left behind so that the more high grade and easier to access coal could be mined instead. One U.K. company, RecyCoal, is helping Australian min-

ers to access, and process this coal. Tom Allchurch, RecyCoal’s CEO, told Australian Mining “we’re different from other recovery processes as we use dense medium technology. “While most processing takes the dirt out of the coal, our technology takes the coal out of the dirt.” Allchurch went on to say it also differs as “we don’t use water and magnetite in washing, instead we use fine dirt as the washing medium”. He went on to say that it uses slimes to wash the coal. RecyCoal “increases the gravity of the cycle through pressure rather than just the medium. “This has made it very good at handling very dirty stuff, with dirt and shale,” Allchurch told Australian Mining.

According to the company its patented system is able to produce export quality coal from coal seam cleanings, clay contaminated, banded and heat affected coal in a magnetite free washing process and uses plate and frame filter presses to eliminate tailings dams. “Where this can really added value is for dirty or clay bound coals, such as those found in the Surat Basin.” However Allchurch added that “while many mining companies process tailings as well, we just go after the coarser coal from 250 microns upwards. “We’re not going after tailings, we’re helping miners to access and process their coarser materials.” The company is currently working towards bringing the technology to Australia. www.miningaustralia.com.au

AD_AMFLSOCT_12.pdf

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Maximise your flotation performance As the recognised industry leader for flotation cell technology since 1951, FLSmidth has installed and supported over 52,000 flotation cells in mine sites around the globe. We deliver the world’s most efficient designs by offering both WEMCO® naturally aspirated and Dorr-Oliver® forced-air mechanisms which can be utilised together in a Mixed Circuit™ or Mixed Row™ to give you greater control over coarse and fine particle recovery. When searching for a large cell capacity to reduce footprint and operating costs, look no further than FLSmidth. We have successfully installed over 100 of our 250m3 cells and have sold more than 50 of our 300m3 SuperCell™ flotation cells. FLSmidth continues to lead the way with our new 600m3 SuperCell™ flotation machine, the largest in the world. FLSmidth is a full solution provider offering metallurgical, ore characterization, analytical and separation testing with and process optimisation to maximise your performance. Our process experts have the right solution for your application. For more information, visit us at www.flsmidth.com

AM.OCT12.PG052.pdf

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MINERALS PROCESSING

Super sized flotation As the mining boom grows, so too does cell size.

ow grade and complex miner alogy ores, the need to improve the recovery of fine and coarse particles and lowering energy, capi tal and operating costs are just some of the challenges faced by mineral processing operations today. However improvements in flota tion cell and circuit design, operation and optimisation – among other ad vances – have allowed mining com panies to meet these challenges. Among the main advances, the development of large flotation cells handling high tonnage, high pulp den sities and coarse grinding to increase efficiencies is particularly interesting. The minerals industry has realised the economic benefits of large flota tion tank cells with volumes greater than 250 cubic metres to lower capi tal, operating and maintenance costs – fewer cells, better control, smaller footprint and lower installed power and consumption. Complex mineralogy ore bodies, lower cutoff grades and stripping ratios, and high tonnage plants with larger grinding mills are driving this push towards large capacity flotation machines. In addition, economies of scale, de clining ore grades and nearterm com modity pricing stability bode well for the integration of “super cells” into large concentrators. In fact, single flotation cell vol

October 2012

AustralianMining

ume has more than doubled over the past decade. A recent new development is the launch of FLSmidth’s SuperCell 600 series with active cell volumes from 600 cubic metres to 660 cubic metres with a multitude of mechanism offerings. A feature of the SuperCell 600 se ries is the ability to interchange natur ally aspirated or forced air mechan isms: Wemco, DorrOliver and Xcell; the first one is selfaspirated; the latter two are forced air machines. Opera tion of the series does not differ from other cylindrical cells in the SuperCell range. The SuperCell 600 series is twice the size of existing equipment permit ting an easy reconfiguration of flow sheets currently in design. Its capacity can match the throughput of the larg est SAG mills in a single train, thus minimising installation, operation and maintenance cost. The SuperCell 600 series has been designed using leading technologies including inhouse developed compu tational fluid dynamics (CFD) with first principle flotation models. And, it is expected that the SuperCell 600 series will be used mainly for rough erscavenger duty in gold, copper and molybdenum flotation circuits in very large throughput plants. Hydrodynamic and metallurgical testing of the SuperCell 600 series is slated for the first quarter of 2013. www.miningaustralia.com.au

AD_AMJAWAUG_12.pdf

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AM.OCT12.PG054.pdf

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MINERALS PROCESSING

Down to the grain A collaboration between BASF and the CSIRO is working towards greater coal recoveries.

espite best efforts, there is always a de gree of coal lost dur ing its processing. These particles may be lost as dust, during transfer, or even afterwards in tailings. While it may not seem like a major loss if a few stray particles are gone here and there, over the space of a month, or even a day, it can result in much lower product levels. Over the space of a mine’s life this can poten tially result in huge tonnage levels that are simply lost. And with the current prices of coal at their low est all year, dropping from $115 per tonne in February down to $87 per tonne in July, coal is only a few dol lars off the massive slump of the global financial crisis, Fine coal lost during processing can build up in to serious levels over time, hurting mines’ output. which saw coal at $83 per tonne. duction more efficient and Initially the CSIRO’s slurry actually boosted yields Now the CSIRO and potentially increasing reve Coal Grain Analysis tool “and has the potential to sig BASF have collaborated to nues for coal producers”. identified that particles from nificantly increase the avail gether to improve coal recov The “new coal particles certain coal types were dif ability of saleable coal”. ery and reduce lost product recovery process offers sig ficult to recover from flota Neil Fitzmaurice, the head rates. nificant improvement in the tion methods. of BASF’s Industry Group According to BASF the recovery of difficult to float After this it began a col Mining Asia Pacific explained two groups have created a coal”. laboration with BASF, which that “high quality coking coal process that improves the Froth floatation is a well had created block copoly is a key ingredient for steel “recovery of coal particles recognised process for recov mers, and found that intro production and critical for the that are otherwise lost to ering fine coal, as coal itself ducing these copolymers as development of the emerging A D _ A MK E R O C T _ 1 2 . p d f a ge 1 6 / 0 9 / 1 2 , 1 : 1 1 PM tailings, making coal pro is naturallyPhydrophobic. promoters to the fine coal economies of Asia.

“This new coal particle recovery process offers a significant improvement in the recovery of coal, maxi mising yield and lowering production costs.” CSIRO research manager for coal preparation, Bruce Firth, added there are sig nificant variations in different types of coal, adding that “we can determine the flotation response of specific coal types by the Coal Grain Analysis method, the introduction of BASF’s chemical reagent into the process increases the at tachment of particularly coal particles to flotation bubbles”. According to the CSIRO’s laboratory studies and plant scale tests, the addition of block copolymers improves recovery for both fine and coarse coal particles. The new process requires only minor modifications to existing industry methods, BASF adding that it is cur rently in the process of com mercialising the flotation promotion agent. The research was sup ported by the Australian Coal Industry’s Research Program, and was presented to the Aus tralia Coal Preparation Socie ty Conference and Exhibition in September.

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AD_AMMETJUN_12.pdf

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AM.OCT12.PG056.pdf

Page

21/09/12,

12:12

MINERALS PROCESSING

What’s driving milling? ABB’s Tatiana Ravani von Ow, Anu Tuomaala and Jouko Virta discuss developments in mill motors.

he choice of drive type for ring-geared mills has been influenced by major trends in the operating environment. These trends include increasing mill sizes, requiring drives that can supply higher power while avoiding stress to the network and mechanical equipment; rising energy costs, focusing attention on the need for energy savings; and greater awareness of the opportunities for process optimisation, which has highlighted the advantages of variable speed operation. Taken together, these factors have boosted demand for low speed drives using synchronous motors and frequency converters.

Compact, lower-cost synchronous motors

To meet the high torque requirements of today’s large ring-geared mills, low speed drives generally use synchronous motors. The motors are usually rated in the range 3.5-9 MW and operate at a nominal speed of approx. 200 rpm. Compared to the The constant demand for more milling is putting a greater demand on motors. large 30-40 pole synchronous motors typically used in fixed speed drives, of variable over fixed speed drives, and keeps the requirement for AC/AC synchronous motors for variable because eliminating the clutch from excitation power low. The brushless speed operation have only 8-12 poles the system reduces maintenance exciter is a separate rotary transformand are less expensive, more compact needs. Variable speed operation also er mounted on the motor shaft, and and lower in weight. They are there- provides smooth starting, avoiding the motor supply, excitation control fore easier to transport to remote the stresses imposed on the mill ma- and protection are all provided by locations, have a smaller footprint chinery and electrical network when the frequency converter. This compares favorably with the wound rotor within the mill and can use lighter a fixed speed system starts up. motors sometimes used in high fixed foundations than fixed speed motors. speed solutions: these more complex As a result, installation of variable Brushless motors mean less maintenance motors need frequent maintenance speed motors tends to be easier. Low speed synchronous motors As the grinding process is not highly due to wearing of the brushes and with frequency converter control can dynamic, low speed synchronous mo- carbon dust build-up. Other disadgenerate sufficient torque to start a tors in mill drives can use brushless vantages of wound rotor motors are AD _ PAC E S I Cneeding A U G _an 1 2 df P a gThis e 1eliminates 1 6 / 0wearing 7 / 1 2 , that 8 they : 4 3put A M significant stress on the mill turning without air. p excitation. clutch. This is a major advantage parts, helping to reduce maintenance, network and mechanical components

Turning heads: the PBS pressure Switch from SICK 56P00000880_PBS_Ad.indd October 2012 AustralianMining 1

during start up, and that gear reducers are needed. As low speed synchronous motors generate high torque at low speeds, they need efficient cooling. A TEWAC (Totally Enclosed Water to Air Cooled) enclosure is the optimal solution in dusty environments, however air cooled motors are also an option. Low speeds mean that the motors can use self-lubricated sleeve bearings with hydraulic jacking pumps. As a result they can be operated at around Continued on page 58

Universal - versatile - better - the only option! The PBS is an electronic pressure switch, pressure transmitter and display in one. With up to three output signals, a multitude of process connections, double rotatability of the housing and complete pressure measuring ranges for gauge pressure, absolute pressure and vacuum ranges, it is the optimum solution for all machine construction and engineering requirements. • Now available with flush mount membrane • The one unit for so many applications & environmental conditions For more information please visit www.sick.com.au or call 1800 334 802 (Tollfree). 10/07/2012 1:46:18 PM www.miningaustralia.com.au

AD_AMMINOCT_12.pdf

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7/09/12,

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AM.OCT12.PG058.pdf

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MINERALS PROCESSING

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5-10 per cent of nominal speed during starting and servicing. The bearings are either flange mounted on the end shields of the motor or, for higher power ratings, pedestal mounted. Motors with ‘integrated pedestal bearings’ are as easy to mount and align as those with flange mounted bearings, as they are delivered completely assembled and so no on site assembly is needed. Low speed operation also avoids the mechanical problems that affect high speed mill drives. The weakest point in high speed drive solutions tends to be the gear reducer which couples the motor to the pinion. This additional component increases the amount of equipment and the required maintenance, and it also decreases the reliability and efficiency of the complete mill.

Tailored requirements

In many cases low speed synchronous motors can be tailored to suit the application or customer specifications. For dual pinion mills, for example, customers often specify that the terminal boxes and cooling systems should be located centrally so that the cables and cooling water supply, if used, can be brought to a single point. Motors for dual pinion mills can be designed to reduce the need for spares. By building the motors so that cooling units can be turned and the terminal boxes swapped from one side to the other, a single spare motor can be used to replace either the left or right motor in a dual pinion system.

Frequency converter solutions

The industry has been quick to adopt frequency converter solutions using low speed synchronous motors because they permit soft starting and controlled stops, while at the same

time enabling the grinding process to be optimised. The operator can easily react to changes in ore characteristics and throughput, which is ideal for ores with varying grinding properties, and mills are able to achieve higher throughput for the same energy input. Process optimization can also reduce variability in the output particle size and decrease utilization and wear of grinding media. Frequency converters with direct torque control (DTC) deliver precise and effective speed and torque control during start up and when the material is cascading. DTC can reduce wear and tear to extend gear life by up to 30%, helping to ensure high availability and minimize backlash. The ring-geared mill drive solutions developed by the ABB minerals unit, for example, have a dedicated integrated mill controller, permitting smooth starts and controlled stops, reducing stress on the equipment and providing critical monitoring during the starting period to protect against frozen charges. In dual pinion systems, torque and load sharing between motors is very accurate, improving the lifetime of the pinions. The mill drive controller also provides service operating modes such as creeping and positioning, so the drives do not need additional equipment for maintenance purposes. Creep mode can be used to slowly rotate the mill for visual inspections or grinding out. Fast and automatic positioning of the mill based on angle or liner reference reduces the downtime needed for changing liners. These factors have encouraged many mill operators to upgrade from fixed to variable speed operation based on low speed synchronous motors and frequency converters. Many SAG mills already use variable speed drives, and variable speed is increasingly the preferred option for ball mills, too. www.miningaustralia.com.au

AD_AMOUTOCT_12.pdf

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AM.OCT12.PG060.pdf

Page

13/09/12,

7:52

MINERALS PROCESSING

Compressor control Selecting the right control system is crucial in processing, Amin Almasi* writes.

he importance of correct selection of turbo-compressor system control elements (such as the anti-surge valve selection, valve opening and closing times and others) should always be emphasised. The dynamic simulation should be employed as a tool to achieve the optimum sizing and selection for control components and parameters in each stage of the project. In other words, dynamic simulations should be performed at different stages from basic design, to detailed design, final verification, and during operation. Usually in early stages of a project, some assumptions should be made for the first dynamic simulation. While these assumptions should be on a correct basis, they may not be the best options for the final turbo-compressor arrangement. The design should not be limited to those initial assumptions.

In this way, the simulated control systems do not represent the functionality of actual field controllers, which could have a server effect on the results of the dynamic simulation. A recommended solution for inaccuracy of simulated controllers could be using a â&#x20AC;&#x153;direct control-hardware linked simulationâ&#x20AC;? approach instead of conventional software emulation. This method can guarantee the simulation accuracy and the functionality of field-installed controllers. During the dynamic study, an integrated software-hardware solution should be developed by linking a rigorous plant dynamic model to a vendor supplied controller emulator (based on the actual vendor controller). The requirement should be discussed with the compressor vendor (or the supplier of the anti-surge system) in the bidding stage, before the order placement. Once a dynamic model is developed, it should be validated against the design and the actual operating data to ensure the accuracy of the modelling.

Control element selection

The origin of many parameters particularly control valve or on/off valve opening/closing times are initial assumptions made in an early stage of design to let the first dynamic simulation completed for finalization of some critical issues such as the antisurge valve sizing, the hot-gas-bypass requirements, the basic anti-surge arrangements or similar. In a case study for a centrifugal compressor, for the dynamic simulation at the basic design stage, an assumption was made to use 0.8 second per inch of valve sizes for opening and closing time for all suction/discharge valves (since valve data were not available that time, at early stage of the project). This assumption could reflect the maximum actuation time that may be expected for some large on/off valves (ordinary on/off actuated valves can achieve around 0.5-0.8 second per inch). These assumptions were used for the basic design dynamic simulation which resulted in the anti-surge arrangement freeze, anti-surge valve sizes and antisurge valve opening/closing time (in this case 2 second opening time and 4 second closing time). However, the engineering contractor used basic design dynamic simulation assumptions as a basis for specifying all actuated valves in the suction and discharge. In this way, the engineering contractor specified 0.75-0.85 second per inch for all 60

October 2012

AustralianMining

Valve selection

Having the right levels of consistent power is important in keeping plants running.

main suction/discharge valves opening/closing time, considering if initial assumptions of the first dynamic simulation kept within certain limits, the first dynamic simulation could remain valid and there is no need for other dynamic simulations. It is a poor design decision. These specified values (0.75-0.85 second per inch for opening/closing time) may not be wrong based on the initially assumed timing value (0.8 second per inch), but there could be some difficulties to supply or verify actuated valves with such tight actuation timing and also the final result could be a suboptimum arrangement. Optimum valve characteristics should be obtained based on a new dynamic simulation. In this case, the second dynamic simulation is per-

formed (considering the anti-surge arrangement, anti-surge valve sizing and anti-surge valve opening/closing time as final) and optimum reaction times are obtained as 0.71 and 0.64 second opening/closing time per inch for the suction valve and the discharge valve, respectively. To accurately and reliably predict the dynamic behaviour of turbocompressor systems, the dynamic model has to be supplemented with accurate input data based on as-built equipment performance. For example, volume of various vessels and piping systems should be accurately modelled based on fabricated (or isolated) pieces of equipment. The controllers used in the dynamic simulation models are often simplified based on basic control strategies.

Anti-surge valve requirements depend to a large degree on the turbo-compressor details, and the turbo-compressor system arrangement. The different aspects of the anti-surge valve sizing and selection are described. The larger the anti-surge valve, the more flow that can be moved from the discharge side of the turbo-compressor to the suction side. The speed of valve opening is also important for a turbo-compressor anti-surge application. Generally, the larger the valve, the slower its opening time. Also, the larger the valve, the poorer its controllability at a partial recycle. The situation could be improved by using a large valve that is boosted to open, thus combining a high opening speed with a high-flow capability. An optimum anti-surge valve should be selected for any turbo-compressor. In a case study for a turbo-compressor, two anti-surge valves with the same opening time (around 1 second) were evaluated. The small anti-surge valve resulted in the shutdown surge at a moderately high pressure. The large anti-surge valve Continued on page 62 www.miningaustralia.com.au

AD_AMANDMAY_12.pdf

Page

12/04/12,

4:23:13

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AM.OCT12.PG062.pdf

Page

21/09/12,

12:05

MINERALS PROCESSING

Continued from page 60

(with around two times the Cv compared to the small one) resulted in a major reduction in the head. The shutdown surge occurred at a pressure just above the suction pressure. Most information required for the sizing of the anti-surge valve is available on the turbo-compressor map. Commonly used margins are that the anti-surge valve should be capable of passing 100% of the surge flow-rate at around 50% of the valve opening. In other words, the anti-surge valve Cv is selected from approximate range of two times of the required Cv based on the surge flow on the curve of the highest turbo-compressor speed (on the turbo-compressor map). The other requirements of antisurge control valves are: 1 â&#x20AC;&#x201C; Reduction of the stroke time. 2 â&#x20AC;&#x201C; A stable response. 3 â&#x20AC;&#x201C; Minimized overshooting during valve adjustment steps. Too fast a response could result in an excessive overshoot and a poor accuracy. However, too slow a response may result in sluggish opening of the anti-surge valve. Correct size and configuration of the required instrumentations A Dactuators, _ A MK E S OCT _ 1 2 . p and accessories could guarantee an

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October 2012

AustralianMining

anticipated noise level (before an external should never 1 0 : 5 3attenuation) AM exceed 100-110 dBA with fluid velocities below 0.3 Mach. The inline and symmetrical flow path eliminates indirect flows and unnecessary changes in flow directions through an anti-surge valve. An axial-flow anti-surge valve is a wellknown option. The â&#x20AC;&#x153;breaker vanesâ&#x20AC;? are often used in the downstream section of the valve body, which cut and streamline any flow turbulence (significant reductions in the noise, the turbulence, and the vibration). High range-ability (the ratio between the rated Cv with completely open valve and the minimum Cv that the valve can control) is required (typical range-ability â&#x20AC;&#x153;150:1â&#x20AC;?), which means a successful control even with a high Î&#x201D;P and a low flow. To increase the range-ability, special trims should be used. In order to obtain service reliability, following considerations should be respected: 1 â&#x20AC;&#x201C; Anti-surge valves usually fitted with pressure balanced pistons (the thrust should be independent of differential pressure across the valve). 2 â&#x20AC;&#x201C; Bushings are anti-seize and selflubricated. 3 â&#x20AC;&#x201C; Proper packings should be used. 4 â&#x20AC;&#x201C; The trim materials are carefully chosen. The material should be corrosion-proofing and erosion-

proofing. Proper stainless steel alloys for usual services, or sintered tungsten carbides for special cases are typically specified. Rapid changes in the differential pressure across the anti-surge valve should have no effect on the stability of the valve position. In modern designs, the sealing is achieved usually by the position (and not by the torque). Leakages across the anti-surge valve will influence the efficiency of any turbo-compressor system. In a case study for a medium size high pressure centrifugal compressor, with an 8â&#x20AC;? class 900# anti-surge valve and 70 bar differential pressure, the valve leaked approximately 150 NmÂł/h of the process gas. A typical â&#x20AC;&#x153;one anti-surge valve, one turbo-compressor casingâ&#x20AC;? arrangement is always recommended. More complex systems of cascaded valves or valves around multiple compressors require a more detailed analysis and sophisticated provisions. Generally two types of antisurge valves are used: â&#x20AC;˘ Globe valve. â&#x20AC;˘ Noise-attenuating ball valve. The globe valveâ&#x20AC;&#x2122;s capacity (Cv) approximately varies with the square of the percentage travel. The noiseattenuating ball valveâ&#x20AC;&#x2122;s capacity (Cv) varies roughly with the cube of the percentage travel: â&#x20AC;˘ Cv~(travel)2 for a globe valve â&#x20AC;˘ Cv~(travel)3 for a ball valve The noise-attenuating ball valve will have more capacity to depressurize the discharge volume compared to the globe valve with the same size. In a case study for a 6â&#x20AC;? (150 mm) size anti-surge valve, the Cv of a selected ball valve was more than 2.5 times of the Cv of selected globe valve (the same size). At 2/3 of valve travel, the selected ball valve flow was more than 50% higher than the same size globe valve flow. This additional flow capacity sometimes makes the noise-attenuating ball valve theoretically a better choice in an anti-surge installation (it is only a theoretical and textbook priority). On the other hand, the globe valve behaviour is more predictable and more control-able (less nonlinear). A ball valve usually offers a highly-nonlinear behaviour (Cv~(travel)3). Both globe valve and ball valve are used in modern antisurge systems. Practically the globe valve is more common in turbo-compressor anti-surge systems. *Amin Almasi is an engineer at WorleyParsons. www.miningaustralia.com.au

AD_AMMATOCT_12.pdf Page 1 AM1210MH:Layout 1 4/9/12 4:18 PM Page 1

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AM.OCT12.PG064.pdf

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18/09/12,

2:59

SOFTWARE & HARDWARE

INCREASING mining’s ICT

With profits more stretched than ever, mining companies are turning toward information communication technology to stay profitable.

ith commodity prices falling and costs rising mining companies are increasingly looking toward research and development to keep their heads above water. And while mining R&D covers a wide range of topics its future will be well and truly focused on information technology. BHP Billiton confirmed as much earlier this year when it said it would look toward “new technologies” to revive its plans for the mothballed Olympic Dam expansion. Mining’s focus on IT was again in the spotlight recently with research house IDC releasing a paper predicting a sharp rise in the industry’s spending on this front. IDC said mining’s spending on the IT and communications market was expected to beat some industries that had traditionally made a name for themselves in the area. In a statement released with its paper IDC said the mining boom “may have reached its peak” and companies would now turn toward finding new techniques 64

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to squeeze extra profits out of their projects. “The sector will be increasingly challenged by the requirement to manage costs within a global environment of moderating growth, and within a local context of high labour and energy costs in Australia,” it said. High labour costs are of particular concern to companies, with many peak bodies, including the Minerals Council, recently warning that if wage pressure continued it would make some new projects unviable. Some pundits have even estimated that it costs resources companies almost $1 million a year to hire drivers to operate a single truck on a continuous basis. But software advances are already well down the road of helping solve this problem, with a spate of mining companies, particularly in the Pilbara, pushing for the introduction of autonomous equipment on site. Just this year Rio Tinto announced it would spend $483 million installing 41 autonomous trains for its iron

ore mines, and Fortescue Metals Group has already made moves to introduce satellite tracking for its rail network. BHP Billiton has gone full steam ahead with remote operations on its Pilbara mines, with a heap of new software helping it control and monitor from afar. While BHP has so far not looked toward autonomous trains it already owns locomotives that are “autonomous capable,” which leaves it open to pursuing this strategy in the future. Mining companies themselves aren’t the only ones who are looking toward expanding on information communication technology (ICT). Equipment manufacturers and service companies are also turning toward the field to stay up with the demands of resources companies. On this front the trend is all about giving companies the choice to move into automation. Like BHP’s “autonomous capable” locomotives, most manufacturers are looking at designing and building equipment that can be used by an

operator but also has the ability to be controlled by software with only minimal upgrades. Vermeer’s T1500 surface miners are a good example of such equipment, with FMG recently snapping up a handful of the machines. But while the focus is most often on driverless trains and trucks a whole range of equipment is being eyed for an upgrade. Autonomous drills are already in use in the Pilbara and the CSIRO and mining companies have completed significant research on autonomous blasting, excavation, and rock breaking. Moving operations onto the internet, or into the ‘cloud,’ is also a big focus for resources companies and contractors. By cutting down on physical equipment and making data and operations more mobile, it’s hoped these advances will mean more improvements for mining companies. With all of these new fronts open in ICT it’s little wonder the mining industry has been earmarked as a major spender for the future. But according to IDC the sec-

tor has not traditionally been a “big spender” in IT, and its outlays were only expected to be higher than the market average over the coming years. The resources industry accounted for six per cent, or $2.51 billion, of ICT spending in 2011, and ICD said this figure was expected to grow by 3.8 per cent to 2015. The market average for ICT spending is 2.7 per cent. “As the sector starts to experience moderate growth, it is very heavily focused on improving operational efficiency and improving productivity to drive up margins,” IDC said. But while companies will no doubt be looking toward the ICT sector to support their growth many local software providers are still finding difficulty attracting funding and interest. With a relatively low pool of ICT talent in Australia many companies and entrepreneurs are heading overseas to find backers. Whether this trend will decline as we head toward 2015 is unknown, but all indicators point toward a bright future for software and communications in mining. www.miningaustralia.com.au

AD_AMDAVMAR_12.pdf

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Davey Bickford Australia Pty Ltd PO Box 298, Osborne Park, WA 6917 T 08 9207 1066 E admin@daveybickford.com.au www.daveybickford.com.au

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AM.OCT12.PG066.pdf

Page

21/09/12,

3:44

SOFTWARE & HARDWARE

Stability simulations New simulation programs are helping miners to gain stability in the fluctuating coal market.

he instability of the coal industry along with the constant search for alternative energy resources, has led many Australian coal miners to invest heavily in R&D to discover the optimal coal-to-liquid process (CTL). With CTL plants costing billions to establish it is critical to ensure the project is viable before proceeding. Sophisticated software simulation and process analysis tools have aided the reduction of costs during the feasibility phase and bring alternative, green energy to the market sooner.

Motivations for CTL

fication designs is the Integrated Gasification Combined-Cycle (IGCC) plant. But since the plants represent investments of hundreds of millions of dollars it is essential to use the most advanced technology to identify the optimal process configurations. This will not only help to design equipment that will run reliably and safely, but also develops accurate cost estimates to ensure that the right decisions are made early in the design lifecycle.

The simulation solution Simulation software can aid miners in making the shift to coal to liquids processing.

The volatility of coal prices and the unpredictability of energy production need to The coal-to-liquid proccoal demand are among the make decisions on the most ess, in most instances, means reasons many Australian coal suitable liquefaction process, that existing coal mines can miners are exploring new and estimate the associated costs convert coal into synthetic complementary coal mining and predict the return-on-in- crude oil for further refining processes. A D _ ACoal M G Ominers L O C in, T _or1 2 vestment . p d f for P athe g stakeholders e 1 2 1 / 0into 9 / diesel 1 2 , and 1 2other : 1 0fuels, PM considering, coal-to-liquid during the current flux. adding revenue and eco-

nomic sustainability to the miner. What is most crucial to the efficiency to all CTL processes and their variations is the gasification phase. One of the most common gasi-

Decision makers need to consider the challenges of simulating IGCC and other large-scale integrated processes. According to Steven Kratsis, director of area sales for AspenTech Australia â&#x20AC;&#x153;recent advances in engineering software and the re-

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AM.OCT12.PG067.pdf

Page

21/09/12,

12:29

SOFTWARE & HARDWARE

lentless progress of Moore’s law have made it possible to simulate large scale processes such as IGCC plants at increasingly higher levels of fidelity”. Simulators such as Aspen Plus allow users to break the process down into hierarchical sections ensuring each hierarchy captures an area in the plant, such as an air separation unit or the power island. The hierarchical sections are connected by the ‘boundary streams’, representing the material, heat, electricity, or shaft work flowing from one section of As the coal price suffers globally, many miners are turning to new ways to harness their coal. the plant to another. Hierarchical models can into an existing simulation ments. As a result, the CFD from the high-order models. also be used as contain- case. models have been used pri- The models are fitted to comers for complex equipment marily in isolation to design plex equations which capture models. Gasifier models may Advances in design key equipment. the essence of the equipment be assembled from combina- The gasifier is the core of the Recent work led by the De- behaviour. The ROMs are tions of ideal reactor blocks, IGCC plant. It is essential to partment of Energy National much less computationally infurnace models, mixers, and design the gasifier properly to Engineering Technology Labs tensive than the original highsplitters. Building these re- ensure high energy efficiency (DOE/NETL) show great order models and can work actor models in a hierarchy and good process economics. promise for improvement. inside simulators to help precontainer allows the model Engineers can apply com- A number of organisations dict the global optimum operdeveloper to package the putational fluid dynamics working together under the ating conditions. entire structure as a reusable (CFD) tools which optimise NETL-sponsored Advanced Since all mines have diftemplate. The resulting tem- equipment design to identify Power and Energy Co-Simu- ferent grades of coal across plates can be inserted into a and eliminate dead zones, hot lation (APECS) project are de- their landscape the first step process model just like any spots, and other potential op- veloping methods to convert is to select the location of the rigorous models (including optimum coal source. Using of the built-in unit operation erability problems. These types of CFD mod- CFD models) to reduce order Aspen Plus, miners can enmodels. Hierarchies improve the els can also be used to charac- models (ROMs), which in ter the properties (moisture, usability of these complex terise equipment performance turn can be used as integrated carbon content etc) of a coal simulations by organsing the over a range of operating con- plant process simulation mod- sample and then model the models into a sensible struc- ditions improving predictions els. Advanced mathematical gasification process to deture. In addition, hierarchies of efficiency and performance modelling techniques such as termine both the gas output neural networks and principle and the yield. This process make the models easier to under various scenarios. Although CFD models component analysis (PCA) are is repeated until the best site maintain since entire sections of a process can be updated are very powerful they have used to perform data regres- is identified. The next step is D _ A M MaI single N O Cobject T _ 1 2 high . p dcomputational f P a g e require1 6 / 0 9 / 1against 2 , simulation 4 : 5 9 results PM sion by Aimporting design.

www.miningaustralia.com.au

Detailed first-principle gasifier models have been developed using equation-oriented modelling tools such as Aspen Custom Modeller (ACM). These models, which capture rate-limited reactions, massand heat-transfer, can be used to optimise the steady-state operating conditions and the equipment designs. Such models can also be used to study process dynamics, to test control schemes, and to identify the best startup and shutdown procedures for these plants. These custom models can be plugged directly into the steady-state simulation environments (such as Aspen Plus) to examine the process as a whole. Process simulation models can be used to predict the mass and energy balances and key equipment sizes for IGCC plants. These results can be used together with rigorous cost modelling software, such as Aspen Icarus Process Evaluator (IPE) and Aspen Process Economic Analyser (APEA), to carry out detailed economic evaluations of various process configurations and scenarios. Rigorous cost modelling provides the accuracy needed to make the right investment decisions and to reduce the risks of cost overruns. Further, these tools allow estimators to carry out detailed economic analysis of various scenarios such as future escalation in coal production costs, and fuel price changes.

AustralianMining

October 2012

AD_PACEEMEAPR_12.pdf

Page 1

14/03/12,

9:34

Escaping steam means lost energy and lost profits. If only I could monitor my steam traps without running all over the plant.

YOU CAN DO THAT Capture elusive energy savings with real-time automated steam trap monitoring. Knowing the status of every steam trap could enable you to save up to 20% of steam loss and $4 million dollars a year in lost energy. With the Rosemount 708 Wireless Acoustic Transmitter, you’ll have instant visibility to all your critical steam traps through a non-intrusive, WirelessHART® monitoring system. Backed by Emerson’s proven experience in Smart Wireless field instrumentation, the Rosemount 708 will enable you to effectively and easily capture significant energy cost savings without running all over the plant. Talk to Emerson. We’re the experts in wireless so you don’t have to be.

AM.OCT12.PG069.pdf

Page

25/09/12,

8:48

SOFTWARE & HARDWARE

Now for the NBN While the industry remains cautious, more industry leaders are starting to see the allure of the National Broadband Network.

hile software and communication companies are focused on driving their own solutions for the mining industry, a single piece of infrastructure underlines most innovation in the sector. Whether developers are for or against it, there’s no doubt the Federal Government’s National Broadband Network will be a big part of the future industry. On the whole most people in the technology sector support the NBN, but so far the mining industry has kept its distance. Part of the industry’s agnosticism can be attributed to the lack of information technology talent in the mining sector, and Australia as a Access to broadband will open new opportunties for miners to increase productivity. whole. Part of it can also be at- dustry figures in supporting mation and remote control While simple face-to-face tributed to the lack of study, the network. technology. discussions over the internet particularly cost benefit analBut concerns over the It also provides more are the starting points for ysis, that has been undertak- NBN’s speed and cost still bandwidth for companies and such advancements, soften to prove the NBN’s value. abound, and the industry software providers looking to ware providers are already Nevertheless the mining still seems to be hesitant of do business over the internet. developing more advanced sector isn’t without a voice supporting it. For miners looking to tools to help with equipment on the issue. For its backers in the improve communication, the maintenance and day-to-day Some industry bosses mining industry the NBN NBN will also play a critical work. have already started to rally represents a key piece of role in improving the qualThe endgame for such support for the NBN, joining infrastructure that will help ity and ability of workers to pursuits could see workers A D _ A of MS NOAO C Tin_ 1 promote 2 . p d f the Prollout a g e of 1auto2 1 /transmit 0 9 / 1video. 2 , 3 : 5 5 P M walking around the mine a number pundits and

www.miningaustralia.com.au

with cameras in their hardhats, transmitting a video feed to people in the site office or head office thousands of kilometers away. For trainers and education providers doing business over the internet, of which the number is growing, the NBN will also provide the same benefits. And for companies, entrepreneurs, and other businesses that can’t immediately identify a practical use for the NBN, the increases in bandwidth and speed it provides free up new possibilities for future solutions. But beyond these business concerns, NBN advocates say the network will provide rural mining communities with a host of community benefits. Access to broadband is now considered a human right, and its implications for population growth, education, healthcare, and regional development are well known. If mining companies can get on the front foot with ensuring the NBN rollout, particularly in regional Australia, it’s hoped that it won’t just be businesses that benefit from the network.

AustralianMining

October 2012

AM.OCT12.PG070.pdf

Page

21/09/12,

3:47

SOFTWARE & HARDWARE

Fighting the flame war Energy companies in the Middle East are increasingly falling prey to viruses and hackers, sounding a warning for Australian producers on the importance of cyber security.

he threat viruses and hackers pose to mining and energy companies was brought into sharp focus recently, with a spate of attacks locking down systems overseas. And while Australian companies have so far avoided similar strikes, the door remains open for smart hackers to expose flaws in our local industry. The most publicised setbacks recently were for Qatar-based gas producer Ras Laffan LNG, where a virus shut down parts of its computer system for a number of days. Gas production remained unaffected but computers and systems in company offices were impacted. An unknown entity in Australia, RasGas exports around 36 million The spread of the Flame virus through the Middle East. tonnes of LNG each year. It’s one of the largest players in It’s also proof that hackers may world’s largest exporter of crude the global energy industry and proof be looking to increase their efforts in oil – also announced the outing of a that it’s not just the small end of exposing energy firms. similar virus that had been wreaking town that has to worry about cyber The attack on RasGas came a A D _ A M1 2 D O C T _ 1 2 . p d f Pa ge 1 1 4 / 0 9 / 1 2 , 3 havoc : 3 7 onPits M systems. Discovered by security. day after Saudi Arabian Oil – the researchers at Symantec and McAfee,

the “Shamoon” malware that hit Saudi Arabian Oil was designed specifically for the energy industry and had the potential to steal information and wipe data. In a blog Symantec said the destructive qualities of Shamoon were “not typical” of attacks launched on specific industries or companies, with such traits more common among viruses targeting regular users. Security experts theorised Shamoon could have been a reworking of the Wiper virus that also hit Iran’s oil sector earlier this year. It shows just how serious cyber security is for the sector. The attacks on Middle East energy companies earlier this year were not state-sponsored, but Kaspersky Lab does believe they were deliberate attempts at sabotage. As early warning signs of the spread of ‘hacktivism’ to industries and businesses not previously targeted, it sounds a clear warning for the global energy industry.

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MAR1969_FP_ADv2.pdf

Page

10/07/12,

10:45

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AM.OCT12.PG072.pdf

Page

24/09/12,

8:03

COMMUNICATIONS

In the LOOP

he modern mine site “For many years now, is a hub of communi- mining has been integral in cation. ensuring a strong Australian Miners are constantly economy. looking for ways to com“For such important opmunicate better, and the erations, it makes sense to release of new digital radio have reliable communicaequipment is helping them to tions equipment to help deachieve those aims. liver safety and productivity Communications com- within an industry that is depany Icom has released the pended upon greatly.” new IDAS IC-F4263D series, He said that the highwhich is based on 6.25 kHz light of the radio, with its Frequency-Division Multiple use of FDMA frequency, is Access (FDMA) technology that they work better underand incorporates an inbuilt ground – a huge advantage GPS receiver, is waterproof, for miners. dustproof and features the “We’ve had great success most innovative digital tech- with the application of these nology. radios underground,” Cooke Steven Cooke, Icom’s told Australian Mining. communication coordinator, “More reliability undersaid these features make the ground means far greater new radio ‘suitable for all transmission clarity and an conditions.’ improvement in the distance Cooke went on to say of transmission whilst unthat digital radio technology derground. hasS H many L 1 9clear 5 6 _advantages D E X _ U L E L “The _ S Erange . p dand f clarity P a g of e for use in the mining industry. digital radio is also far greater

New digital radios are making communication easier on site. than standard analogue and added privacy is available through secure encryption.” Cooke also explained the new radios helped improved issues around safety due to their inbuilt GPS capacity. With technology that to,be con1enables 1 6 the / 0 radios 8 / 1 2 4 : 2 nected to location software

via a PC, the radios can constantly send signals back to the home base, allowing greater awareness of where workers are at all times, a handy piece of technology in the case of emergencies. Icom has also recently re4leased P Mits new Land Mobile Radio (LMR) equipment, that

ranges from basic 16-channel handhelds to digital transceivers that can integrate with large-scale systems, as well as its air band, marine, receiver and UHF CB products. Melbourne-based Icom has been supplying radio communications products across Australia for 30 years.

Use Less Emit Less

Shell Diesel Extra’s unique formulation is designed to keep injectors clean and prevent deposit formations occurring during long periods of engine operation. Maintaining your engine in peak condition and running efficiently helps reduce the fuel consumption of your equipment. Lower fuel consumption helps you use less fuel and emit less. For other benefits of Shell Diesel Extra visit shell.com.au/commercialfuels or talk to us on 1300 134 205. *Compared to regular diesel without the Shell Diesel Extra additive.

October 2012

AustralianMining

www.miningaustralia.com.au

AD_AMOPTOCT_12.pdf

Page

13/09/12,

Inspired by Safety Driven to Change There is a sense of victory in this. The pride in knowing you have greatly reduced the risk of a fatigue related accident. Heâ&#x20AC;&#x2122;s pushed through the approval chain and the politics because he believes safety is profit. He realises that simplistic processes to measure the complexities of fatigue donâ&#x20AC;&#x2122;t cut it... the variables are just too great. The predictive and real time nature of the data he receives every minute makes him a better manager and his team better drivers. He has joined the global Optalert safety community. He has arrived.

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AM.OCT12.PG074.pdf

Page

23/09/12,

10:16

COMMUNICATIONS

Keeping connected Fibre optic cable connectors are improving data communications.

he mine site is becoming data and information heavy. There is now more communication and data information flowing back and forth across the mine and to head office than ever before. Broadband is playing a major part in this, and IBM predicts that Australia’s mining industry will be one of the major benefiters from the NBN and broadband boom. By 2050 it is believed that infor mation and communications tech nology (ICT) will generate around $1 trillion in revenues for the coun try, and importantly mining will be amongst the five industries to bene fit from this development. According to IBISWorld head Phil Ruthven “smart sensors and machine to machine communica tions will reap productivity benefits for mining by taking out labour costs and increasing efficiency. “Superfast broadband will play a very important function in logis tics, A Dvirtual _ A M Hoperations Y T O C T _(including 1 2 . pd robotics), ore grade use optimisa

October 2012

AustralianMining

As the mining industry transmits more data via fibre optics, heavy duty cabling and connectors are needed.

tion, and exploration analyses,” he in the 2020s, if not earlier.” As it said. “This will become much more ramps up for this ICT boom, the in increasingly installing fibre f important P a g e as1 mineral 1 4 / 0prices 9 / 1pause 2 , 4 dustry : 4 1 is P M and fall after the current cycle peaks optic cables to transmit the informa

tion across site and take advantage of the technology. However the harshness of the min ing environment is making this con tinual data flow difficult; as dirt often makes it way into the cables’ connec tors, disrupting the data. If the indus try is unable to ensure its connections are clear then it will be unable to fully utilise this coming ICT evolution. Speaking to Australian Fibreoptics Communications’ Clayton Macken zie, he told Australian Mining that fibre optic cable connectors will be key in the next few years. The company’s new fibre optic cable connectors dif fer from those in the market as they don’t need cleaning to continue oper ating. “They have been designed for harsh environments, and operate by actually expanding the beam so that dirt doesn’t affect the transmission of information,” Mackenzie said, adding this completely plug and play system is able to expand the beam, negating the influence of dirt or grit, and bring the beam back in at the other end of the connector.

www.miningaustralia.com.au

AM.OCT12.PG076.pdf

Page

23/09/12,

10:27

PRODUCT FOCUS: PROCESS CONTROL

Brought to you by

Process controllers

Temperature test and control

AUTOMATED Control and West introduce the Incorporates tuning algorithms. 6170+ valve motor drive process controller. It incorporates advanced tuning algorithms, with selectable pre-tune and self-tuning for easy setup. The self-tune reduces output activity to a minimum without compromising control quality, and according to the company, reduces wear and tear on mechanical components including valves, contactors and relays. Westâ&#x20AC;&#x2122;s plug-and-play technology allows the user to add to the controllerâ&#x20AC;&#x2122;s features by installing additional plug-in boards. Inputs, outputs, alarms and communications are all field upgradeable. â&#x20AC;˘ Automated Control Pty Ltd www.automatedcontrol.com.au

ThE new sensor design of Michell Instrumentsâ&#x20AC;&#x2122; S8000 Remote chilled mirror hygrometer combines high-accuracy temperature control with new materials to improve reliability and avoid Prevents risk of condensation. condensation. The relative humidity in climatic chambers will always deviate from the set point. Even in high precision chambers this deviation is typically between 1-3% Rh, which can have a considerable effect on the results of many tests. A calibrated reference instrument such as a chilled-mirror hygrometer reduces this uncertainty to just 0.5% Rh, but can be difficult to install and bulky, reducing the amount of usable test space within the chamber. To overcome these space issues, Michell Instruments has introduced an innovative sensor design with the launch of their S8000 Remote chilled mirror hygrometer. The compact remote sensor head features an open cell design, removing the need for any complex heated sampling arrangements or an external pump. Installing the sensor is simply a matter of placing it in an appropriate position within the chamber, and routing the cable externally to the instrument. â&#x20AC;˘ AMS Instrumentation & Calibration Pty Ltd 03 9017 8225 www.ams-ic.com.au

Operating precision DEWTRON has released the new DEWE2 series. DEWE2 data acquisition systems set new standards in user flexibility, accuracy, ruggedness and performance. Simultaneous sampling TRION plug-in modules combine the modularity of PXI with a larger front panel capable of containing 8RJ45 connectors for strain gauge sensors, 6 or 8 IEPE sensor connectors, or 4 or 8 isolated high voltage inputs on a single TRION module. The modules are inserted from the front of the DEWE2 chassis, each module can be combined and exchanged directly by the user in seconds. They plug in and out using the same locking/ejector mechanism made popular by the PXI standard. This allows the adaptation of DEWE2 instruments for every sensor and every application quickly. â&#x20AC;˘ Metromatics www.metromatics.com.au A D _ A MC O N O C T _ 1 2 . p d f Pa ge 1 6 / 0 9 / 1 2 ,

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YOKOGAWA Australia has announced the release of the ROTAMASS LR, described as one of the worldâ&#x20AC;&#x2122;s smallest dual bent tube Coriolis mass flowmeters. The flowmeter is designed to measure both liquids and gases, with an effective turndown of Measure both liquids no less than 2,000:1 for liquids and 5,000:1 for gases. It has a and gases. mass flow measurement range that spans from 10.5 g/h up to 40 kg/h, achieving a measurement accuracy of Âą0.15% of reading for liquids and Âą0.5% for gases. The flowmeter employs a dual bent tube that optimally decouples the core measuring element from process vibration that can cause fluctuating zero stability and decrease measurement accuracy. By design it is insensitive to fluctuations in the ambient temperature and is capable of achieving zero stability under changing process conditions. The two tubes are made from C-22 alloy, which is less susceptible to thermal expansion than conventional stainless steel. â&#x20AC;˘ Yokogawa Australia www.yokogawa.com/au www.miningaustralia.com.au

AD_AMIFMJUL_12.pdf

Page

13/06/12,

10:38

Reliability in the most extreme conditions. More machine uptime. Tough sensor solutions. ifm design and test our products in environments far exceeding your application environment. Position sensors Fluid sensors Control systems Robust control system ecomatmobile is the perfect solution of mobile applications. 1300 365 088 sales.au@ifm.com www.ifm.com

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AM.OCT12.PG078.pdf

Page

23/09/12,

10:32

PRODUCT FOCUS: PROCESS CONTROL

Brought to you by

Heavy duty processes

Vibration isolation

MOTION Technologies is now distributing the Empire Magnetics range of products in Australia. Empire Magnetics provides quality motor products designed to perform in environments and applications where ordinary motors are unsuitable. Custom systems and modifications are available upon request. The Empire Magnetics product line features 1.8o hybrid permanent magnet stepping motors, selected brushless servo motors and feedback devices Cryogenic series motors. for positioning applications that demand sealed motors for wet, dusty or hazardous environments or specialty motors for vacuum, radiation and extreme temperature operation. Radiation hardened products in the range combine radiation resistant materials with practical commercial practices to provide products with the longest possible service life within pragmatic budgetary considerations. • Motion Technologies 02 9524 4782 www.motiontech.com.au

THE Accurion halcyonics_i4 is a state of the art active vibration isolation system now available from Scitech. According to the company it is ideal for isolating high resolution measurement equipment from disturbing vibrations typically caused by machinery, air conditioning systems, the shaking of buildings, vibrations caused by nearby traffic, etc. Besides the low profile carbon design, the system features straightforward handling for an easy operation. The working surface of 400 x 500 mm² has a maximum load capacity of 120 kg. The i4 system is multifunctional active vibration isolation system for a variety of applications. This allows the operator flexibility for future applications with just one model. A major advantage is the lack of a low frequency resonance, which is a frequency where passive isolators amplify vibrations instead of isolating them. There is no compressed air supply needed to operate the isolation system. AC power from an electrical outlet is sufficient. The halcyonics_i4 provides active compensation in all six degrees of freedom. The control panel of the i4 is self-explanatory and the entire system is controlled by only three buttons. No manual adjusting or tuning is required. This enables the user to completely concentrate on the application. The isolation effect starts at 0.6 Hz, achieving the max. performance of -40 dB at 10 Hz, where 99.0% of the vibration is isolated. It also features an automatic load adjustment and transportation lock, has no natural low frequency resonance, and requires no compressed air to operate – just a power supply. • Scitech 03 9480 4999 sales@scitech.com.au www.scitech.com.au

Flow meters TRIMEC Flow Products has released the MP Series MultiPulse flow meters for volumetric flow rate measurement in flow monitoring and control applications. The flow meters are suitable for a wide range of measuring flow of clean fluids including viscous lubricants, chemicals, adhesives, resins, paints, food bases, essences, alcohols, edible oils and non-conductive low viscosity solvents. The products are manufactured in sizes up to 50mm and Has temperature ratings up to 200°C. available in aluminium or stainless steel. The UPVC is manufactured in the 20mm size only and is ideally suited for use with corrosive fluids, such as sodium hypochlorite, acids and photographic solutions. • Trimec Flow Products www.trimec-fp.com.au A D _ A MME T MA Y _ 1 2 . p d f Pa ge 1 3 / 0 4 / 1 2 , 1 1 : 3 0 AM

October 2012

AustralianMining

www.miningaustralia.com.au

AD_AMNATOCT_12.pdf

Page

21/09/12,

4:17

MS2689_rsurvey_AM.pdf

Page

15/08/12,

11:52

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AM.OCT12.PG081.pdf

Page

26/09/12,

8:31

SAFETY

RISKY WORK in WA M

ines in Western AusThis last fact is of considtralia are amongst erable importance given the the most unsafe in steep rise in workforce numthe country, and fatalities are bers WA has experienced over rising as more workers flock to the years. the state to find jobs. From the three year period According to new figures from 2007-08 to 2010-11, 16 from Safe Work Australia mining workers died in WA more mining workers die in compared to six in QueensWA than any other state and land, five in New South Wales while the region accounts and South Australia, and two for over a third of Austral- in Victoria. ia’s mining workforce it acWhat’s interesting to note counts for almost half of the is that while WA boasts a deaths in the industry. large workforce that could Research off the back of skew the fatalities record, the new data by Perth outlet QLD is also bursting at the The Sunday Times has also al- seams with rising populations leged a “culture of cover ups” but has managed to register reigns on some WA sites, with much lower fatalities. workers reluctant to report inWhat makes WA’s prijuries or accidents. marily open cut industry a litBut the figures aren’t all tle more dangerous than the bad news for the WA sector, coal-focused QLD sector isn’t with much of the data indi- easy to say, but the question cating that while WA is still of union influence is likely to the most dangerous region be a future pressure point. in AAustralia, are1 2 . p QLD D _ A M L Ifatalities NOCT _ d f isPhome a g eto more 1 1un4 / not climbing sharply. ionised mining workers than

New figures show more workers die in Western Australia than any other state, and fatalities aren’t slowing down.

WA, with the Construction, Forestry, Mining and Energy Union driving a hard bargain on conditions and safety inspections over east. Indeed for much of the last decade the CFMEU has been locked out of contract negotiations in WA, and has only been strengthening its presence in the Pilbara very recently. Looking over historical 0data, 9 / previous 1 2 , Safe 1 1 Work : 2 3 AusAM tralia records show over a six

year period from 2003-04 to 2009-10, 25 mining workers died in WA. In the same period 15 workers died in QLD. From 2003-09 the fatality rate in WA leveled at over four a year, and from 200710 it rose slightly to over five a year. But worker advocacy groups say many studies never show the full extent of safety problems because accidents can be covered up.

They say that at some sites companies link bonuses to lost-time injury rates and workers are often reluctant to report accidents for fear of retribution or loss of benefits. There’s no doubt this debate still has some time to play out, and more study will be needed to form a full picture of the industry. But measurements are already indicating there’s still work to be done on securing safer sites.

Visit us at GME 2012 Stand 2067

www.miningaustralia.com.au

AustralianMining

October 2012

AM.OCT12.PG082.pdf

Page

26/09/12,

10:15

SAFETY

Saving our miners Understanding the consequence of injuries is just as important as stopping them in the first place.

omplacency is a killer on mines. You can do the same job every day, and carry it out one hundred times without an incident, but it might be that one hundred and first time where something goes wrong. You can follow the procedures, but the unexpected still happens. Speaking to S.O.S.’s Dean McSporran, he told Australian Mining that while the unexpected and drastic event may occur, it is not the end of the world. McSporran knows this first hand. A former miner himself, McSporran worked at the Austar coal mine in the Hunter Valley. “I worked in a high risk job in underground mining working five 8 hour days a week on a rotating roster. Days, nights and afternoon shift. I had been doing this for nearly five years working my way up from a person new to the industry to driving miners and other mining equipmentAthat used D _ was A MS WI in O underground CT _ 1 2 . p d f mining,” he said.

Pa ge

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AustralianMining

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Until the fateful night. Working a normal shift underground, McSporran was installing mesh, and had laid some of the roof mesh on top of the idle miner. “I was hanging onto the mesh so that when the miner moved forward the mesh didn’t get caught on the ribs and getting all twisted, this again was a practice that I had been shown when I had first started and had done this practice thousands of times.” It was then that the miner moved and one of the drills that installs the mesh entangled his arm, mangling it as it pulled him into the mesh. “It was then that I had realised that my arm was mangled in the mesh with only a small amount of skin keeping the arm attached to the rest of body. I remember saying to my mate take your time as the arm has gone, as I was showing him where to cut the mesh. Once I was free I gathered the mesh, the drill, and what was left of my arm and walked off the back of the miner to where other work colleagues had got a trauma pack which had bandages and other medical supplies.” McSporran was quickly cut free, given emergency first aid, and evacuated from the mine.

Despite doctors’ efforts, they were unable to save his arm below the elbow. Like many miners injured at the work place, this altered his life. “After the accident I went through a situation where I had little direction, and knew I’d never work in mining again due to the disability,” he told Australian Mining. For many injured miners this, unfortunately, is usually the end of the story. However McSporran decided to use his injury to teach other miners, setting up S.O.S. and providing presentations to people in the industry showing that a serious injury does not mean the end. “I speak to fellow miners on safety, and how accidents can happen, even when following procedures,” he said. “And how their life can change dramatically, and what can be taken away from them. “To date I’ve worked with BHP, Xstrata, Centennial, and Peabody,” he added. Since the incident, McSporran’s life has changed dramatically, and he has become a national gold champion, and will be representing Australia at the Paralympics in Rio in 2016. www.miningaustralia.com.au

EV2756_MiningCon_AM.pdf

Page

7/09/12,

11:51

GET SERIOUS ON MINE SAFETY

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Simon Ridge Director of Mine Saftey Department of Mines & Petroleum WA

INSURING WORKERS MENTAL HEALTH OF WORKERS

Dr Jennifer Bowers CEO, Australian Centre for Rural & Remote Mental Health The Hon Norman Moore MLC WA Minister for Mines and Petroleum; Fisheries; Electoral Affairs And more...

For more information and to register, visit www.miningaustralia.com.au/conference or call (02) 9422 2257

AM.OCT12.PG084.pdf

Page

23/09/12,

10:54

SAFETY

Australian Mining’s Safety show Our inaugural safety conference is designed to help you work safer.

afety is integral to all aspects of mining. And mining in Austra lia is about working efficiently, and importantly, as safely as pos sible. But as the mine site changes, tech nology advances, and automation becomes a more prominent part of the industry, how we work changes. With this constant need to de velop the industry’s understand ing of safety and how to make the workplace safer, Australian Mining is holding a safety conference. Beginning in Perth this year, and to be held in Queensland next year, The show will focus on the key aspects affecting safer operation on mines. this magazine is aiming to help the resources industry work better. Launching this event will be cur Moore was also a major support We’ll be highlighting the lat rent West Australian mines minister er of the state’s Reform and Develop est trends and technologies, market Norman Moore, who has been a fix ment at Resources Safety (RADARS) thinking, and practices that is making ture of the state’s resources industry program, which seeks to overhaul the mine site a less dangerous place to for years. how health and safety is regulated in operate. He has been a driving force in the resources industry. We’ve sought to gather a number ensuring that Western Australia’s One of the key speakers will be of recognised names and faces in the mining industry is the safest in Simon Ridge, the current director of industry who have dedicated their Australia, and he has succeeded in mine safety for the West Australian careers and Petroleum. A D _toAmaking M T R Esure 2 F you’re E B _ 1getting 2 . p d dramatically f P a g e cutting 1 1 not 0 / only 0 1 / injury 1 2 , Department 1 1 : 5 1 of A Mines M home at the end of the working day. 1/5/12 frequencies, Ridge has led the push for more EmulsionPlant122x210Ad.pdf 8:26:42 but PM also fatalities.

safety inspectors across Western Australia, and has overseen the train ing and deployment of a number of new inspectors. Miners’ mental health is also play ing a key role at this conference, and will be discussed by the Australian Centre for Rural and Remote Mental Health Queensland’s chief Jennifer Bowers. The conference is also looking at specific aspects of mining, such as underground mining, drilling, and blasting safety. It will focus on safety in automa tion, and how automating processes will cut injury rates on site. The CSIRO’s Minerals Down Under Flagship director Jonathon Law will also take the stage to high light technology changes, and how automation Insurance is also playing a part, with Aon Hewitt’s Simon Godfrey explaining the importance of insur ance on site. The event will be held on 23 Oc tober in Perth’s Pan Pacific Hotel.

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AD_AMTYCAUG_12.pdf

Page

20/07/12,

12:23

Going to greater depths. Productivity is often the first thing that draws mining industry professionals to Shurjoint ring joint piping systems. Our couplings and fittings join pipe 3 to 4 times faster than welded or flanged joints. Shurjoint products are ideal for applications requiring: • Thick-wall, large-diameter piping • More security than standard roll or cut-groove piping • Fast, easy assembly/disassembly, service and system expansion In the long run, it’s depth of service, supply and support that keep the relationship between Tyco and the industry so strong. Explore Shurjoint Products today. For more information visit www.shurjoint.com.

AM.OCT12.PG086.pdf

Page

23/09/12,

10:57

PREVIEW

Goldfields mining exhibition preview Held every two years, the Goldfields Mining Expo is a chance for industry members and the public alike to converge in WA’s hard rock heartland.

his year’s Goldfields Mining Expo – to be held in Kalgoorlie from October 30 to November 1 – will again feature a solid line up of exhibitors. After 27 years in the Goldfields the expo will again give those in the industry a chance to meet, network, and do business in one of Western Australia’s mining hotspots. And as well as the regular offerings from top exhibitors and buyers, GME will also feature a number of community-focused events aimed at different parts of the industry. The community presentations will form part of the event’s focus on attracting frontline workers to the show, including operators, maintenance crews and others. The GME Women in Mining Day will also help celebrate the role of women in the industry and help promote gender diversity in the sector. presentations lo-d AItDwill _ Afeature MD MF O C T _ 1 2 by . p cal women who are forging success-

Massive mining machinery will be on show at Kalgoorlie in late October.

ful careers at all levels in the industry and give prospective workers advice on how to get started and succeed. Building on the tips from the women f P a gine mining 1 6day / 0GME 9 / 1will 2 , also1 host a careers and recruitment day.

The recruitment day will look at job opportunities in the Goldfields for those with the rights skills and experience and give miners advice 2 on : 5how 1 they P M can best develop their careers in the field.

Reed Mining Events exhibition director Paul Baker said in a statement organisers had done well all over Australia attracting a range of attendees at each expo. “Over the past 12 months, Reed Mining Events has had considerable success in attracting broader crosssections of the mining community along to our mining exhibitions in Perth, Sydney, Mackay and Newcastle,” he said. “For GME 2012, we are developing our mining community program in close consultation with our exhibition partners, the KalgoorlieBoulder Chamber of Commerce and Industry, as well as local mining companies and suppliers of products and services.” Baker said GME 2012 was open to everyone. “It’s also an opportunity for miners to see new products and services – as well as giving ‘hands-on’ feedback to exhibitors.”

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For over 40 years, DMF has been providing solutions to control busy doorways from temperature loss, dust entry, and draft. There is an increasing need in the mining industry for this control, in workshops, critical spares warehouses, and in some underground applications. DMF’s high speed roll doors operate at 2m/sec, and are designed for large openings, high wind capacity, and high frequency of use. And, we will custom manufacture to suit your needs. Increase your EOHS prole, and reduce your carbon footprint. Contact DMF today. DMF INTERNATIONAL P/L 3/88 Magowar Rd, Girraween, Sydney, NSW, 2145 Ph 02 9636 5466 Fax 02 9688 1531 www.dmf.com.au

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AD_AMBEAOCT_12.pdf

Page

21/09/12,

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AM.OCT12.PG088.pdf

Page

23/09/12,

11:15

FLOORPLAN

ENTRY

9410

3023

3020

9408

3017

3010

9175

3081 3082

3012

3008

3057

3068

9174

3062

3058 3 052 3059

3083 3084 3085

3006

3004

3003

3002

3034

3033 3038

3 043

3053

9404

3032

3042 3049

3 030

3067

3078

3076

3013

3063 3064

3079

3077

3056

9406

3027

SUPER PIT PAVILION

3035 3036

3046

3024

016 5 3 3 01 4 301

9402

3031

9400

3 000

3086 3087 3088 9208 9204

3074

3073

9200

3071 9196

9194 9190 9186

9171

9182

9210

9176

9160

9164

9156

9140

9146

9152 9150

9178

9008

9012

9018

9020

9028

Floorplan correct at time of publishing 20/9/12

October 2012

AustralianMining

www.miningaustralia.com.au

9034

AM.OCT12.PG089.pdf

23/09/12,

1:25

FLOORPLAN

1020 1022

1020

9410

9408

9410 9412

9412

9420

9406

9422

9430

9404

9424

2102 2064 2095 2064 2095 2024 2055 2024 2055 2017

1016

1103

2015

2065 2094 2065 2094 2025 2054 2025 2054 2103 2015 2093 2093 2066 2066 2053 2053 2026 2026

1015

1014

9400

1007

9402

9400

9436

1024

1024 1066

1066

1109

1010

1110 1030 1049 1030 1049 1009 1070 1088 1070 1088 1032 1046 1032 1046 1008 1111 1073 1086 1073 1086 1033 1007 1033 1006

1005

1074 1085 1074 1085 1034 1045 1034 1045 1005 1114

9436

1003

1000

1004 1077 1083 1077 1083 1037 1043 1037 1043 1118 1003

1078 1040

1000 1040

1078

9246

9240

9318

9312

1120

1106

1108

2011

1109

3 2010

1110

2009

1111

9312

9262

9146

9140

9136

9132

9136

9262 9126

9132 9130

9126

9122

2007

2110

2071 2087 2071 2087 2111 2033 2046 2033 2046 2007 2073 2086 2073 2086

2111

2112

2114

2077 2083 2077 2083 2039 2043 2039 2043 2118

2118

2120

2004

1118

2003

9306

9120

9130

9116

2074 2114

1114

2000

2108

2110 2070 2089 2070 2089 2030 2049 2030 2049 2009

2074 2034 2045 2034 2045

1120

2106

2109

3 2010

2078 2040

2000 2040

9300

2078

9300 9292

9272

9122

2104

2109

9284 9272

2103

2067 2092 2067 2092 2027 2052 2027 2052 2106 2012 2028 2051 2028 2051 2090 2069 2069 2090 2108 2029 2050 2029 2050 2011

2012

9208 9246

2102

2104

1006

1004

9208

1103

1052 1092 1067 1092 1027 1052 1027 1067 1106 1012 1068 1051 1028 1051 1028 1068 1090 1090 1069 1069 1108 1029 1011 1029

1008

9402

2099

2017

1009

9424

2060 2099

2060 2022

1102

1010

9404

2020 2022

2020

1099

1102 1017 1026 1055 1026 1055 1064 1095 1064 1095

1011

9422

1060 1099

1060 1022

1017

1012

9430

204

Page

9116

9112

9110 9112

9110 9108

9290

9284 9106

9034

9036

9044

www.miningaustralia.com.au

9044 9048

9052 9048

9054 9052

9054

9056

9290

9106

9108

9120

9076

9028 9034

9292

9062

90629064

9076

9064 9068

9068

AustralianMining

October 2012

AM.OCT12.PG090.pdf

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26/09/12,

8:55

EXHIBITORS LIST

Stand n n n n n n n n n n n n n

1003 1004 1005 1006 1007 1008 1009 1010 1011 1014 1015 1016 1017

n 1020 n 1022 n 1024 n 1026 n 1027

n n n n n n n n n n n n n n n n n

1028 1029 1030 1032 1033 1034 1037 1040 1043 1045 1046 1049 1051 1052 1055 1060 1066

n n n n

1067 1068 1069 1070

n 1073 n 1074 n n n n n n n n n n

1077 1078 1083 1085 1086 1088 1090 1102 1103 1106

Company/Trading Name

Stand

Kais Contractors Energy Services Inviromental Aqua Guardian Group Fogmaker Australia Pty Ltd Rowe Scientific Pty Ltd Keramos Pty Ltd McNaughtans Pty Ltd Durst Industries Pty Ltd Aury Australia Pty Ltd Stratco Seadan Security & Electronics G Corp International Pty Ltd Qingdao Hanhe Cable (Aus) Pty Ltd Global Communication Services Hahn Electrical Contracting Pty Ltd Minecorp David Brown Gear Industries Ltd Flexicon Australia Pty Ltd/ Nesco Electrical Products Pty Ltd/Ampere Electrical Manufacturing Pty Ltd AusProof Pty Ltd Mancala Pty Ltd Mintech Chemical Industries ACCB Hearing Services RS Components Pty Ltd Westrade Aust Pty Ltd Pressure Systems Pty Ltd Alfabs Mining Equipment Pty Ltd Tyco Fire Protection Products Discovery Parks MarketBook Clear Edge Filtration Uretek Ground Engineering Sew-Eurodrive Pty Ltd Berendsen Fluid Power Pty Ltd Schlumberger Australia Pty Ltd Workplace Access & Safety Pty Ltd Dy-Mark (Aust) Pty Ltd Automated Positioning Systems VETASSESS Bohler Uddeholm (Australia) Pty Ltd Control Devices Australia Pty Ltd Brown & Watson International Pty Ltd CTS Crane Technical Services Australian Mining Herrenknecht Group Atlas Medical Cooper Split & Kaydon Bearings Digital Radio Systems Pty Ltd Shaw Almex Pacific Pty Ltd Betta Roads Zip Heaters (Aust) Pty Ltd Strata Products Australia Pty Ltd

n n n n n

1108 1108 1109 1110 1111

n n n n

1114 1118 2003 2004

n n n n n n n n n n n n n n n n

2007 2009 2010 2011 2012 2017 2022 2024 2026 2027 2028 2029 2030 2033 2034 2037

n n n n n n n n n n n n n n n n n

2045 2046 2049 2050 2052 2055 2064 2067 2070 2071 2073 2074 2077 2086 2089 2092 2104

n n n n n n n n n n n n

2109 2112 2114 2118 3000 3002 3003 3004 3006 3008 3010 3012

October 2012

AustralianMining

Company/Trading Name

Stand

Company/Trading Name

Cortland Jeyco Hydratight Icom (Australia) Pty Ltd Healthscope Pathology Norbar Torque Tools (Aust) Pty Ltd Cirlock Ego Pharmaceuticals Girbau Australia Haefeli-Lysnar Survey Equipment TK Distributors Telstra Jotun Australia Pty Ltd CPE Machinery Pty Ltd Auto Control Systems Watering Concepts Smenco Pty Ltd Airtech (Aus) Pty Ltd Sitech WA Pty Ltd RBM Industrial Bags Pty Ltd Appliances Online General Marking Australia Medic One Kerrick Industrial Equipment Cooper Industries Australia Bulk Handling Australia Group Pty Ltd Redox Pty Ltd Iterra IP Satellite Chemsearch Australia Sika Australia Pty Ltd Natural Power Solutions Pty Ltd Power Parameters Pty Ltd Kimberly-Clark Professional LINAK Australia Pty Ltd SKYLOTEC Fleet Commercial Gyms Automation IT Richmond Wheel and Castors Rhino Water Tanks Cardno HNZ Australia BlueScope Water Pty Ltd Goldfields Institute of Technology MSA Australia Pty Ltd Siemens Ltd KAB Seating Tablet PC Pty Ltd Engraving Supplies Nexans AmerCable Australia Bladon W.A. Antec Engineering Pty Ltd BAC Systems Pty Ltd Gallagher Tidal Fluid Power Goldfields-Midwest Medicare Local

n 3013 L. E. Jarvis, a member of the ABB Group n 3014 Pivotel Satellite n 3015 Samson Controls Pty Ltd n 3016 Spraying Systems Co n 3017 ESS Engineering Services & Supplies Pty Ltd n 3020 Russell Mineral Equipment n 3023 Amiad Water Technologies n 3024 RS Enterprises WA n 3027 LEDiQ – Shen Zhen XLC Technology Limited n 3030 Ion Analysis Australia n 3031 ASSA ABLOY Australia Pty Ltd n 3032 Grundfos Pumps Pty Ltd n 3033 Friction Innovations n 3034 Aspermont Limited n 3035 Perth Petroleum Services n 3036 Macmahon Contractors Pty Ltd n 3038 DT Australia n 3042 Bosbox Pty Ltd n 3043 Hella Australia n 3046 Mine Site Technologies n 3049 Sunlec International n 3052 Vinidex Pty Ltd n 3053 Minova Australia Pty Ltd n 3056 Ashdown-Ingram n 3057 Draeger Safety Pacific Pty Ltd n 3058 GME Standard Communications n 3059 Oli Vibrators Pty Ltd n 3062 Remote Control Technologies Pty Ltd n 3063 Honeywell Safety Products Pty Ltd n 3064 Oliver Footwear Pty Ltd n 3067 Dyno Nobel Asia Pacific Ltd n 3068 Real Time Group Pty Ltd n 3071 Acromet (Aust) Pty Ltd n 3073 Mining FM Pty Ltd n 3074 FOXTEL for Business n 3076 Safemate Anti-slip Pty Ltd n 3077 Huski n 3078 Australasian Mining Review & Australasian Mine Safety Journal (APRS) n 3079 Kalgoorlie Boulder Chamber of Commerce & Industry n 3081 City of Kalgoorlie-Boulder n 3083 Kinyun Australia Pty Ltd n 3084 Kershki Pty Ltd n 3085 Central Equity Ltd n 3086 Bluestream n 3087 AMMS Group n 3088 David Moss Corporation Pty Ltd n 9008 McCullochs Manufacturing n 9012 Hanjin D&B Co Ltd n 9018 Squirty Hydraulic & Mechanical n 9018 Australian Mining Technologies

Stand n n n n

9020 9028 9034 9036

n n n n n n n n

9044 9048 9052 9054 9056 9062 9068 9076

n n n n n n

9106 9110 9112 9116 9120 9122

n n n n n n n n n n n n n n n n n n n n

9126 9132 9136 9140 9146 9150 9152 9156 9160 9164 9174 9176 9178 9182 9186 9190 9194 9196 9200 9204

n n n n n n

9208 9210 9240 9246 9262 9272

n n n n n n n n n n

9284 9292 9300 9306 9312 9318 9410 9420 9424 9430

Company/Trading Name King Caravans SingTel Optus Pty Ltd Mono Pumps (Australia) Pty Ltd Murphys Spray & Blast Equipment Adaptalift Hyster Coventry Fasteners Cougar Parts & Equipment APS Lighting & Safety CJD Equipment Pty Ltd State West Group CPC Engineering – Goldfields Crushing & Mining Equipment Pty Ltd Covs Parts Pty Ltd Tru Blu Hire Australia Pty Ltd TPCM Xylem Water Solutions Becker Mining Systems Powerlink Machine (Australia) Pty Ltd Daimler Trucks Perth Explorex Caravans Redpath Australia Pty Ltd Resource Equipment Ltd JCB BA Equipment Group Pty Ltd IDS Australasia Pty Ltd Fusion Plast WA KSB Australia Pty Ltd RUD Chains Pty Ltd Essential Mining Services WA Hino Sales & Service Higer Bus Centre WA WT Hydraulics Hoshizaki Lancer Outotec Pty Ltd Resources Trading Hub RSEA One Stop Safety Shop MineARC Systems Kaeser Compressors Australia Pty Ltd Aerison Pty Ltd Linkforce Engineering ET Mining Solutions Ford Motor Company CAPS Australia Sulzer Pumps Wastewater Australia Pty Ltd Power Equipment Pty Ltd MacLean Engineering DRA Engineering Heatleys Safety & Industrial Subzero Group ElectCables Drilling Australia Pty Ltd Romex Australia Pty Ltd Natrad MAXAM Australia www.miningaustralia.com.au

AD_AMXYLOCT_12.pdf 235x297mm Umbrella Ad.pdf

Page

8/08/2012

24/09/12,

11:55

2:37:11 PM

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AM.OCT12.PG092.pdf

Page

A D _ A M S E WO C T _ 1 2 . p d f

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1 4 / 0 9 / 1 2 ,

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PREVIEW Gearmotors \ Industrial Gear Units \ Drive Electronics \ Services

Health care services

Stand 1052 30 Oct-1 Nov 2012 Kalgoorlie, WA

AtlAs Medical will promote its medical services for isolated worksites on stand 1085 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30November 1, 2012. Atlas Medical’s Brett Ferguson said quality healthcare could be a challenge in remote locations, but Atlas Medical’s team of experienced, highly qualified Paramedics and Critical care Nurses provide 24/7 support, emergency care and primary health care 365 days a week. “We provide clinical care specialties in primary health, including management of the day to day issues like headaches, general illnesses such as mild gastro, flu, rashes, chest infections, and ear, nose and throat problems,” Ferguson said. “Atlas Medical sets the benchmark for medical support in remote locations, meaning most mine workers can be treated onsite.” Access to a broad range of medications, including antibiotics, are available so any non-serious cases can be managed effectively, avoiding unnecessary evacuations. Consequently, lost time Incident Rates (ltIR) could be reduced and absenteeism minimised, due to illness or injury, Ferguson said. “And our emergency care teams are chosen for their ability to control and manage emergency situations, with their diverse backgrounds meaning they are highly skilled at dealing with potential or actual life threatening situations.” Atlas Medical also offers nationally accredited drug and alcohol testing and training services, Occupational health monitoring and testing, RtO-accredited first aid training and recertification courses, Flu vaccinations and medical and safety toolbox briefings. Ferguson said the directors of the Australian-owned company which is headquartered in Queensland, had been involved in providing world-class medical services to in some of the most geographically remote areas of Australia for more than a combined 70 years. • Atlas Medical Brett Ferguson 1300 459 970 bferguson@atlasmedical.com.au www.atlasmedical.com.au

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October 2012

AustralianMining

sew am 9.12 1_2p man in tunnel.indd 1

AutOMAtION It will showcase industrial software systems designed to improve mine site efficiency on stand 2073 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October Improving mine efficiency. 30-November 1, 2012. the Queensland based company, which opened a Perth office earlier this year, offers complete turn-key control systems engineering services from project management and conceptual design to final site commissioning. In addition, they also perform customised PlC and sCADA training, either onsite or in Perth. Geoff Bladon, Automation It’s business development director, said the company had a strong presence across the Australian mining industry, with its experience in both metalliferous and coal open-cut and underground mines involving production monitoring; oil lubrication; conveyor systems; process water; fuel farms; sAG mills; crushing plants; draglines; shovels; longwalls; shiploaders; product stackers/reclaimers; the run-of-mine (ROM); and coal preparation and handling plants. Customised solutions for a range of problems faced by both operations staff and management of large organisations were a speciality of Automation It, Bladon said. these included Enterprise Resource Planning (ERP) integration, alarm rationalisation, downtime analysis, process improvement, control system software change management, equipment condition monitoring, Asset GPs location management and custom applications for tablets and smart phones. Among the services offered by the company are feasibility studies, MCC and PlC cubicles, PlC and sCADA software engineering, Rtu networks, electrical installation, training and support. • Automation IT Frank Greenaway 0438 111 027 sales@automationit.com www.automationit.com www.miningaustralia.com.au

12/09/12 8:09 PM

AM.OCT12.PG093.pdf

Page

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PREVIEW

Radio technology

Dump truck trays

Icom will display a new radio combining digital technology, an inbuilt GPS receiver and waterproof and dustproof construction on Stand 1109 during the Goldfields mining Expo (GmE). “Digital radio technology has many clear advantages,” Steven Greater range and clarity. cooke, Icom’s communications co-ordinator, said. The new IDAS Ic-F4263D series, based on 6.25 kHz Frequency-Division multiple Access (FDmA) technology, offered spectrum efficiency and had advantages in the event of infrastructure failure, he said. “The range and clarity of digital radio is also far greater than standard analogue and added privacy is available through secure encryption.” Icom will also use GmE to show its Land mobile Radio (LmR) equipment ranging from basic 16-channel handhelds to digital transceivers that can integrate with large-scale systems, as well as its air band, marine, receiver and UHF cB products. “For many years now, mining has been integral in ensuring a strong Australian economy,” cooke said. “For such important operations, it makes sense to have reliable communications equipment to help deliver safety and productivity within an industry that is depended upon greatly.” melbourne-based Icom (Australia) Pty Ltd has been supplying radio communications products across Australia for 30 years. All Icom products are made in Japan to strict quality standards and offered unsurpassed reliability that suited the rigours of the mining industry. • Icom (Australia) Pty Ltd Steven Cooke 03 9549 7519 stevec@icom.net.au www.icom.net.au A D _ A MC I R O C T _ 1 2 . p d f Pa ge 1

CIRLOCK LOCKOUT / TAGOUT EQUIPMENT

DT Australia will promote its unique curved-style Hercules dump truck bodies on Stand 3038 at the Kalgoorlie Boulder Racecourse from october 30-November 1, 2012. The Perth-based, Australian-owned company describes the Hercules as the strongest truck body on earth. It features “a uniquely engineered and patented design” with curved floor sheets instead of a conventional square body. “The Hercules is a high-performance dump truck body which has many unique and cost-saving features that enhance the performance of haul trucks,” Steve Turner, DT Australia’s sales and marketing manager said. “Heavy duty, lightweight and durable, it is designed to suit all oEm makes and models.” made from a flexible, hardwearing steel plate, the Hercules body increases mine productivity and bottom line profitability, he said. “Its key features include lower body weight, reduced wear, reduced maintenance, and increased durability and reliability. “And apart from extra capacity, it also enhances truck stability, dumping and has a simplified single shovel target area for loading,” Turner said. other features included a heavy-duty design for outstanding wear resistance; a unique panel construction that greatly reduced downtime; as well as unique, curved floor sheets that were stronger and more durable. “All our engineering designs, tray enhancements and our rich knowledge base have developed over the 16-year evolution of the Hercules.” • DT Australia Steve Turner 08 9365 6888 sturner@dthiload.com www.dthiload.com

Mining services cARDNo, the ASX-200 professional infrastructure and environmental services company, will be highlighting its services during GmE. The company has expertise in the development and improvement of physical and social infrastructure for communities around the world. cardno’s team includes leading professionals who plan, design, manage and deliver sustainable mining projects and community programs. With local, highly skilled teams based in regional centres around Australia, it is positioned to deliver innovative solutions for a range of projects. Working with some of the world’s largest mining companies throughout Australia and Internationally, cardno works towards exploring and deliver resourceful solutions. Its environmental services, civil and structural design, geotechnical investigation and testing, and open cut and underground mine surveying and engineering services, combined with local project management capabilities enable cardno to deliver a full range of cost-effective and sustainable solutions to the mining and resources industry. • Cardno www.cardno.com 2 0 / 0 9 / 1 2 , 3 : 4 4 PM

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AustralianMining

October 2012

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Industrial bags RBM Industrial Bags will showcase industrial tool and equipment bags for the mining industry on Stand 2027 during GME. The Kingaroy, Queensland, company Heavy duty, PVC kit and tool bags. designs, manufactures and supplies bags such as electrical and field maintenance bags; fitters bags; kit bags; pouches; tool rolls; spanner wraps; welder helmet bags; meter pouches; linesman pole bags; water bottle bags; back packs; and document wallets. The bags are generally manufactured in PVC (PolyVinyl Chloride), with selected items made from duck canvas. With more than 60 years of collective experience in motor trimming, upholstery and canvas manufacturing, the directors of RBM Industrial Bags describe the company’s product range as durable, visually appealing and manufactured to the highest possible sewing standards. “We strive to supply high quality products in an efficient and reliable manner,” said Betty Stallwood, RBM’s co-founder and managing director. “And this presents us with unique opportunities and challenges to thrive in what is often said to be struggling … the Australian manufacturing industry.” • RBM Industrial Bags Anitta Stallwood 07 4162 5734 anitta@rbmbags.com www.rbmbags.net A D _ A ME R I J U L _ 1 2 . p d f Pa ge 1 2 0 / 0 6 / 1 2 ,

Road stabilisation BETTA Roads will showcase a new dry spread application method for its PolyCom Stabilising Aid on Stand 1102. Australian-made PolyCom, which is used to stabilise earthworks’ materials, is supplied in a powder form and conventionally spread with a water cart, grader and roller. The new application method involves surface scarification to the desired depth, dry spreading the prescribed dosage evenly, blade mixing, watering and rolling. “From haul roads to access tracks and everything in between, PolyCom is ideal for remote area works where sourcing good materials is difficult,” Paul Bright of Betta Roads said. “It stabilises and changes the properties of material to enable less effort and stronger, more workable soils that were previously considered unsuitable,” he said. The surface of a PolyCom-treated area was comparable to one treated with lime or cement but PolyCom was easier to apply and could be re-worked at any time, Bright said. He said other benefits included the fact that PolyCom-treated roads better withstood water and traffic damage; the intervals between grading and maintenance were substantially increased; it significantly reduced costs and water usage; that trucking in of new materials was heavily reduced and so reduced cartage costs and damage to surrounding roads; delivering improvements to in-situ ground normally cut to spoil: improving clays, silts, sands and variations of those to deliver useful and workable in-situ ground, saving time and money for projects. • Betta Roads paulb@bettaroads.com.au www.bettaroads.com.au

Plastic pallets BulK Handling Australia (BHA) will unveil a new plastic export pallet, described as a costeffective replacement for wooden export pallets for Bulk bags, on Stand 2037 at GME. The BHA Bag Pallet is designed to move polypropylene bulk bags (Flexible Intermediate Bulk Containers or FIBCs), and has been patented internationally. 4 : According 5 3 PtoM BHA, the 4.1 kg pallets weigh about 10 or 11 kg less than export wooden pallets, which increases a 40 ft container payload by a potential 400 kg. The pallets also offered noteworthy space savings with 11 of the stacked packets measuring 280 mm in height, Ian Shaw, BHA’s managing director, said. And the dimensions are the same as a wooden export pallet: 1100 mm in width and length. The new pallets have a 3-tonne Safe Working load. Made from the same HDPE material as wheelie bins, the pallets can be used with filling systems that complete bag filling on the pallet, as well as those where the bulk bag is filled and then placed on the pallet. As with wooden pallets, bags can be stacked two-high and strapped to the pallet. Mining applications include minerals and mineral sands. The uV-treated pallets are manufactured by injection molding. BHA says the new pallets also have a potential recycle value of $1.60 to $3.20 each and are immune to water issues. • Bulk Handling Australia Group www.bha.com.au

Boring systems HERREnKnECHT will feature technical innovations for sinking vertical shafts to depths of up to 2000 m on Stand 1083 during GME. The German company says it is a technology and market leader in mechanised tunnelling systems, delivering cutting-edge tunnel boring machines for all ground conditions and diameters from 0.10 m to 19 m. Herrenknecht had also developed technical innovations for the mining industry, such as machines for the development of deep, vertical blind shafts and the excavation of inclined shafts as well as applications for underground production processes, company representative Benjamin Künstle said. “For deep vertical shafts with depths up to 2000 m, Herrenknecht has developed mechanised shaft boring systems enabling excavation diameters of up to 12 metres in hard and medium soft geology,” he said. “Our strong Raise Boring Rigs (RBR) can sink and extend shafts to depths of up to 2000 metres.” The rigs incorporated a proven variable frequency drive concept, used by other Herrenknecht machines, which enabled variable control of speed and torque, Künstle said. The company will also use GME to showcase its newly developed Boxhole Boring Machine (BBM) for drilling the vertical or inclined small-diameter slot holes that need to be excavated in many underground mines. • Herrenknecht AG kuenstle.benjamin@herrenknecht.de www.herrenknecht.com

October 2012

AustralianMining

www.miningaustralia.com.au

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Water tanks

The workbenches are designed for heavy duty storage and applications.

Workshop storage BAC Systems will showcase a range of high-density drawer storage modules on Stand 3006 during the Goldfields Mining Expo (GME). “Visitors will be invited to sample the quality and strength of the BAC drawers and see how adopting BAC drawer storage in a component store can result in space gained, allowing room for future growth and functionality,” BAC’s Robert Griffin said. GME visitors would also be able to see how the BAC free-flow system could be enhanced with dust control screens that provided a category 5 level of dust protection for components, Griffin said. BAC workbenches, designed for heavy-duty workplace applications, will also feature on the company’s GME stand. These can be combined with the drawer storage modules for customised workshop solutions. “For 35 years, BAC Systems has been manufacturing quality workshop and storage equipment specifically designed to meet the rigours of the Australian workplace,” Griffin said. “Durability is a key feature of a truly reliable product and BAC Systems’ products are built with this fact in mind. “When you purchase a BAC product, you know you will get reliable functionality in all conditions.” • BAC Systems Robert Griffin 02 9832 2777 robert.griffin@bacsystems.com.au www.bacsystems.com.au A D _ A MS P R O C T _ 1 2 . p d f Pa ge 1 1 8 / 0 9 / 1 2 , 1 0 : 3 6

BluESCopE Water Tanks will exhibit fire protection, rain water and water treatment tanks on Stand 2092 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from october 30-November 1, 2012. The company says that over the past 20 years it has progressively improved its tanks to ensure they suit different mining industry applications and it now supplies tanks to some of Australia’s biggest and most remote mining operations. BlueScope Water Tanks’ general manager, Daniel Wyatt, said that while a standard tank held up to five million litres of water, tanks could be customised to a larger size to suit the needs of a mining project. “The tanks are built to withstand the extreme weather conditions that mining sites could experience as well as such factors as limited water supply, poor water quality, heavy vehicle movements and mine blasting,” Wyatt said. “our staff will be on hand at GME to assist organisations to decide which tank best suits a project site according to environmental, weather and water conditions.” The tanks are manufactured in Australia using 100% Australian-made steel and are available in the 20 standard BlueScope Colorbond steel colours. BlueScope Water Tanks is a preferred supplier for key resource industry players, including BHp, Rio Tinto, Fortescue Metals Group and Chevron. It is currently providing 23 one-mega litre tanks for Chevron’s Wheatstone project in WA. Wyatt said cutting-edge processes and stringent quality control procedures ensured all BlueScope Water Tank products are efficiently designed, produced, delivered and assembled. “All our products meet required Australian and American Standards and are independently verified by consulting engineers,” he said. “Great focus is placed on safety during transport and installation. our installation crews follow strict protocols, guidelines and quality standards and we ensure they meet a site’s safety requirements.” “our tanks are installed at ground level using a jack installation system, which minimises the use of heavy machinery at installation and maximises safety. BlueScope Water Tanks will also display its exclusive range of tank liners, which are designed to ensure high quality drinking water and maximum water storage safety, at GME. The liners are uV stabilised and resistant to mild acids, alkalis and other chemicals. BlueScope Water Tanks, which has offices throughout Australia, is backed by its parent company BlueScope Steel, which has been making steel and supplying steel products in Australia since 1915. • BlueScope Water Tanks Rob Callcott 0407 466 370 rob.callcott@bluescope.com www.hbluescopewater.com.au AM

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AustralianMining

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Raise drilling rigs MacMahon will promote what it describes as “the world’s most powerful” raise drilling machine on Stand 3036 during the Goldfields Mining Expo (GME). The new custom-built RBR 900VF has a continuous operating torque of 900 knm (approximately 670,000 ft-lbs) and a thrust capacity of 22,0000 kn (approximately 5 million lbs) which, the company says, makes it nearly 50 per cent more powerful than any existing raise drill. Macmahon says it can create a shaft with a 6-8 m diameter to a depth of up to 2000 m, depending on ground conditions. It is expected to be operating, either in australia or overseas, before the end of the year. according to the company, the new machine could change the way mines are designed and create new opportunities for Macmahon, both in australia and Can create shafts of 6m in diameter. overseas. The RBR 900VF rig was purchased after Macmahon recorded significant growth in inquiries from operating mines seeking larger diameter, deeper shafts, both in australia and internationally, Greg Miller, Macmahon’s executive general manager underground, said. Machinery currently available across the industry was limited in the load that could be applied to the cutters while still having the torque to rotate the reaming head, Miller said. “adequate weight per cutter (WPc) is required to ensure the efficient formation of chips and this is the fundamental requirement for mechanical excavation by the raise drilling process,” he said. “We needed a machine that could provide the load needed for efficient breaking and the torque to turn the head.” The large German tunnel boring machine manufacturer, herrenknecht aG, was chosen to develop the new machine. Macmahon’s raise drilling operations manager Kim anderson, who has had 40 years of experience in raise drilling, liaised with herrenknecht to develop the specification for the “big rig”. “herrenknecht was an obvious choice to work with in developing the new machine,” anderson said. “They have vast experience in the mechanical excavation of tunnels, coupled with heavy engineering design and manufacturing capability.” • Macmahon Brett Maney 08 9232 1690 bmaney@macmahon.com.au www.macmahon.com.au A D _ A MK A R J U L _ 1 2 . p d f Pa ge 1 2 0 / 0 6 / 1 2 , 9 : 3 2 AM

Environmental services ESI Group will showcase services designed to enhance mining and industrial efficiencies and cost-effectiveness while reducing their environmental impact on Stand 1004. Filtration, refurbishment, regeneration of transformers and transformer oils are among the company’s offerings, which include transformer oil regeneration to improve quality to new oil parameters, online and offline; the supply of regenerated transformer oil according to site needs; collection and recycling through regeneration of waste/old PcB-free transformer oil; vacuum filling of new transformers; vacuum drying of transformers including degassing and removal of particles; the supply and installation of filtration and dry out systems for transformer winding, tap-changer and switchgear; management and transportation of PcB transformer oil and hard waste, including retrofills of contaminated equipment as required; transformer service and maintenance; gasket and bushing replacement; as a supplier of Velcon Filters; education seminars; and SD Myers Transformer maintenance seminars. ESI will have a portable trolley filler, and transformer vacuum and degassing units, both essential tools in transformer maintenance, on display at GME. • ESI Group Rob Teversham 02 6204 0900 rob@esigroup.net www.esigroup.net

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October 2012

AustralianMining

www.miningaustralia.com.au

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Evaporation control

LED Lighting

AquAArmour will show an evaporation and algal control system said to reduce evaporation loss from water storages by 88% and inhibit algal growth on Stand 1005 during the Goldfields mining Expo (GmE). The AquaArmour system, which is manufactured in melbourne, Victoria, has also been shown to reduce water body temperature; inhibit algal growth; suppress wave action; and reduce bank erosion. AquaArmour modules could be deployed to a maximum coverage of 80% of a total water surface area, and is scalable from small to any size storage, Danny De Graaf, Cuts water storage losses by around 88%. AquaArmour’s national sales manager, said. The white, hexagonal modules are manufactured from food-grade, high-density polyethylene (HDPE) and are about 1.2 m wide. Double-sided, they weigh about 3.8 kg when empty. Ballasted with 80 kg of water when in use, they resist wind gusts and sustained winds of up to 200 kph. “Evaporation loss on a country’s potable water supply is enormous and expensive. “In Australia alone, evaporation loss represents about four times the country’s total annual rainfall, and water quality issues such as algae are huge,” De Graaf said. AquaArmour had been independently proven to save 88% of evaporation loss and inhibit algae growth he said. It was also cost-competitive and environmentally friendly as there were no energy requirements once deployed, unlike desalination and wastewater recycling, De Graaf said. “For example, just 1 hectare of AquaArmour deployed in WA will, dependent on the location, save between 37 and 58 megalitres a year for the next 20 years with no ongoing energy costs or infrastructure requirements,” he said. The modules are free-floating, self-tessellating and can be boomed or corralled if required. De Graaf said installation was simple and maintenance minimal and the modules did not require cables or tethering in deployment. • AquaArmour Danny De Graaf 03 8530 2000 dannyd@aquaguardiangroup.com www.aquaguardiangroup.com A D _ A MS T A A U G _ 1 2 . p d f Pa ge 1 1 8 / 0 7 / 1 2 , 4 : 1 4 PM

LEDiq, in conjunction with Shen Zhen XLC Technology of China, will display industrial, mining and office LED lighting on Stand 3027 during the Goldfields mining Expo (GmE) at the Kalgoorlie Boulder racecourse from october 30-November 1, 2012. “our aim is to give mining and industrial businesses in the Goldfields the ability to save electricity which means a saving in dollars and a reduced carbon footprint,” Trevor Burleigh who represents the two companies in the region, explained. LED products on show at GmE will include high-bay lights, from 50 W to 200 W producing 13000 lumens, for workshops and sheds; floodlights, from 30 W to 150 W, for general external lighting, mills and open-cut operation; tunnel lights, from 30 W (2520 lm) to 140 W producing 12,600 lumens, for underground lighting; street lighting, from 30 W to 120 W, for mills, car parks and safety lighting; diesel-powered portable floodlights for outdoor operations such as open-cut and drill sites; solar -powered portable floodlights, for outside areas such as open-cut and drill sites; and office lighting, including replacement LED tubes and downlights. XLC Technology will have three engineers at GmE to answer questions and demonstrate products. Visitors to the LEDiq-XLC stand will also be able to learn about LED lighting cost savings. “We have a ‘black box’ that measures the amount of watts (power) your existing lights are burning so bring one of your existing lights for comparison and we will calculate the savings to be made with an equivalent LED light,” Burleigh said. • LEDiQ Lighting Solutions – XLC Technology Trevor Burleigh 0428 711 299 sales@lediq.com.au www.lediq.com.au

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AustralianMining

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Wheel loaders

Slope monitoring radar

CJD Equipment will display a new quarry-sized Volvo wheel loader on Stand 9056 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30-November 1, 2012. CJD’s Steve Gunn said key features of the new Volvo L250G included a Z-bar linkage that provided high breakout force to enable stronger, more powerful digging of hard Includes a Z-bar linkage for higher breakout forces. materials. “With a high lift capacity, fully loaded buckets and other attachments can be elevated to a maximum height while fast hydraulic speeds mean quick-load cycles for faster production,” Gunn said. The L250G also featured load sensing hydraulics, with variable-flow axial piston pumps enabling stronger lift and tilt functions and superior load control, that matched required power and resulted in lower fuel consumption; and the Volvo OptiShift system, which included a torque converter with lock-up and reverse-by, brakes for faster loading cycles and incline climbing performance, even during deceleration. CJD Equipment is a privately owned Australian company, established in 1974. Its 16 facilities across Australia include a Kalgoorlie branch. The company is a national distributor of Volvo and SDLG construction equipment and has been an exclusive Volvo construction equipment dealer for the past 10 years. • CJD Equipment Steve Gunn 08 9277 0111 sgunn@cjd.com.au www.cjd.com.au

Specialist bearings COOpER Split Bearings and Kaydon Bearings will highlight its increased range of specialist bearings on Stand 1086. Key applications include material handling conveyors, ventilation shaft and air movement fans, crushing and milling, hauling and winding, stockpile and surge pile management, screening, sizing and washing. “Cooper Split Bearings is the global leader in split-to-shaft bearing technology, which is designed to save massive amounts of time and money by reducing downtime and increasing productivity,” Cooper’s Stuart Goates said. “The split feature means maintenance and replacement is cut to a minimum while the superior sealing promotes longer bearing life. As a result, business profitability is increased.” Goates said Kaydon Bearings had been a leading US manufacturer of slew ring bearings for more than 60 years, with its slew ring bearings ranging in size from 10 cm to more than 6 m in diameter. Kaydon specialises in mining and heavy machinery applications such as mining shovels, excavators, reclaimers, stackers, port ship loader cranes, forestry equipment and aerial platforms. • Cooper Bearings Group Stuart Goates 08 9397 9990 sgoates@kaydon.com www.cooperbearings.com www.kaydonbearings.com A D _ A ML O C J U L _ 1 2 . p d f Pa ge 1 1 5 / 0 6 / 1 2 , 1 0 : 0 4 AM

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IDS Australasia will display its radar for monitoring slope displacement in mines at Stand 9152 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30-November 1, 2012. IBIS-FM slope monitoring radar is designed to monitor mine wall displacement 24/7 with sub-millimetric accuracy at distances up to 4 km; provide reliable early warning for progressive slope displacement that could potentially lead to mine wall failure; and map the long-term evolution of slowmoving slopes. IBIS-FM technology uses Synthetic Aperture Radar (SAR) techniques, assists with the risk assessment for worker safety and helps optimise mine operation productivity, pieter van Jaarsveld, CEO of IDS Australasia, said. “In particular, SAR has revolutionised the sampling process and has overcome the limitations of traditional technology by providing higher spatial resolution, longer monitoring distances and faster sampling rates,” van Jaarsveld added. Consequently, he said, production delays due to slope instability were better managed by the availability of accurate data that the SAR system provided. The IBIS-FM system had few moving parts, van Jaarsveld continued. “The small horn antennas are not affected by wind and produce a wide radar beam, illuminating the entire monitored area repeatedly during a single acquisition sequence lasting a few minutes.” The monitored scenario is sampled 400 times from slightly different angles in just a few minutes, drastically reducing traditional acquisition-sampling times. Another feature of IBIS-FM was that it used a processing algorithm for “automatic” atmospheric correction, he said. “Atmospherics can be interpreted as false displacement, but the algorithm used by IBIS-FM is based on the permanent Scatterer technique developed for satellite monitoring applications.” This meant the system’s atmospheric correction was an automatic process and did not require the user to manually select reference points. It also enabled monitoring at distances of up to 4000m, out of blasting zones. IDS Australasia has offices in Brisbane and perth, with its principal head office in pisa, Italy. IDS specialises in the design and production of ground-penetrating and interferometry radar products. IDS have subsidiaries in the UK, Canada and Brazil. • IDS Australasia Melinda Burdon 07 3205 5524 melinda@idsaustralasia.com www.idsaustralasia.com

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Density gauges Realtime Group will release a new digital density gauge with an iPad interface for measuring slurries and liquids on Stand 3068 at Gme. the DD-1000 gauge features fully digital operation, automatic gain stabilisation, low source activity and iP67 stainless steel construction. a new wristwatch dosimeter/radiation monitor will also be featured on the Realtime Group’s stand. among other products on display will be its moistscan – microwave moisture analyser for bulk materials such as iron ore and bauxite; the allscan – Prompt Gamma Neutron elemental analyser (PGNa); conveyor belt scales; tramp metal detectors; and radiation survey monitors. Fully digital density measuring. established in mackay, Queensland, in 1992, as a coalmine service company, Realtime Group also has an office in Belmont, Wa. as well as installation, commissioning, calibration and maintenance of all products supplied, the company says it is the largest industrial radiation service provider in australia. these services include site audits for regulatory compliance, radiation protection and emergency response planning, radioactive source supply and disposal, radiation survey monitor calibration, and environmental monitoring of Naturally Occurring Radioactive material (NORm). it also operates an accredited Nata laboratory for analyses of radioactive material in soil, water and other samples. • Realtime Group Will Robinson 08 9475 0099 willem.robinson@radiationsafety.com.au www.realtimegrp.com

Mine welding SmeNcO will show a new mma (manual metal arc) welder, designed for safe welding in mines and other confined spaces, on Stand 2022 during the Goldfields mining expo (Gme). the 4.7 kg Fronius tP125VRD-10 mine-Spec has 125 amp output with a maximum effective supply current |1eff =10a and a welding current range of between 10-125a. anthony england, Smenco’s managing director, said the mma Voltage Reduction Device (VRD) exceeded the latest australian requirements for safe welding in mines. He said that, to Designed for mine safe welding. his knowledge, the tP125RD-10 was the only available VRD machine to meet the latest mine safety specifications. “We have worked hard to ensure our machines lead the field in aspects like ‘Fail to Safe’, 10amp maximum effective current supply, HiVis cables and braided cables.” For example, england said, australian standards addressed the safety critical aspect of open circuit voltage (OcV) by demanding a maximum of 35V OcV at the electrode when a mma VRD machine was not welding. “the Fronius tP125-10 VRD is12V; three times lower than the standard. and the software that controls the machine is designed to put the machine in fault mode if the VRD is not working, hence the tP125VRD-10 mine-Spec machine is deemed to be ‘Fail to Safe’,” england said. Operator fatigue was also reduced because there was no need to continually hold down buttons during welding while the braided heavy-duty input power cable gave extra strength and protection, he stated. Other key features include that fact it is generator compatible (min 8KVa); iP23 rated for wet areas; has a thermostatically controlled fan; is ce and c-tick approved; has an ant- stick electrode function; meets aS6097/aS1674.2-2007 standards; and features arc force dynamic functions. • Smenco Dave Smith 03 9466 4060 dave@smenco.com.au www.smenco.com.au A D _ A M WA D S E P _ 1 2 . p d f Pa ge 1 2 2 / 0 8 / 1 2 , 1 0 : 0 6 AM

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Drill core trays StRatcO will promote its core trays, in plastic as well as steel, for drill core storage on Stand 1014 during the Goldfields mining expo (Gme) at the Kalgoorlie Boulder Racecourse. the company, which has been supplying steel products to the mining and general building industries for more than 60 years, has recently released the australian-made Orebox plastic core tray. manufactured from injection-moulded, UV-resistant polypropylene, the Orebox is said to be corrosion proof and ensures there is no cross contamination of stored ore. the Orebox is available in B, N, H and P sizes, measures 1000 mm x 385 mm and has interlocking lugs at each corner for efficient stacking and packing. Stratco’s steel core tray, also in B, N, H and P sizes holds a full metre of core in each core compartment along with the Orebox. it is designed for optimal safety and utility, the company says. Stratco, one of australia’s largest suppliers of high-quality steel products, services the Wa mining industry from canning Vale. it engineers, manufactures and supplies roofing and walling, rainwater goods, steel building frame, structural steel, aluminium steps, verandas and patios, fencing, rainwater tanks, and solar power and heating systems. the company also operates a network of home improvement stores in Wa with Kalgoorlie in the centre and stretching from Busselton in the south of the state to Broome in the north. the company is committed to producing high quality, reliable products, innovative research and development and customer service. • Stratco Angelo Tiboldo 1300 185 185 angelo.tiboldo@stratco.com.au www.stratco.com.au

www.miningaustralia.com.au

AD_AMVERAPR_11.pdf

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THIS IS WHERE THE NAME ON THE MACHINE MATTERS MOST.

ALTERNATIVE TO DRILLING AND BLASTING PRIMARY CRUSH NOT REQUIRED CUT SQUARE CORNERS AND VERTICAL WALLS SELECTIVE MINING AND BETTER GRADE CONTROL INCREASE PRODUCTION WITHOUT THE NEED FOR PERMANENT INFRASTRUCTURE QUICK START UP IN GREENFIELD PROJECTS SUITABLE FOR SITE PREPARATION AND ACCESS ROADS PATENTED TECHNOLOGY THE IDEAL IDEAAL SO SOLUTION OLUTTION FFOR OR SSURFACE URFACE M MINING INING AAND ND M MORE. ORE. We know the cconditions ondiitions yyou ou fface ace ar are re ddemanding emanding - tthat’s hat’ss wh why hy w wee m make akke su sure ure oour ur Whether equipment q p is upp to the ttask. ask. W hethher yyou’re ou’rre ffacing acing tthe he hhassles asslles ooff bblasting lastingg oorr hhammering, ammering, g solution which helps you get Vermeer has the nneighbourhood-friendly eighbourrhood-fri i end d l y s o l u t i o n w h i ch h help p s y o u g e t more value from yyour ouur mine. A Vermeer Terrain Terraain Leveler® su surface urface eexcavation xcavation machine cuts bback ack tthe he ooperating pperatingg hours, investment support equipment. whilst reducingg your y investm ment iinn ccostly ostlyy sup pppport eq quipment. SSoo when it’s tough g ggoingg out there, look to Vermeer - the trusted name for pproven equipment q p and reliable support. For more information, please contact your nearest Vermeer Dealership.

QLD/NSW/VIC/SA QLD/ D/NSW/VIC/SA 1800 620 720 www.vermeer.com.au w ww.vermeer.com.au WA/NT 1800 195 558 www.vermeerwa.com.au

AM.OCT12.PG104.pdf

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PREVIEW

Planetary gear units

Water treatment

SEW-EURODRIVE will feature its P-Series of industrial planetary gear units on Stand 1052 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30-November 1, 2012. The P-Series, designed for applications where low speeds and high torques are required, is now available in 11 sizes and covers rated torques from 24 to 500 kNm. SEW-EURODRIVE says the units are designed so the gear motor is mounted directly in front of the planetary gear unit, eliminating the need for couplings, intermediate Designed for low speed, high flanges and adapter flanges, which saves space and reduces costs. torque applications. SEW-EURODRIVE will also show its locally-assembled X-Series range of helical and bevel-helical gear units that cover a torque range of 6.8 to 475 kNm. The X-Series is designed for heavy-duty applications such as mining conveyors, bucket elevators, crushers, mixers, agitators and shipping cranes. “SEW-EURODRIVE industrial gear units have superb power, quality and are sturdy,” Wayne Martin, the company’s WA sales manager, said. In addition, their modular concept enabled a high degree of customisation. “People don’t just want products, they want complete solutions. “SEW-EURODRIVE offers complete customer service from initial quote enquiry to commissioning and installation advice to support for the life of the product,” Martin said. Established in 1931 and headquartered in Germany, SEW-EURODRIVE’s Australian division was established in 1982. It is based in Melbourne with offices in Perth, Adelaide, Sydney, Brisbane and Townsville. The company’s products are used in both surface and underground mining. “Our new heavy industrial solutions division in Melbourne, measuring 10,000 square metres, is being fitted out to assemble and service the largest drives in Australasia,” Martin said. “This investment enables us to increase local assembly, holding and servicing of products, allowing our customers to become productive much quicker than previous times.” The state-of-the-art fit out of the facility includes cranes capable of handling 50 tonne loads and a storage capacity in excess of 3000 pallets. • SEW-EURODRIVE www.sew-eurodrive.com.au A D _ A MA D A 2 O C T _ 1 2 . p d f Pa ge 1 1 4 / 0 9 / 1 2 , 3 : 3 5

AMIAD Water Systems will feature filtration and water treatment systems along with automatic control valves and air valves for the mining industry on Stand 3023 during GME.Amiad designs and project manages filtration systems that include manual and automatic filtration, deep bed media filtration and self-cleaning cartridge filters. “No matter the quality of water, we are able to offer a cost-effective solution and effective and timely project execution,” Jamie Pickford, Amiad’s WA state manager said. “We are committed to clear and appropriate solutions for specific and varied requirements involving water.” Amiad will also use GME to showcase Dorot hydraulic valves, which it has been supplying to the Australian mining market for more than 30 years. Assembled in WA, these can be internally Corro-coated for aggressive water applications and are available in 20 mm to 750 mm sizes. “They are a simple, reliable valve for sustaining, relieving and reducing pressure and for flow control and we have vast knowledge and experience in this area,” Pickford said. Another feature of Amiad’s GME stand will be ARI air valves. “Often overlooked as a necessity on pipelines, air valves provide a safe and effective method of removing air during pipe filling, normal operation and pipe draining,” Pickford said. “Without the use of air valves, pipe collapses and bursts and wasted energy use can all impede dewatering and fluid transfer operations.” The ARI air valve range, which has more than 45 models, was designed for low pressure, surge prevention, raw water and aggressive fluids applications, Pickford said. “Today, much of the water handled in dewatering situations contains suspended solids or the fluid itself is aggressive or hyper-saline. “ARI’s rolling seal technology, inert plastic components and especially designed bodies prevent the suspended solids and aggressive fluids from coming into contact with the sealing mechanism and eliminate the risk of leakage to the environment.” • Amiad Water Systems 08 9303 2222 www.amiad.com.au

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Refuge chambers

Speciality steel

Strata Products will showcase emergency mine refuge chambers on Stand 1106 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse. The company says it has models to suit most mines, including hard-rock mines, as well as coal and lowseam operations – and can provide many examples worldwide where its refuge rooms have saved lives. “A well-performing chamber that provides immediate Built for both coal and hard rock mines. protection and breathable air can be imperative to the safety of miners if an accident happens,” Strata’s Tony Farrugia said. He said Strata’s chambers could be operated long-term with a connection to underground compressed air and power sources, or for 72 hours in stand-alone mode with protection provided by on-board backup power, oxygen generation and active toxic gas removal systems. Simplicity was an important design element, Farrugia said. Strata’s chambers include features such as toxic gas removal, oxygen generating systems, food, water supplies, first aid kits, toilet facilities and air-lock entrance compartments. Models for coalmines are designed to be moved easily into underground locations and incorporate a steel walk-in, inflatable fresh air bay, powerless operation and explosion-resistant construction. AC or DC powered air-cooling systems and dehumidifiers are also included. They are also equipped with on-board breathable air and a carbon dioxide scrubber for removing CO2 and replenishing oxygen levels. Models for hard rock mining applications include a steel walk-in chamber that accommodates eight to 30 individuals and has toxic gas scrubbing systems. The Strata range also includes portable four, six and eight-person Airdoc refuge chambers for underground situations where miners are working in a blind cutting or dead heading and may not be able to access a normal refuge station when exposed to a danger such as a vehicle fire. • Strata Products Tony Farrugia tfarrugia@strataproducts.com.au www.strataworldwide.com/australia A D _ A MB R E MA R _ 1 2 . p d f Pa ge 1 1 7 / 0 2 / 1 2 , 1 2 : 1 1

Bohler Uddeholm Australia will promote high-performance steels for Australia’s mining industry on Stand 1070 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30-November 1, 2012. The company’s High Performance Steels are designed to reduce breakages, wear, corrosion, fatigue and downtime while increasing production. Typical mining industry applications include Plant Equipment. Underground Drilling.Mining Wear Parts. “To meet the needs and demands of Australia’s mining industry, Bohler Uddeholm focuses on offering High-Performance Steels that deliver Optimum results in the mining and engineering fields,” Gary Hill, the company’s national components manager (Mining), said. “Australia’s harsh working environment subjects all mining equipment to extensive wear and tear.” Gary said this meant maintenance costs represented a large part of all companies’ expenditure and a high proportion of these could be reduced using Bohler Uddeholm steels. “Using high performance metals in lieu of traditional alloy steels will give maximum performance in the harshest operating conditions,” Bohler Uddeholm was established in 1991 with the merger of Austrian company Bohler, and Swedish company, Uddeholm. Bohler Edelstahl describes itself as one of the world’s top producers of High-Performance Steels, High-Speed Steels and Special materials, producing bar, round and flat steels as well as wire. Electro Slag Remelting (ESR), Vacuum Art Remelting (VAR) and Vacuum Induction Melting (VIM) can be used in its production processes. Uddeholm is said to be the world’s leading manufacturer of steel for industrial components. Bohler Uddeholm’s Australian operations are in WA (Canningvale and Welshpool) and further branches in Melbourne, Wollongong, Newcastle, Brisbane, Launceston and Townsville • Bohler Uddeholm Australia Gary Hill 08 9455 8673 www.buau.com.au

No two conveyors are the same. At Brevini Australia, we have tailored-solutions based on our unique PIV Drives. With efﬁciencies at up to 97%, these compact drives are easy to install and align in very restricted spaces. We also design and manufacture take-up winches to provide the tension requirements unique to each conveyor. Our Engineering Department has experience and capability to design to your speciﬁc needs. And, our Brevini Service is there 24/7 to see to your maintenance and parts requirements. Your investment in Brevini equipment is a long term proposition, with big returns for your peace of mind. Call us NOW to discuss your needs.

Brevini Planetary Samhydraulik VPS Brevini Brevini Winches

www.miningaustralia.com.au

Brevini Hydraulics Aron Hydrapp Pullmaster

PIV Bevel Helical Emmegi PT Tech PIV Posiplan

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Underground concrete agitator CPe machinery will showcase a new concrete mixer for use in underground mines on Stand 2011 during the Goldfields mining expo (Gme) at the Kalgoorlie Boulder Provides high temperature cleaning for mining equipment. Racecourse from october 30-November 1, 2012. the Putzmeister mixKret4 is described as a compact concrete agitator that offers great manoeuvrability through small galleries and tunnels, perfect concrete mixing, and quick and effective discharging. It has a six cylinder, 130 kW diesel engine. CPe, which supplies and maintains specialist machinery for mining, tunnelling and construction the Pilbara Clean machines (tPCm) will promote its cleaning services for earthmoving applications, will also use Gme to promote Schopf-mining underground mining loaders. equipment and mine sites on Stand 9112 during the Goldfields mining expo (Gme) at the “Schopf’s LHDs are suitable for heavy-duty underground hard rock mining applications Kalgoorlie Boulder Racecourse from october 30-November 1, 2012. these include highand are characterised by a simple technical design for low acquisition, operating, pressure, high-temperature cleaning for structural inspections, maintenance and repairs; maintenance and repair costs,” David Bond of CPe said. high-pressure, high-temperature cleaning of bulk hydrocarbon storage areas; workshop esser-Werke twin pipes will be another feature of CPe’s Gme stand. and wash pad cleaning; mine site clean-up work; clean-up of hose reel and bulk oil transfer the twin and single wall paste and slurry conveying pipes and fittings are highly areas; and equipment and component cleaning. the PCm, which has offices in Perth and the wear-resistant and enable users to achieve an optimal result in the price-performance Pilbara, also undertakes cabin and vehicle detailing. It offers short-term mobile units and hire relationship, Bond said. International representatives of Putzmeister, Schopf and esser equipment as well as long-term site-based labour hire and equipment. will join CPe’s proprietor David Bond on Stand 2011 at Gme. “As a service provider to the mining and resource sector, we understand the needs, restraints CPe will also show ChemGrout grouting equipment for tunnel lining, contact grouting, and targets of our customers,” Darren Waters, tPCm’s director said. “our Safety management shaft waterproofing, rock bolts, cable anchors and bore hole abandonment at Gme. System complies and often exceeds expectations from major mining companies requirements. ChemGrout equipment is designed to handle a diverse range of materials and capacities our late-model equipment is specially designed and engineered to provide great results in from 4 to 280 lit/min and pressures from 350 to 13, 500 kPa. the safest environment and our professional teams are the best in the business with safety CPe, which was established more than 30 years ago, supplies and maintains specialist as their top priority,” Waters said. An in-house training program is provided to all employees, machinery for mining, tunnelling and construction applications. other brands represented whether site-based or mobile, with on-going support, he said. in Australia include trelleborg concrete delivery hoses, Allentown and Sika-Aliva • The Pilbara Clean Machines shotcrete equipment. Darren Waters • CPE Machinery 0417 941 066 David Bond darren@miningequipmentwash.com.au 1800 307 115 www.miningequipmentwash.com.au david@cpemachinery.com.au www.cpemachinery.com.au A MH OO LL I IO M CA TR _ _ 1 1 2 0 . .p p dd f f PP a a gg e e 1 1 2 8 4 / 2 0 /9 1 / 0 1 ,2 , 1 0 3 : 2 3 7 A PM AD_ L

Machinery cleaning

Remote control mining Remote Control technologies will be celebrating its 40th year at the Goldfields mining and engineering exhibition (Gme) in Kalgoorlie-Boulder in october. originating in the town itself, RCt will have Precise machinery control. on show its latest products and offerings, including surface Control Station for Underground mining, and its semi-Automated Guidance with more than 40 systems operating in the Australian and international market. New software enhancements have also enabled users of Remote Control technologies’ Control master Guidance System to step up a gear with mining equipment fitted with the technology. the company, meanwhile, is accelerating deployment of Control master Guidance System’s in offshore markets. the latter effort is currently aimed mainly at Africa, with RCt having recently opened an office in Johannesburg, South Africa. However, the company has also reported good results from initial installations in Indonesia and is working to open up other markets. RCt national sales and marketing manager (Australia-Asia) Craig Buchanan said that the development of the V2 software upgrade for Control master Guidance System was in line with the company’s ongoing commitment to improve the product to optimise productivity. “We’ve seen enhanced [underground load-haul-dump vehicle] speed and cornering, allowing the machine to get into higher gears faster,” he said. “Speed around a 90-degree corner can be as much as 5km per hour faster – though this is always dependent on the size of the drive.” RCt has upgraded at least a dozen existing Systems and is fitting all new Guidance Systems with the V2 software. • Remote Control Technologies www.rct.net.au

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// B E C A U S E Y O U D O N ’ T D O T H I N G S B Y H A LV E S

Hitachi AC Drive dump trucks. Built to match Hitachi excavators. Our trucks and excavators are brothers. They’re designed by the same engineers, assembled in the same factories, and built to the same quality. If you’re running a Hitachi excavator, then you’ve already experienced half of the Hitachi advantage. Now it’s time to see what a fleet can do.

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Tyre protection

Friction lining

RUD Chains Australia will showcase its latest innovations in tyre protection chains and lifting chains and components on Stand 9164 during the Goldfields Mining Expo (GME) at the Kalgoorlie Boulder Racecourse from October 30-November 1, 2012. The display will incorporate recently patented additions to the company’s lifting and lashing range. Heavy duty machinery protection. Heading the stand will be RUD’s ABA weld-on pad-eye lifting device that offers between 1.6 tonnes and 31.5 tonnes full Working Load Limit (WLL) in all lifting directions. RUD’s lifting and lashing product manager, Stuart Nolan, says this device also has a number of significant safety features and has been in high demand since its release. RUD will also use GME to promote its ICE 120 6 mm to 16 mm chain range, which offers an increase of up to 60% in WLL, compared with the same size Grade 80 chain. “This means higher WLL in lifting and lashing can be achieved with a much smaller and lighter chain, providing important cost and safety advantages,” Nolan said. RUD will also feature its TORO tyre protection chain at GME. Designed for underground loaders with low-profile tyres, the chain had proven to provide exceptional wear protection for tyres in hostile underground environments. Established in 1984, RUD Chains Australia is a subsidiary of the family owned and German-based RUD Chains, founded in 1875. • RUD Chains Australia 07 3712 8000 info@rud.com.au www.rud.com.au A D _ A MQ U I 2 O C T _ 1 2 . p d f Pa ge 1 1 4 / 0 9 / 1 2 ,

FRICTION Innovations will showcase brake, transmission and other friction discs lined with the world’s most advanced friction lining for surface and underground mining vehicles at Stand 3033 during the Goldfields Mining Expo (GME). The Melbourne-based company supplies brake, clutch and transmission plates lined with 100% Kevlar fibred textile polyimide composite friction lining manufactured by US high technology company Tribco, Inc. “Tribco’s innovative friction linings, called Braketex and Clutchtex, last three to five times longer than traditional linings. They are suitable for both wet and dry mining friction applications such as clutches, power transmissions, PTOs, torque converters, synchronisers and off-road brakes,” Friction Innovations’ Chris Ford said. Ford went on to say the linings do not contain heat sensitive ingredients such as cotton or cellulose. “This means they can take heavier loads and withstand higher temperatures and pressures to deliver increased torque, improve vehicle performance and reduce vehicle downtime.” Additionally, they are totally non-abrasive and will not wear down metal mating surfaces. “This allows flywheels, rotors, drums and metal separators to last much longer. They also keep oil cleaner and are ethylene glycol resistant.” Braketex and Clutchtex wet friction discs have been performance proven in some of the world’s harshest environments, Ford said. Here in Australia there are many Tribco wet and dry friction discs in use, helping to solve brake, clutch and transmission problems by directly replacing OEM paper, sintered bronze, graphite, elastomeric and other conventional linings.” Ford said Friction Innovations keeps a well-stocked inventory of Braketex and Clutchtex wet friction discs that suited the wheel ends, torque converters and transmission rebuilds of surface and underground mining equipment. “This allows us to provide same-day shipping for many critical friction discs. At GME we will show how well Tribco’s 100% Kevlar fibred discs perform and ask you to consider trialling them in demanding applications so you can experience and evaluate their performance.” • Friction Innovations Chris Ford cbford@frictioninnovations.com www.frictioninnovations.com 2 : 0 1 PM

DESIGN | CONSTRUCT | INSTALL Mining and Natural Resource Sectors Modular Building Design, Construction and Installation Services

Sales: 04 2420 8374 P: 02 6654 0974 F: 02 6654 8246 abn: 59158323883 E: sales@quickspec.com.au W: quickspecmodular.com.au

QLD | NSW | VIC | SA | NT 108

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PRODUCT SHOWCASE

High capacity scalper Can process materials up to 6 inches in diameter.

VSI crusher CEMCO has released a new crusher that has the ability to process materials up to 6-inches in diameter. Dubbed the Turbo 128 V-Twin VSI Crusher it is among the largest models in CEMCO, Inc.’s complete line of vertical shaft impact crushers. The crusher is ideally-suited for the production of 1½-inch aggregate rock. Additionally, the Turbo 128 is fully customisable to enable production of several types of aggregate materials. Driven by a dual-drive, optimally-balanced V-Twin motor design, it is available with more than 600 kW of power, weighs approximately19 tonnes and offers production capabilities up to 1,000 TPH. It features heavy-duty selfaligning spherical roller bearings, allowing it to handle dynamic loads up to 366,000-pounds. It comes equipped with a Shoe Table rotor and Anvil Ring. A Rockshelf anvil is available for the processing of medium to low-abrasion material. It is equipped with a hydraulic lid lifter for regular inspection and maintenance. • CEMCO www.cemcoturbo.com 2 6 0 3 4 4 Mi n i 1 2 2 5 7 1 1 5 6 . p d f

IROCK, has released the new TS-516 High Capacity Scalper. The highly durable tracked scalper improves productivity in a range of applications with greater hopper capacity, larger screens and a wider, oversize conveyor. The company designed the TS-516 to be used in a primary crusher circuit for materials such as construction and demolition waste, iron ore, aggregates, coal, recycling and heavy rock. The machine can also handle sticky clay and topsoil. It is powered by a 96kW Caterpillar C4.4 engine and is capable of processing materials at rates of up to 570 TPH. The equipment can be folded and loaded onto a truck or trailer for transportation. As the largest tracked screener in its size class, the TS-516 also has the greatest hopper capacity. The equipment also increases production capacity with a total of 14.6 square metres of screening area having a 4.88 metre by 1.5 metre top deck and a 4.7 metre by 1.5 metre bottom deck. This design allows users to produce and sort products in up to three different sizes, and the decks can be interchanged so customers have more control over end product size. In addition, to accommodate the high productivity of the rest of the machine, the TS-516 also features a 160 centimetre oversize conveyor. With a width that improves on the nearest competitor’s scalper by 38 centimetres, the conveyor accommodates higher tonnages and alleviates much of the potential for congestion. • IROCK www.irockcrushers.com Pa ge 1 1 3 / 0 9 / 1 2 , 1 1 : 4 9 : 2 6

Can drive stepper motors and rotary servos.

Position control OMRON Electronics has releases the CJ1W-NC4 series of position control modules, for their CJ1 and CJ2 PLC platforms. The CJ1W-NC4 series are fourth generation and can produce output pulses at up to 4Mbps, for high speed, high resolution position control. Each CJ1W NC4 cards can control two or four axes, using either line driver or open collector output. The axes can be co-ordinated for a linear or circular interpolated output. They can drive not only stepper motors and rotary servos but also linear drives and even direct drive motors. The CJ1W-NC4 cards include advanced features such as fully closed loop control, where absolute and incremental encoder signals are fed back directly into the controller card. • Omron Electronics 1300 766 766 www.omron.com.au AM AEST

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Justin Di Lollo Managing Director Hawker Britton

Ben Ali Vice President – Finance Santos

Register before 26 October and save up to $410 with early bird discounts. Find out more and register at cpaaustralia.com.au/miningandenergy

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PRODUCT SHOWCASE

Certified diesel packs

Off road trucks Lusty EMs has released a new vehicle for the industry – an OffRoad side tipper. With a 180 tonne carrying capacity, the new tipper is designed for off-road use, making it perfect for operations carrying heavy loads The off road side tippers are customisable. across large sites, such as coal and iron ore mines. Lusty EMs general manager, Andrew Wibberley, stated that the Off-Road side tipper is designed specifically with the resources sector in mind. “We have had an increasing number of requests for a high mass-carrying capacity and durable tipper,” Wibberley said. A Hardox steel tub is supported by heavy duty spring suspensions across each axle, and has mine-spec lights and polyurethane 2 pack paint. It is also highly customisable. “From a single trailer up to C-triple configuration, the inherent ability to run these trailers off-road means we’re able to bypass many of the usual road authority restrictions,” he said. “the tubs can also be built to differing heights, dependent on the density of the load. “so if you’re carrying a relatively light load, the tub can be as much as 3m high, but for denser loads, you may only require the tub to be 1m high, both of which are possible with this new trailer.” • Lusty EMS www.lustyems.com.au A D _ A MC H E 1 O C T _ 1 2 . p d f Pa ge 1 1 4 / 0 9 / 1 2 ,

POLyMAstER has released new diesel ute packs certified for use on mines. Certified for mine conditions. According to the company these packs are fully compliant to the Worksafe Packing Group 3 standard. these new Certified Diesel ute-packs are designed for the mine environment, and provide safe operation in demanding refuelling duties. this range has been extensively tested and approved to the uN specification for the transport of Dangerous Goods and Worksafe Packing Group 3 standards. testing methods included the tanks being drop tested from various heights while frozen to minus 20 degrees Celsius. According to the company these units replace old methods of refueling such as using 40 gallon drums or other unsafe plastic containers. the drums feature certified diesel-grade cross linked polyethylene – ensuring no leaching of diesel; four metres of hose and battery leads; a steel filling plate and cap; fully enclosed lockable lid; heavy duty swivel fittings; and a brass y strainer – to prevent any sediments from getting into pumps. the Bulk Diesel range of Cartage tanks is also available with capacities of up to 3000 litres. these tanks incorporate moulded internal baffles for vehicle stability and pin mounts to ensure easy attachment to vehicle or trailer chassis. the trailerised units include a fully galvanised single or tandem axle trailer complete with jockey wheel, hydraulic or electric brakes, LED lights and toolbox. • Polymaster www.industrial.polymaster.com.au 2 : 4 8 PM

performance when it counts Exhaust Conditioners - Controlling Diesel Fume me Pollution The World Health Organisation recently classed diesel fumes as “carcinogenic”. Protect your workers and the environment ment with a Chess Exhaust Conditioner. Key Features: s s s s s s

Allows prolonged underground work Made to suit all applications Heavy duty Stainless Steel construction Available fully installed or in kit form Low maintenance Quick delivery

For further information:

Laurie Davis - Chess Engineering l.davis@chessindustries.com.au

+61 2 9772 2355 101 Fairford Rd Padstow, NSW 2211, AUSTRALIA www.chessindustries.com.au www.miningaustralia.com.au

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Slider beds SpillaGE can be a common occurrence in load zones because of the nature of material transfer. now available from Flexco is the new range of EZ Slider Beds. Manufactured and assembled in australia, the Slider Beds are engineered to provide containment around load zones while minimising drag on the conveyor belt. EZ Slider Beds feature hard-wearing Coretech rolls and long-lasting UhMW slider bars. the UhMW slider bars effectively seal the load zones, when combined with Flexco skirting systems. Coretech nylon rolls reduce drag on the conveyor belt. Slider Bars are easy to service, with troughs lowered for access to the bars and bolts. the EZ Slider Beds can be set at three troughing angles: 20˚, 35˚ and 45˚ and can accommodate belts from 600 to 1800 mm in width that will work with belt speeds of up to 5 m/sec and will take impact energy of up to 25kg-m. With these Slider Beds users can seal load zones in both impact and non-impact areas. • Flexco www.flexco.com

Designed to be mine site dust proof.

Fighting fatigue Marathon Group has created new specialised fatigue huts for miners who may otherwise face workplace oh&S problems due to inadequate rest. Customisable in size, the fatigue huts are made of welded steel and provided with retractable lifting lugs on the base for easy pickup, transport and on-site manoeuvrability with a forklift or crane. Each fatigue hut is fitted with closed-circuit tV monitored corridors and filtered fresh air in constant supply. these strong units are made for a long lifespan in harsh conditions and include UV-resistant paint. While mine and construction sites have for a very long time had no choice except single rooms, simple site sheds or very basic tin sheds as rest options, these fatigue huts each have five individualised and self-contained rooms with 250mm thick walls and floors. all floors, walls and ceilings are insulated against noise and temperature; with regard to noise, they are designed and constructed with sound barriers so as to blot out any sound made by trucks or heavy vehicles passing by. they are also dust proof. • Marathon Group www.mgpl.com.au A D _ A MA U S O C T _ 1 2 . p d f Pa ge

Work at speeds of up to 5m/sec.

Carbon emission measurement

SiCK has developed new control systems to accurately measure carbon emissions in real time. according to the company its new in-situ GhG Control system “delivers accurate Co2 and n2o values directly from the exhaust ducts in real time”. this means companies do “not pay more for emissions than necessary”. it provides an exact numerical basis by measuring using actual process conditions in wet exhaust gas. Conventional methods of sampling and measuring different material flows, complex analyses of coal and ash, as well as discontinuous laboratory analyses are significantly simplified. it consists of the multi-component analyzer GM35, which simultaneously 2captures 4 / 0Co2 9 / and 1 n2o 2 , concentrations, 2 : 0 6 with P Ma highly precise

deviation of ≤ 2%. another incorporated technology is that used in the flow measurement device FloWSiC100, which determines the volume flow. the declared mass flow is determined by an innovative control unit for calculation and output of the measured values. this makes the GhG Control a foundation for reliable monitoring and precise reporting. the GM35 includes the sender and receiver unit and the reflector which are mounted on opposite sides of the exhaust duct. the light beam traverses the entire duct cross-section twice thereby increasing measuring precision. • SICK www.sick.com.au

Specialised Protection… Bearings to containers…

New Ferro Foil™ Australian Inhibitor, a niche market research and development packaging specialist, has introduced onto the Australian market a new VCI (Vapour Corrosion Inhibitor) laminate that combines tough BOPP laminated film to foil with the inclusion of inside VCI actives in low density film, to assist in the prevention of corrosion of metal products either in storage or transshipped overseas. This specialist material can be made into bags of any size, eg 100mm x 100mm up to bags to house aeroplane parts, gun turrets and machinery of any size. Australian Inhibitor is a major supplier to local manufacturing machinery exporters as well as Auto, Military and Mining Companies. Established over 50 years ago, Australian Inhibitor is a world leader in patented award winning designed VCI rigid plastic products, VCI flexible films and related rust preventative products.

Winner of two Australian Packaging Design Awards 2011 GOLD: Packaging for Industry SILVER: Innovation

Now Military Approved

VCI triple layer • Long term storage of machinery • Overseas shipment of specialized CNC machinery Australian Inhibitor successfully launched a new Triple Layer VCI film that combines increased Moisture barrier protection and longer VCI activation to protect ferrous and non ferrous metal items either in storage or shipment. CNC Machinery transshipped overseas has been well proven for many years employing MonoVCI heavy gauge film exporting to many global sites. The new Triple Layer VCI film was tested under Stringent controlled structural fatigue and corrosion monitoring at one of Australia’s largest Defence facilities. VCI Testing was conducted over a 6 year period commencing 2000–2006 with outstanding results leading to the development of this new material specifically to protect for even longer periods. The material combines three layers of specialized polymers with the Inside layer containing the VCI (Vapour corrosion inhibitors). Middle layer containing tough new barrier polymers with the outside printed layer containing U.V. inhibitors to prevent outer film degregation are all part of this new and exciting product development.

Contact Les Amy • Phone: (03) 9768 2322 • Email: enquiries@australianinhibitor.com.au 112

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Global Innovative Solutions, Local Knowledge

Transportation

Automotive Aftermarket

Marine

Appliance and Components

Professional sealants adhesive systems BLA/SAM/0912/SIK

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9th Annual Australian Mining Prospect Awards In this issue we have a brief word from some of the sponsors about their companies and why they choose to sponsor the Prospect Awards. Invensys Rail

Prospect Consulting

Invensys Rail, a division of the global technology group Invensys, is a multinationl leader in delivering state of the art railway control and communication solutiions. We enable the world’s, and mining’s, railways to help meet the ever increasing demand for rail services by providing a range of solutions that safely increase the capacity of their networks by increasing frequency and maximising operational effectiveness. With more than 140 years experience in the industry, we believe rail signalling and control technology lies at the heart of meeting the future demands on transport infrastructure, with our portfolio of systems and products covering every aspect of integrated control and signalling from simple products to complex fully integrated systems. We are a proud sponsor of the Prospect Awards and look forward to congratulating the finalists on the night.

Prospect Consulting provides outstanding Recruitment and Management Consulting services to the resources and energy sectors nationally. Our experience gives us knowledge of the real issues facing organisations, allowing us to focus on developing solutions that are relevant, pragmatic and cost-effective. Whether it has been providing Recruitment Process Outsourcing services to meet bulk recruitment needs, delivering tailored safety programs or implementing a global management operating system on behalf of a client, we are a trusted partner to leading industry players through all phases of the boom and bust cycle. Since 1993 we have been helping organisations maximise their people and business performance. Our approach is simple: performance through people. Prospect Consulting is proud to once again be a sponsor of the Australian Mining Prospect Awards. We are excited to be associated with the Awards and to be able to officially recognise the mining companies and individuals that have shown innovation and superior performance throughout 2012.

ABB ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people. ABB Australia is a proud sponsor of the Prospect Awards. At ABB we aim to support the development of young people throughout our organization globally. These individuals are also making significant contributions and are establishing global benchmarks and helping to drive the future of mining. These awards provide a platform to recognise emerging young talent in the mining sector, who have a passion for what they do. Let’s help them grow and learn by acknowledging, encouraging and supporting their further development. Good luck to each and every nominee!

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Be a leader in Australia’s mining industry and nominate today

www.miningaustralia.com.au

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NOMINATIONS NOW OPEN For close to ten years the Australian Mining Prospect Awards has recognised and celebrated innovation and performance in the industry. Last year close to 400 of the industry’s best gathered to highlight an industry that is excelling amidst a global down turn. And now it plans to gather again to showcase all that mining in Australia can do, and those that are making a difference. Are you?

2012 NOMINATION DEADLINE 7 SEPTEMBER 2012 CATEGORIES • Mine of the Year • Hardrock Mine of the Year • Coal Mine of the Year • Explorer of the Year • Mine Manager of the Year • Contract Miner of the Year • Minerals Processing Plant of the Year • Contribution to Mining

• Employer of Choice • Mining’s Woman of the Year • Young Achiever • Community Interaction • Innovative Mining Solutions • Excellence in Mine OH&S • Excellence in Environmental Management • People’s Choice NEW

DON’T MISS MINING’S NIGHT OF NIGHTS

BE A PART OF IT! Download the nomination kit at www.miningaustralia.com.au/awards

For further information, please contact (02) 9422 2759 or email awards@miningaustralia.com.au