Australian Mining February 2022 by Prime Creative Media

INDUSTRY OUTLOOK KAOLIN SPOTLIGHT VOLUME 114/1 | FEBRUARY 2022

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INDUSTRY OUTLOOK KAOLIN SPOTLIGHT VOLUME 114/1 | FEBRUARY 2022

MINING SERVICES

CRUSHING COSTS

TECHNOLOGY BOOSTS BOTTOM LINE

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COMMENT

IMPORTANCE OF ESG WILL CONTINUE TO GROW THE AUSTRALIAN GOVERNMENT’S AIM OF NET-ZERO EMISSIONS BY 2050 AND THE FALLOUT FROM THE DESTRUCTION OF JUUKAN GORGE IN WESTERN AUSTRALIA HAVE CONTRIBUTED TO A FOCUS ON SOCIAL ISSUES FOR THE MINING SECTOR.

MICHAEL PHILIPPS michael.philipps@primecreative.com.au

nvironmental, social and governance (ESG) were the buzzwords for the mining industry in 2021. For resources companies, expectations of corporate behaviour are changing rapidly. More and more investment capital is being redirected towards responsible entities and the image portrayed to the investing public has become more important than ever. This has seen a rise in production of ESG reports, which keep investors and the public aware of the efforts a company is making to address environmental, social and governance issues. However, in many ways the mining and resources sector is leading the way in social responsibility, especially in terms of environmental impact and on-site safety. In his address to the COP26 Glasgow Climate Summit in Scotland, Minister for Industry, Energy and Emissions Reductions Angus Taylor outlined the ways in which Australia would reduce its emissions using a range of new and future technologies. The technology-driven plan sets out a credible pathway to net zero by 2050, establishing Australia as a leader in lowemissions technologies. Six priority areas for investment were highlighted in the plan – clean hydrogen, energy storage, low carbon materials including green steel and aluminium, carbon capture technology, soil carbon measurement, and ultra-low-cost solar. Last year saw a massive uptake in these investment areas from the mining industry.

CHIEF EXECUTIVE OFFICER JOHN MURPHY PUBLISHER CHRISTINE CLANCY ASSISTANT EDITOR MICHAEL PHILIPPS Email: michael.philipps@primecreative.com.au JOURNALISTS EMILY MURPHY Email: emily.murphy@primecreative.com.au TOM PARKER Email: tom.parker@primecreative.com.au HENRY BALLARD Email: henry.ballard@primecreative.com.au

Aurizon and Anglo American are investigating hydrogen-powered bulk freight trains to create more sustainable supply chains in mining. Fortescue Metals Group will look to roll out its new hydrogen-powered haul truck in the second half of this decade, with the company having commenced testing of the new vehicle. Rio Tinto will be the first to deploy Caterpillar’s 793 zero-emission autonomous haul trucks, once development is complete at the Gudai-Darri iron ore mine in Western Australia. Gudai-Darri will be one of the world’s most technologically advanced mines, with many of the company’s new technologies to be implemented at the site. State governments are also playing their part, with one of the major selling points for mining in Tasmania being its commitment to netzero emissions. Tasmania has been carbon neutral in six of the past seven years thanks to its abundance of forests and an electricity grid run completely on renewable energy since 2020 – mostly hydropower and wind. The combination of increased investment and advances in technology will mean that the mining and resources industry will not only lead Australia in ESG - it also has the potential to lead the world.

Michael Philipps Assistant Editor

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AUSTRALIANMINING

FEBRUARY 2022

FRONT COVER

In this edition of Australian Mining, we include a special focus on the crushing and screening sector, with a series of feature articles profiling key suppliers in this area. This issue puts the spotlight on the iron ore sector with analysis of the junior and mid-tier companies aiming to capitalise on high process for the steelmaking material. We look at Australia’s commitment to net-zero emissions by 2050 and how the industry will take the next step in this direction as technology improves. And as usual, we cover the latest mining equipment and technology in our products section.

Cover image: Flexco.

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IN INTHIS THISISSUE ISSUE

36 20

INDUSTRY OUTLOOK

A look through the crystal ball: Mining in 2022 What transformations might occur across Australia’s mining industry in 2022.

COMMODITY SPOTLIGHT

The allure of halloysite-kaolin The most researched clay mineral in the world

MINING EQUIPMENT

Automated ground support a bolt from the blue Rangecon from conception to commercialisation

FUTURE OF MINING EMISSIONS

Powering towards a sustainable future Mining is leading the way in sustainable practices

50 38

CRUSHING & SCREENING

WASTE MANAGEMENT

MATERIALS HANDLING

Taking belt cleaner maintenance to another level Software that allows customers to monitor belt cleaners anywhere

MINING SERVICES

REGIONAL SPOTLIGHT

The power of collaboration The importance of optimising productivity

50 PROFILE

Workplace culture a focus for Walsh The Weir Group celebrates its 150th anniversary

DIGITAL MINING

WATER MANAGEMENT

Redefining underground water management Solving the world’s most challenging water issues

Digero reduces mining to ash with Inciner8 Disposing of rubbish on site in a responsible way Powering future mine sites Aggreko discusses the growing issue of energy in mining Rio Tinto engages conveyor specialist TS Global’s experience a valued attribute in the partnership The trees aren’t all that’s green in Tasmania The focus is thrown to another of Australia’s quiet achievers

69 TECHNOLOGY

Smarter, safer AI-driven mining fleets Machine learning can play a big role in fleet management

PRODUCT SPOTLIGHT

Gloves by name, gloves by nature Revolutionising the industry and setting a new benchmark for safety

REGULARS 5 COMMENT 8-18 NEWS 72-73 PRODUCTS

74 EVENTS

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NEWS

THE LATEST MINING AND SAFETY NEWS AUSTRALIAN MINING PRESENTS THE LATEST NEWS FROM THE BOARDROOM TO THE MINE AND EVERYWHERE IN BETWEEN. VISIT WWW.AUSTRALIANMINING.COM.AU TO KEEP UP TO DATE WITH WHAT IS HAPPENING. HYDROGEN RAIL ON THE AURIZON FOR ANGLO for its ultra-class 290 tonne haul truck fleet – on Aurizon’s Moura (180 kilometres) and Mount Isa (977 kilometres) rail corridors in Queensland. This technology includes hydrogen fuel cell and battery hybrid power units. The Moura and Mount Isa lines run from Anglo’s Dawson metallurgical coal mine and the Gladstone Port, and the North West Minerals Province to Townsville Port, respectively.

Aurizon and Anglo American are investigating hydrogen-powered bulk freight trains to create more sustainable supply chains in mining. As Australia’s largest rail freight company and one of the country’s largest miners, respectively, the two companies saw mutual benefits in the agreement to reach their decarbonisation goals. A feasibility study will consider using Anglo American’s hydrogen power technology – already in use

WORKING WITH OTHER COMPANIES IS KEY TO ACHIEVING DECARBONISATION GOALS.

Aurizon managing director and chief executive officer Andrew Harding said this was the next step in rail freight technology. “Hydrogen offers enormous opportunity in decarbonising and continuing to improve the competitiveness of Australia’s export supply chains,” Harding said. “This is especially true for bulk products underpinning the Australian economy including minerals, agricultural products and fertilisers, industrials, and general freight.” Rail freight already produces up to 16 times less carbon emissions per tonne per kilometre than road, according to Harding, but Aurizon wants more. “Aurizon is excited to be teaming up with Anglo American on this project, particularly given their success to date in developing unique technology solutions for use in mine haul fleets,” Harding said. Anglo American has publicly stated its goal of making its mining operations carbon neutral by 2040, with Scope 3 emissions to be halved by then. Anglo American chief executive officer in Australia Tyler Mitchelson said working together with other

AUSTRALIAN MINING GETS THE LATEST NEWS EVERY DAY, PROVIDING MINING PROFESSIONALS WITH UP-TOTHE-MINUTE INFORMATION ON SAFETY, NEWS AND TECHNOLOGY FOR THE AUSTRALIAN MINING AND RESOURCES INDUSTRY.

industry leaders would be key to achieving these goals. “We know that we cannot achieve all of this alone, so we are working with partners along our value chains and outside our industry to find technical solutions to decarbonise,” Mitchelson said. “This collaboration with Aurizon is a great example of the power of partnerships to help address the urgent issue of climate change, while we also look to catalyse new markets to support the development and growth of the hydrogen economy,” he said.

COAL PRICES FACE STARK FORECASTS TO 2024: KPMG KPMG has predicted the decline of coal prices towards 2024 with a fall of more than 20 per cent on the horizon for hard coking coal. The multinational advisory released its quarterly coal price and FX market forecasts report for September/October 2021, the first release since the beginning of 2020 to predict a decline in coal prices. The report took a current average price for hard coking coal in the mid-$US180s per tonne. It showed this average price to remain steady in 2022 before diving to $150 in 2023 and into the mid-$140s by 2024.

According to the report, 2025 showed a slight rebound to about $150, however, fewer contributors hazarded a guess at these longerterm forecasts. KPMG fielded the forecasts of 23 separate contributors, each from various research databases and broker reports on the price of hard coking, PCI, semi-soft coking and Newcastle benchmark thermal coal. The latter three coal prices also received negative forecasts. The last time hard coking coal was forecast to decline was in the December 2019/January 2020 report, when the 2020 AUSTRALIANMINING

price of about $154 per tonne was expected to drop marginally down to $150. The report came in the wake of several major deals surrounding the future of coal. The first being BHP’s sale of its stake in BHP Mitsui Coal (BMC) for $1.8 billion to Stanmore Resources, releasing the mining major of the Poitrel and South Walker Creek metallurgical coal mines. Rio Tinto was already doing the same back in 2013, offloading the Clermont, Blair Athol and Coal & Allied assets, before later selling

FEBRUARY 2022

the Kestrel coal mine in 2018 for more than $US2 billion. A joint statement from more than 50 countries and organisations was signed at the United Nations’ COP26 in Glasgow earlier in November, in an agreement to transition from coal power to clean power. While Australia was not one of the dozens of parties to sign the Global coal to clean power transition statement, intentions have been made clear by the likes of BHP, Rio Tinto and Anglo American to sell out of coal mining while prices remain feasible.

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NEWS

MINRES HAULS IN AUTONOMOUS ROAD TRAINS Mineral Resources (MinRes) has announced a partnership with automation specialist Hexagon to develop an autonomous road train solution for its haulage fleet in Western Australia’s Pilbara region. The solution integrates driveby-wire technology with an autonomous management system to orchestrate vehicle movement in road-train haulage, as part of the Mineral Resources mining services infrastructure supply chain solution. “In recent years, we have implemented a number of new technologies which have enhanced the

safety and operational efficiency of our long-distance road train haulage fleet, reducing the risks of driver fatigue and increasing fleet availability,” Mineral Resources’ mining services chief executive officer Mike Grey said. “The autonomous road trains will take us to the next level again. They provide a safe, cost-efficient solution for hauling ore, which is key to unlocking stranded tonnes in the Pilbara.” An autonomous road train configuration of this scale is a worldfirst and reflects MinRes’ approach to continuous improvement and

innovation. MinRes will initially adopt the technology for its own operations, with a view to offering the solution to its large tier-one customer base, further growing its mining services business. MinRes is renowned for providing innovative and low-cost solutions across the mining infrastructure supply chain, and the autonomous road trains will form an essential part of the Ashburton Hub iron ore project. Mineral Resources is planning to run a fleet of 425-tonne gross combination mass triple-trailer road trains operating across multiple

convoys, with each road train convoy consisting of up to five prime-mover trucks, with three trailers each, hauling the ore from the mine site to the Port of Ashburton. “Autonomous vehicles are revolutionising the way we work today and into the future, and Hexagon is very proud to be part of this revolution,” Hexagon president and chief executive officer Ola Rollén said. The automated road-train solution focuses on safety, productivity and sustainability for Mineral Resources operations and will be phased in over the next two years.

AN AUTONOMOUS ROAD TRAIN CONFIGURATION OF THIS SCALE IS A WORLD-FIRST.

CHALICE MAKES AUSTRALIAN HISTORY AT GONNEVILLE Chalice Mining has confirmed an historic mineral resource at the Gonneville nickel-copper-platinum deposit in Western Australia, becoming the largest nickel sulphide discovery in more than 20 years. Gonneville is part of Chalice’s Julimar project, 70 kilometres north-east of Perth, and contains 10 million ounces of palladium, platinum and gold – collectively called 3E, one of several platinum group elements (PGE). These figures make the project the largest PGE discovery in Australian history.

The 330 million tonne resource also holds 530,000 tonnes of nickel, 330,000 tonnes of copper and 53,000 tonnes of cobalt. Chalice managing director and chief executive officer Alex Dorsch said it had been a strong effort by the team to develop Gonneville at such pace. “This is a major milestone for Chalice, coming just 18 months after our stunning first hole discovery at Julimar,” Dorsch said. “Since then, we have completed more than 175,000 metres of diamond and RC (reverse AUSTRALIANMINING

circulation) drilling and now defined a genuine Tier 1 scale deposit of critical minerals with exceptional growth potential.” The resource will position Chalice to become a major player in the production of “green metals,” according to Dorsch, with reasonable proximity to key infrastructure and port facilities. Dorsch highlighted the sheer potential of this undeveloped deposit. “It is also important to emphasise that the current resource covers just 7 per cent of the Julimar

FEBRUARY 2022

Intrusive Complex, which has been interpreted to cover a strike length of more than 26 kilometres,” Dorsch said. “We know that the deposit remains open along strike to the north, and we are very much looking forward to receiving the final clearances to commence our initial low impact drilling program in the Julimar State Forest.” A scoping study remains ongoing for Gonneville, which will be complete before mid2022 to clarify the initial mine development options.

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NEWS

BHP SELLS QLD COAL MINES TO STANMORE FOR $1.8BN BHP has agreed to sell its 80 per cent share in BHP Mitsui Coal (BMC) to Stanmore Resources, offloading two Queensland coal mines and associated infrastructure. BMC owns the Poitrel and South Walker Creek metallurgical coal mines, plus Red Mountain Infrastructure, and the Wards Well development. The sale will see up to $US1.35 billion ($1.82 billion) change hands, with $1.1 billion to occur upon completion of the share sale and purchase agreement. BHP Minerals Australia president

Edgar Basto said the deal continued the company’s transition from large carbon emitting operations. “This transaction is consistent with BHP’s strategy, delivers value for our company and shareholders and provides certainty for BMC’s workforce and the local community,” Basto said. “South Walker Creek and Poitrel are well-run assets that have been an important part of our portfolio for many years, and we are grateful for their contribution to BHP.” Poitrel and South Walker Creek have a combined metallurgical coal

production of about 10 million tonnes per annum and marketable reserves of more than 135 million tonnes, according to Stanmore. “This is an exciting and transformative acquisition for Stanmore, and we are fortunate to be able to rely on the full support received from our controlling shareholders, Golden Energy and Resources as well as the Sinar Mas Group, to successfully execute this deal,” Stanmore chief executive officer Marcelo Matos said. “This transaction will see the

company become one of the leading metallurgical coal producers globally and provide Stanmore with a portfolio of Tier 1 assets. “(It brings) significantly increased reserves and resources base and assets with an expected mine life exceeding 25 years production, positioning the company for substantial cashflow generation and future growth opportunities.” The deal will increase Stanmore’s metallurgical coal production by a multiple of 5.6, while its coal reserves will increase by a multiple of 4.2.

THE DEAL WILL INCREASE STANMORE’S METALLURGICAL COAL PRODUCTION.

DOWNER AND OUT: LEADING CONTRACTOR NO LONGER Downer has officially divested its mining portfolio, completing its sale of the Open Cut Mining East business to BUMA Australia for about $150 million. The Mining East business was the last piece of the puzzle for Downer to divest, with proceeds from the divestment program totalling $778 million. As the sale was announced, Downer chief executive officer Grant Fenn said the company could focus all its energy on its new strategy. “An important part of our urban services strategy was the exit from our capital-intensive mining

businesses,” Fenn said. “The sale of Open Cut Mining East is the last step of this process and follows the divestments of Open Cut Mining West, Downer Blasting Services, Underground Mining, Otraco, the Snowden consulting business and our share in the RTL Mining and Earthworks joint venture.” Downer was previously one of Australia’s leading diversified mining contractors, serving more than 60 sites in Australia, Papua New Guinea, South America and Southern Africa. The various businesses were sold to several high-profile buyers AUSTRALIANMINING

over the past 13 months, including MACA, Byrnecut, Bridgestone Mining Solutions, BUMA and Sigdo Koppers Group. The divestment program was first announced as a possibility in Downer’s 2019 annual report. In March 2020, the advent of the volatility caused by COVID-19 put a temporary halt to proceedings before the annual report in July 2020 said the search for buyers was back on. The first major sale in the divestment program came in November 2020, with the sale of Downer Blasting Services for $62 million to Enaex S.A, a subsidiary

FEBRUARY 2022

of Chilean company Sigdo Koppers Group. This was closely followed by the sale of Open Cut Mining West to MACA in December 2020, for a total value of $200 million. The Underground Mining services at OZ Minerals’ Carrapateena gold mine was handed to Byrnecut Australia in January 2021 for an undisclosed value. The tyre management business Otraco was sold to Bridgestone Corporation in April 2021 for $79 million, before Open Cut Mining East became the last business to fall in line in December.

NEWS

GLENCORE SHIFTING TO SEVEN-DAY ROSTER Glencore’s Mount Isa mines has announced its Mount Isa copper operations (MICO) will be changing its primary rosters to a seven days on/seven days off roster. From late February, workers on the primary roster at the MICO operations will move to the new roster in line with the George Fisher mine, which has been successfully operating on the schedule for several years. The change will improve work/

life balance for the MICO employees in many ways including having every second weekend off to allow Glencore to more easily transfer workers between the two sites to improve productivity. Glencore has been addressing any questions or concerns raised by affected workers, and will continue to monitor and seek feedback as it implements the roster changes. “We are committed to maintaining a local workforce and the move

is not about transferring to a fly-in/fly-out roster,” a Glencore spokesperson said. “Our key focus will remain on the safety and wellbeing of our workforce, as we implement and embed the change.” Mount Isa mines is one of the world’s largest mining complexes and is the hub of Glencore’s copper and zinc operations in Queensland. Mount Isa mines comprises of underground mines, mineral

processing and smelting operations, power generation, and support and administrative services, and operates two mining and processing streams, copper and zinc-lead-silver, to deliver natural resources of enduring value in modern society. Glencore is capable of producing 300,000 tonnes of 99.995 per cent pure copper cathode a year at its Townsville refinery, and 99.7 per cent pure copper plates at the Mount Isa smelter.

THE CHANGE WILL IMPROVE WORK/LIFE BALANCE.

LYNAS RARE EARTHS BEGINS CONTRACTING FOR PROCESS PLANT Lynas Rare Earths has kicked off construction of its Kalgoorlie processing facility in Western Australia, awarding a formative contract to a WestStar Industrial subsidiary for $12 million. The rare earths processing facility will treat concentrate from the Mt Weld mine to produce rare earth carbonate for export to Lynas’ Malaysian facility for further processing. WestStar’s engineering, construction and contracting business Alltype Engineering has been keen to ramp up its strategic plan to deliver major construction projects, and the Lynas contract

will bolster this plan as works begin immediately. Alltype managing director Kelvin Andrijich said the business had been building to this moment for some months. “During our FY21 (financial year 2021) strategic planning in 2020, we identified a niche market opportunity in the rotary kiln and rotating equipment installation space,” Andrijich said. “It is very pleasing to see that the subsequent business case and execution of this strategy 12 months later has resulted in securing our first rotary kiln erection contract as part of the landmark Lynas Rare Earths AUSTRALIANMINING

processing facility development in Kalgoorlie.” The rotary kiln will be six metres wide and 110 metres long. The contract will also encompass the fabrication and installation of the discharge end building, a dust chute, primary leach overflow hopper, and the installation of pumps, agitators, piping and electrical instrumentation. Andrijich said it was rewarding to be acknowledged for Alltype’s expertise in a range of disciplines. “We are pleased that Lynas has recognised the experience and capability of our delivery team, and the proven self-execution multidiscipline construction capability

FEBRUARY 2022

of Alltype Engineering in the gas, energy, petrochemical and minerals processing industries,” Andrijich said. “Alltype Engineering has previously undertaken balance of plant scopes around rotary kilns on operational mineral sands and lithium processing sites in the past and we are excited to now be completing the entire turnkey package in addition to those works.” The Kalgoorlie processing facility was recommended for construction by the Western Australian Environmental Protection Agency (EPA), granted a 30-metre native vegetation buffer was maintained around the site.

NEWS

THIESS TO MAKE A MOUNTAIN FROM AN ANTHILL Thiess has secured two mining services contracts worth a combined $200 million in Queensland, partnering with BHP Mitsubishi Alliance (BMA) and Austral Resources. The BMA contract is worth around $105 million for the provision of mining and maintenance services at Caval Ridge coal mine in the Bowen Basin near Moranbah. The multinational contractor was also notified in October of Austral’s intention to finalise a $95 million deal, with all signatures now confirmed for Thiess to begin works at Anthill copper mine from January 2022. Thiess chairman and chief executive officer Michael Wright said the deals gave the company yet another opportunity to display its expertise in an Australian context. “These contracts reflect Thiess’ ability to deliver value for our clients, providing competitive and sustainable mining solutions across a diversified portfolio of projects,” Wright said. Austral is aiming to produce 10,000 tonnes of copper cathode per annum for the four years from

mid-2022. Austral chief executive officer Steve Tambanis said Thiess was a strong choice to get Anthill off the ground. “Austral is pleased to be partnering with Thiess, a leading mining services provider with superb mining experience and capabilities,” Tambanis said. “They bring a commitment to safe and innovative mining practices, providing certainty of delivery in the development of our new Anthill mine.” Thiess is now mobilising its fleet to Anthill, 80 kilometres northwest of Mount Isa, with 70 people expected to be directly employed

by the contract. The fleet includes a 225-tonne Liebherr R994B excavator and multiple Cat 789 haul trucks. Tambanis added that Anthill would continue to grow elsewhere while Thiess began work on the existing copper asset. “Exploration and development activities are currently being significantly expanded with the goal of fast-tracking discoveries,” he said. “We look forward to further update shareholders as we prepare to commence maiden production at Anthill, and begin exploration and development activities.”

Thiess was in attendance when Austral performed its first blast at Anthill in mid-November, along with blast management company Orica and drill specialists Roc-Drill. The blast was an impressive achievement, coming just three weeks after approval was received to commence mining. A total 110,000 cubic metres of iron stone was broken in the blast at Anthill’s east pit, with the first ore to be mined by April 2022. Copper cathode is expected to be produced in mid-2022 at the company’s Mount Kelly copper oxide heap leach and solvent extraction electrowinning (SXEW) plant. THIESS IS MOBILISING ITS FLEET TO ANTHILL, NORTH-WEST OF MOUNT ISA.

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NEWS

WAS GAINES’ TRANSITION THE RIGHT MOVE FOR FORTESCUE? Analysts have suggested Fortescue Metals Group may be better served by diversifying into more reliable commodities like base metals, rather than renewable energy. Adrian Prendergast of Australia’s largest wealth management network, Morgans, said the recent transition of Fortescue chief executive officer Elizabeth Gaines from the top job was a shock. “Of some concern, our initial impression is that FMG appears to be prioritising getting a new CEO with experience outside iron ore,” Prendergast said. Instead, the senior analyst

suggested Fortescue would be better served by sticking to what it knows in these uncertain times. “We see now as a critical time for FMG to be focusing on the iron ore market, particularly given its position as a mass-scale low-grade producer,” Prendergast said. “Given the iron ore dynamics, we had expected FMG to diversify actively but had thought a safer option might have been to enter other mature markets (i.e. base metals) where cycles and economics are already well established and understood, allowing for a faster transition.”

Morgans expects Fortescue to remain financially dependent on iron ore until at least 2030, while the clean energy transition continues to build momentum. Building on this, Prendergast gave three reasons why iron ore markets may remain uncertain for the next five years: “One, the Chinese steel market has matured (less stimulus, environmental reforms, rising recycling) and unlikely to reclaim previous highs,” Prendergast said. “Two, seaborne iron ore supply is recovering (Vale has mitigated risks while we expect Rio’s operational

performance to eventually improve). “Three, new supply is coming (most notably Simandou but other supply is also responding to the increased rents on offer).” Gaines will transition into a role as non-executive director of Fortescue’s board and as the company’s global green hydrogen brand ambassador. Fortescue’s Board of Directors has started an extensive global search, appointing Egon Zehnder, to identify a CEO and other leaders with exceptional skills and global experience across heavy industry, manufacturing, and renewable energy.

GAINES WILL TRANSITION INTO A NON-EXECUTIVE DIRECTOR OF FORTESCUE’S BOARD.

KALGOORLIE-BOULDER TO ASSESS FIFO POLICY The City of Kalgoorlie-Boulder in Western Australia’s Goldfields region is seeking submissions on a policy which aims to provide guidance on potential accommodation development applications, including for a fly-in, fly-out (FIFO) workforce. Mayor John Bowler said while the policy discourages construction of worker camps for FIFO employees and contractors, it provides a clear framework for assessing workforce accommodation proposals and will help build a more sustainable local community and economy. The objective of the policy is to manage the development of workforce accommodation with a longer-term aim to maximise the residential workforce and ensure that, where workforce accommodation is provided, it

is designed appropriately and contributes to Kalgoorlie-Boulder’s vision to be a place people call home. The council will undertake a consultative process that will guide the policy measures including time limited approvals, need for accommodation, location, design and community integration. The draft policy indicates proposed facilities would undergo a Social Impact Assessment and require a Social Impact Management Plan to identify and mitigate negative effects to the community. “The city acknowledges there needs to be a base level of temporary accommodation available to address the upcoming large construction projects planned for AUSTRALIANMINING

the city,” Bowler said. “However, with the need for workforce accommodation always changing, it is integral that the supply of such accommodation is managed properly. “Local communities benefit from having workers and their families permanently located in the city and can suffer negative impacts from a large FIFO presence. “Key objectives of this draft policy are to achieve reciprocal benefits for the local community and businesses and enable facility occupants to integrate with the community, local businesses and city services.” The policy will ensure any new developments are fully evaluated and properly assessed within the approval process. In addition, 12-months before the

FEBRUARY 2022

expiry of the approved timeframe, the landowner must provide Council with a site decommissioning program or a transition plan. “We would obviously prefer longterm operational workers to be based in our town and contributing to the community,” Bowler said. “Families should be able to tuck their kids into bed every night and spend quality time with their partners. “The policy emphasises that, where long-term town-based FIFO operations are required by industry, council expects their accommodation to be of a high standard; suitably integrated with surrounding development and the community; and not of a camp design or layout appropriate to an isolated/remote camp.”

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NEWS

MONADELPHOUS SECURES RIO TINTO CONTRACTS Monadelphous has secured new contracts and contract extensions with Rio Tinto and BHP in the Pilbara region of Western Australia (WA) worth approximately $110 million. The engineering company has secured two new contracts with Rio Tinto under its sustaining capital projects panel agreement. The first Rio Tinto contract is for the construction of new hawser rails and upgrades to the existing dolphins at Cape Lambert A and B wharves,

which includes design, fabrication, supply and installation which is expected to be completed by July 2023. The second contract is for the upgrade of conveyor gravity take up systems at East Intercourse Island and Cape Lambert, with work expected to be completed in the third quarter of 2022. Monadelphous has also secured a 12-month extension to its existing contract with BHP Iron Ore for the

provision of general maintenance services for shutdowns, outages and minor capital works at the Mt Whaleback, Jimblebar, Eastern Ridge, Mining Area C and Yandi mine sites. The company also won a 12-month extension to its existing mechanical and electrical maintenance, shutdown and project services contract across BHP’s Nickel West operations in WA. These new contracts follow a string of sustaining capital work projects

Monadelphous has won with both BHP and Rio Tinto this year, including providing smelter maintenance works at BHP’s Olympic Dam copper mine in South Australia, and for the provision of construction and support services at Rio Tinto’s Gudai-Darri iron ore project in WA. Monadelphous is a leading Australian engineering group providing construction, maintenance and industrial services to the resources, energy and infrastructure sectors.

MONADELPHOUS HAS WON A STRING OF SUSTAINING CAPITAL WORK PROJECTS CONTRACTS.

PILBARA INDUSTRIAL HUBS TO GROW WITH LOTS OF LOTS Industrial hubs in Port Hedland and Karratha have been opened to new tenants, as DevelopmentWA invests in the Pilbara mining industry of Western Australia. Major engineering contractor Monadelphous is already one of many companies to have taken up residence at the Gap Ridge Industrial Estate in Karratha, as eight new lots are made available. The eight lots in Gap Ridge’s fifth stage range in size from 6722 square metres to almost three hectares. Near Port Hedland, the Wedgefield Industrial Estate has opened its third stage with five lots ranging from 1.5 to 2.4 hectares – suitable for a variety of industrial and transport related uses.

Lands Minister Tony Buti said the new lots were hoped to benefit the industries that best served the state. “The McGowan Government has made a big investment to ensure the rapid development of industrial land across the state, with a focus on regional Western Australia and businesses supporting the resources industry,” Buti said. “This commitment has resulted in an increasing supply of industrial land to meet growing demand.” Stages one and two at Wedgefield have already sold out to more than 20 businesses including Komatsu, Bridgestone, Qube and Reece Plumbing, all taking advantage of the estate’s access to power, water, the AUSTRALIANMINING

national broadband network (NBN) and sewerage. In October, DevelopmentWA chief executive Frank Marra discussed the benefits of strategic industrial areas (SIA) with Australian Mining. The Kwinana and Rockingham SIAs in the state’s southwest – home to the likes of BHP and Tianqi Lithium – inspire similar synergies to those planned in the Pilbara. “The Kwinana SIA and the neighbouring Rockingham SIA are part of the world’s largest integrated ecology industrial estates,” Marra said. “They support growth among industrial businesses by facilitating access to extensive common-

FEBRUARY 2022

use infrastructure, deep pools of skilled labour and proximity to other industrial businesses inputs and outputs that exhibit a high degree of complementarity.” Pilbara Minister Kevin Michel said it was hoped a broad range of businesses would take up the call to join the Pilbara’s resources sectors. “This strategic land release will attract new businesses to Port Hedland and Karratha, which will help diversify our local economy,” Michel said “These industrial lots are another fantastic opportunity for new businesses to join our local business community, providing jobs and growth for the Pilbara.”

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INDUSTRY OUTLOOK

A LOOK THROUGH THE CRYSTAL BALL: MINING IN 2022 FOLLOWING A WHIRLWIND START TO THIS DECADE, ONE CAN ONLY GUESS AT WHAT TRANSFORMATIONS MIGHT OCCUR ACROSS AUSTRALIA’S MINING INDUSTRY IN 2022. BUT THAT’S EXACTLY WHAT THESE INDUSTRY EXPERTS THRIVE ON. HENRY BALLARD WRITES.

he past 12 months have seen record gold exploration, Chinese trade bans, rollercoaster iron ore prices, fly-in, fly-out (FIFO) lockouts, vaccine mandates, skilled labour shortages and more ‘green’ initiatives than you could poke a stick at. Environmental, social and governance (ESG) credentials began each annual report and the transition from coal to clean energy was highlighted brighter than ever at the United Nations climate conference, COP26. Investors placed increasing pressure on mining companies to clean up their act in a shift that may change the way big business operates forever and through it all the industry just kept on keeping on. Looking forward, Austmine chairman emeritus Alan Broome tells Australian Mining he sees ESG as more than just a fad. “The biggest single priority for every mining company now is ESG,

it’s the big deal,” Broome says. “I chair three smaller mining companies and all my boards are looking at this issue very carefully. “It’s going to have an increasing impact on our mining industry for the next few years. Some people think it’s just going to be a shortterm trend, but it’s here to stay because it’s an integral part in making sure we are responsible for how we access our mineral endowment.” These credentials extend from emissions regulation to issues of cultural heritage, as both continued to make headlines in 2021. The Western Australian Chamber of Minerals and Energy (CME) director for Policy and Advocacy, Rob Carruthers, says he sees companies taking real care in the way they manage interactions with Australia’s Traditional Owners. “There’s been a lot of strong investment and support from industries to host communities wherever that may be,” Carruthers AUSTRALIANMINING

says. “That’s not only so that the communities benefit from the operations they host, but also to engage and consult with them on future plans to make sure they’re supportive and understanding of developments. “We’re seeing a lifting of all boats on the tide in consultation with communities and Traditional Owners to make sure the benefits are spread from new mining activities.” And while the mining industry has seen some self-inflicted blows to its ESG reputation, many mining companies have been putting in a significant effort to create lasting relationships with their investors and their host communities. In 2021, PwC Australia released its 16th annual edition of the Aussie Mine report which details the progress of Australia’s mid-tier miners – categorised as the top 50 mining companies outside the top 50 companies (MT50) on the Australian Securities Exchange (ASX50).

FEBRUARY 2022

Considering this report, PwC partner Marc Upcroft believes Australian mining companies have made a lot of progress in responsible operations. “They were already pretty clear on their ESG credentials overall. But if you narrowly focus on energy and emissions reductions, they’ve come a long way in recent months and a really pleasing thing is we’re starting to see the same in the mid-tier space as well,” Upcroft says. “There’s still a large group of mining companies that are yet to jump on board but there is still tremendous opportunity for the others to be fast followers.” More importantly for mining companies, PwC has shown that it’s well in their interests to operate more responsibly going forward. “The analysis that we do shows that it’s worth it, as better ESG credentials leads to more investment,” Upcroft adds. The Aussie Mine report also found that the E in ESG is being

INDUSTRY OUTLOOK

THE NEXT DECADE IN MINING PROMISES TO BE UNPREDICTABLE.

well supported by Australia’s critical minerals sector. For the first time in the Aussie Mine report’s history, the rise in mid-tier critical minerals companies stole the show from another strong

performance in the gold sector. “While gold companies still dominate (comprising 36 per cent of the MT50 by number and 33 per cent by value), critical minerals companies have soared, and now represent nearly a third of the aggregate MT50 value (34 per cent by number and 31 per cent by value),” the report stated. Upcroft says it will be a bumpy ride for all sectors as supply chain and skills issues continue globally, but the critical minerals sector is set for an unheralded period of growth. “Whenever we’ve looked at this mid-tier space, gold has really been the dominant sector,” Upcroft says. “It’s ebbed and flowed over those 20 years, but now we can clearly see critical minerals pushing gold aside as the mineral of the future and we see it as being a sector with lots of tailwinds for the next decade.” And while greater access and production of these critical minerals like lithium, cobalt and vanadium can greatly benefit the development of clean energy technologies and miners’ bottom lines, not everyone has faith in the management of emissions policy. Allon Brent is the principal of Global Minerals Marketing and has enjoyed a 35-year career in the international minerals and metallurgical industries.

PWC NATIONAL MINING LEADER DEBBIE SMITH.

PWC PARTNER MARC UPCROFT.

Brent says forcing companies to target certain emissions reduction regulations may do more harm than good, as they’re forced to shut down or move offshore. “I think it can be unrealistic with the technology we have today. Clearly, we will develop new technology but it’s very risky to promise targets based on things that don’t exist yet,” he says. “I think it’s a bit aggressive and we’ve got to be careful we don’t do permanent harm to our mining and manufacturing base by forcing them to close and having the processes moved onto foreign shores where they’ll be done even less sustainably.” This hesitancy to change at pace

can be seen in the coal industry too, where a transition away from emissions-heavy coal products is being forced upon those who know nothing else. Austmine chief executive officer Christine Gibbs Stewart has her own 30-year tenure throughout the mining industry and hopes those across the coal industry are supported rather than severed in the clean energy transition. “It’s important for small to medium METS (mining, equipment, technology and services) companies who’ve worked in the coal industry aren’t caught in the crossfire between government and environmentalists,” Stewart said. “We need to make sure they

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INDUSTRY OUTLOOK

GLOBAL MINERALS MARKETING PRINCIPAL ALLON BRENT

understand the important role they’re playing in helping us decarbonise the industry over a long period of time. “We don’t have all the answers yet as to how to decarbonise completely, but because there are thousands of companies working across the Australian mining industry, including in coal, they need to be treated as a part of the solution, not the issue.” Upcroft agrees, there is little use in forcing the coal industry to shut prematurely, with nowhere to go and nothing to replace its usefulness on a national or global scale. “We call energy transition a ‘transition’ for a reason and that’s because it’s going to take a while,” Upcroft says. “When you look at the costs involved in that as well, it is quite significant, so coal still has a role to play in the Australian and the global economy.

“At some point, we will turn the corner into a different space but that’s not happening today or tomorrow.” So, while coal’s long-term prospects remain uncertain, the short to mid-term are remarkably positive. Australia is endowed with some of the highest quality coal in the world, allowing it to be burn much more efficiently and with fewer emissions than that of other coal-rich provinces like North America and Russia. As such, the coal debate proves to be much more divisive than first thought, according to Broome. “I can’t believe the prices we’re getting for energy coal in world markets, but there’s a good reason for it,” he says. “The debate we’re going through right now about coal being a dirty word, you’ve got to be careful about that because our coal is the highest quality in the world. AUSTRALIANMINING

“What I think will happen in 2022 is there will be an enormous amount of increasing pressure on the coal industry, in particular thermal coal. “To start new thermal coal projects now is going to be quite challenging, while at the same time I know at least one hard coking coal project which is very well funded and has strong backing from financial institutions.” Bumper coal prices are just the start of Australia’s strong economic outlook too, as iron ore, gold, copper and critical minerals all continue a strong run of form into 2022. While some call it a supercycle, Broome isn’t so sure. “We’re going through a very strong period for the mining industry in Australia, the demand for our resources is as strong as it has ever been,” he says. “It’s not a supercycle, but it’s as strong as the last cycle which we had on the up and it’s got more

FEBRUARY 2022

sustainability this time around than previous.” And while a mining industry of this strength sounds ideal, Carruthers explains how it will pose its own set of issues in 2022 and beyond. “We’ve traditionally seen counter-cyclical cycles where some commodities do well while others experience a trough,” he says. “In my 15 years in the sector, I haven’t seen this where multiple commodity groups have strong production outlooks as well as project opportunities. “These are good problems to have, but it means several commodities are all seeking the same access to skills and capabilities at the same time as the construction sector is also having a very strong period as well.” As is the basis of numerous industries in Australia, access to the international talent pool will be integral to the mining industry’s continued growth. “Australia has been challenged in terms of skilled migration and that’s been core to our economic prosperity for over 100 years,” Carruthers continues. “Certainly, there’s been considerable investment in local skills development and training and that will continue, but if we’re going to capture the upside in the resources sector, we’ll need access to international skills.” In the meantime, however, as borders and migration policy remain unclear and COVID-19 runs its course, Australia’s mining industry has shown it can and will find a way to survive and thrive. After two years navigating virtual meetings, untangling supply chains and being locked in or out of certain states, the industry has proven it is more resilient than first thought. Despite being isolated physically in 2021, business continues to boom into 2022 and a communal pat on the back is well-earned, according to PwC national mining leader Debbie Smith. “While the number of deals were down in 2021, the values were back to the size we were seeing five or 10 years ago,” Smith says. “I think that’s a sign of things to come because they were all done in a COVID locked down kind of world.” “2021 reinforced the resilience of the sector. No matter what gets thrown its way, it manages to find a path through it. “Notwithstanding the pandemic with its lockdowns and closed borders, the mining sector was able to overcome things no one could have expected and it gives me hope for blue skies in 2022.” AM

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COMMODITY SPOTLIGHT

THE ALLURE OF HALLOYSITE-KAOLIN OFT-MISUNDERSTOOD, HALLOYSITE-KAOLIN HAS THE POTENTIAL TO BE A LUCRATIVE COMMODITY IF A COMPANY FINDS THE RIGHT BALANCE AND UNDERSTANDS THE COMPLEXITY OF ITS MARKETPLACE.

alloysite-kaolin is an intriguing commodity. Considered the most researched clay mineral in the world, its potential is largely untapped in Australia. However, there are a handful of emerging Australian companies staking their claim as future producers of the versatile industrial product. Andromeda Metals is the most advanced of those, a company racing towards establishing its Great White kaolin joint venture project on the Eyre Peninsula in South Australia. Working alongside Minotaur Exploration, Andromeda has overcome a number of obstacles to be where it is today and still has objectives to tick off before it can become a producer, however the early signs all point in the right direction. Much of that can be put down to the expertise of Andromeda general manager James Marsh, whose family has been keenly involved in kaolin over the years. After working in Cornwall, United Kingdom, where kaolin was first mined in the 1700s, Marsh moved Down Under in 2002 and steadily began lifting the profile of halloysitekaolin, a high-value derivative of kaolin which had seldom been explored in Australia up until that point. This led him to join Andromeda

in 2018, which has grown from a $3-4 million company when he started, to one with a market capitalisation of more than $400 million. While kaolin has long been used in the filling and coating of paper, its quality for this purpose is lessened when it’s discovered alongside the presence of halloysite. Halloysite disrupts kaolin’s paper aspirations and can be difficult to identify due to its miniscule size. However, it’s considered a profitable resource when used in other applications. Andromeda sees a potential to commercialise halloysite in industries such as construction, agriculture, healthcare, cosmetics and nanotechnology. The company’s offtake partnerships

indicate Andromeda has also proven halloysite’s capability in ceramics. Andromeda has executed an agreement with Japanese porcelain manufacturer Plantan Yamada for its Great White CRM product, which will see the company purchase 5000 tonnes per annum of halloysite-kaolin at $700 per tonne. Marsh says his relationships in the field gave Andromeda an advantage in inking this deal. “We chose ceramics first because we knew it had the halloysite which is where it’s highly valued and luckily with my background – I’ve been selling this stuff for 30-odd years – I’ve got a mass list of customers that I’ve been involved with over the years,” he says. “So that gave us a huge head start,

HALLOYSITE-KAOLIN IS A DIFFICULT PRODUCT TO COMMERCIALISE.

HALLOYSITE-KAOLIN IS A HIGHVALUE DERIVATIVE OF KAOLIN.

AUSTRALIANMINING

FEBRUARY 2022

plus I knew exactly why these buyers would value it and how much it was worth for them because they would never tell you that themselves.” Marsh says much of halloysitekaolin’s complexity comes down to selling the product. It’s a bit of a catch-22 – the commodity’s many unique uses and applications render it an intricate product to market. “It’s a very hard material to market because there’s no index pricing for this stuff. In China alone, there’s over 10,000 users of this material and they’ve all got their own different formulations, their own processes, their own people who work different ways,” Marsh says. “You also don’t talk to the buyers, you talk to the technical people and say, ‘here’s our product, this is its chemistry, this is its particle size, this is how it’s going to perform, this is how to use it in your application’ and convince them how they can use it.” Andromeda has also established an offtake partnership with Jiangsu Mineral Sources International Trading Co for its Great White PRM product. This will see the Chinese commodity trading house purchase 70,000 tonnes per annum of Andromeda’s kaolin product for more than $700 per tonne to be used in the coatings and polymers market. This is distinct from the halloysite-kaolin product to be sold to Plantan Yamada. With Great White’s potential,

COMMODITY SPOTLIGHT

which Andromeda says is at 40 per cent halloysite purity and growing, the recent approval of the project’s mining lease, the established offtake partnerships and other commercial ventures in the works, Andromeda is well placed to elevate Great White into production. Andromeda aims to break ground at Great White in 2022 after it has its Program for Environment Protection and Rehabilitation (PEPR) approved. The total life of mine from the known resource is expected to be 26 years with a production rate of 500,000 tonnes per annum of raw material. Other explorers in the Australian halloysite-kaolin space include Latin Resources, Oar Resources and Suvo Strategic Minerals, all in lesseradvanced phases of development than Andromeda. There’s also iTech Minerals, a company focussed on developing battery and critical minerals such as graphite and rare earths. iTech has its Franklyn and Eyre Peninsula halloysite-kaolin projects in South Australia, the former of which is more developed given the company inherited exploration assets from Archer Materials in 2021. “Both of them (Franklyn and Eyre Peninsula) are relatively early stage. We do have a head start at the Franklyn project … in that we’ve inherited about 10 years of historical

exploration from Archer,” iTech managing director Michael Schwarz says. Archer defined an exploration target of between 45 and 91 million tonnes of halloysite-kaolin at Franklyn prior to iTech taking over and Schwarz says the predecessor found some of its Franklyn drill holes to be particularly halloysite-rich. After iTech completes preliminary testing to identify further halloysitekaolin prospects at Franklyn, the company will look to resume drilling at

the project in 2022. iTech then plans to move its drill rig over to the Eyre Peninsula project where it has various exploration priorities including its Ethiopia prospect. Schwarz says the Eyre Peninsula project is well placed due to its location. “(The Eyre Peninsula project) is probably only about 50 kilometres away from a port at Lucky Bay and 70 kilometres away from Whyalla,” he says. “That’s important because these are industrial bulk commodities in the

first instance before you do any value add, so transport to port is one of the big factors you have to consider.” Port access is just one of the many variables influencing the capability of a halloysite-kaolin project. First and foremost, understanding the market and establishing the quality of the product is critical in making a run at this intricate commodity. Once a company has certified that, it has every chance of capitalising on the expansive buyer base halloysitekaolin can offer. AM

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COMMODITY SPOTLIGHT

AUSTRALIA’S IRON ORE MINERS HAVE AN OPPORTUNITY TO EMBRACE GREEN STEEL.

IRON ORE’S UNCOMFORTABLE TRUTH AUSTRALIA’S CARBON-INTENSIVE IRON ORE INDUSTRY WILL FACE AWKWARD QUESTIONS AS THE WORLD’S NET-ZERO PURSUIT STRENGTHENS, AND THE NEED TO EVOLVE HAS NEVER BEEN MORE PERTINENT.

ampered by decreased prices and inconsistent demand, Australia’s iron ore industry has experienced a difficult end to 2021. Numerous iron ore mining companies were forced to halt operations as a result of the crunch, including Venture Minerals’ Riley mine in Tasmania, Mount Gibson Iron’s Shine project in Western Australia (WA), while Indus Mining had to put its WA Ridges project into care and maintenance. This came as China, Australia’s biggest iron ore customer, began reaching its steelmaking thresholds earlier than expected, while its growth-minded economy slowed in the wake of a boom early in 2021. The environment had a big part to play as well, with the need to reduce air pollution a priority ahead of the Winter Olympics in February. Despite the momentary drop in demand, given iron ore’s role in the world’s industrial movement, there’s going to be a continued need for

this resource. According to Fitch Solutions, worldwide iron ore mine output is set to average 2.4 per cent growth from 2021 to 2025, with Australia’s iron ore production set to increase at an annual average of 1.7 per cent over the same timeframe. Production may increase, but steelmakers will become more discerning as net-zero targets loom large, and low-grade or less sustainable iron ore producers risk being left out in the cold if they don’t make alterations. This is where the concept of ‘green steel’ comes into the picture: a phenomenon that replaces fossil fuels with renewable energy in the steelmaking supply chain. The green steel process also necessitates the use of high-grade iron ore, something which miners can achieve through practices such as beneficiation. Global mining technology developer Metso Outotec is playing, and will continue to play, a critical role in the green steel movement. The company’s involvement in sustainable steelmaking dates back to AUSTRALIANMINING

the 1980s when its predecessor Lurgi Metallurgie developed the Circored process. Circored uses hydrogen instead of fossil fuels in the reduction of iron ore fines to make direct-reduced iron (DRI) or hot briquetted iron (HBI). This can then be used as feed material in electric arc furnaces for carbon-free steelmaking. Circored had only been semicommercialised to this point, but Metso Outotec launched the next generation of the Circored process in December. Metso Outotec Asia Pacific president Stuart Sneyd believes this method has an important role to play moving forward. “Circored is already ready and configured for hydrogen reduction, whether it be grey, blue or green hydrogen – it’s ready to go in that sense,” Sneyd, speaking at the 2021 AusIMM Iron Ore Conference, says. “It can produce a zero-carbon product in the end and we argue that the technical feasibility (of Circored) is proven at an industrial-scale (through a demo plant in Trinidad).”

FEBRUARY 2022

The pilot plant commenced operations in 1999 and produced more than 300,000 tonnes of highquality HBI across several months. Circored is the only 100 per cent hydrogen-based iron ore reduction process capable at such a scale and Metso Outotec aims to announce further additions to its capabilities during the first quarter of 2022. The company is also at the forefront of sustainable pelletising. Proven at producing high-quality pellets at low costs, Metso Outotec’s pellet plants are in use at iron ore operations across the world. According to Sneyd, pellet plants will be an important fixture in an advancing green-steel world and Metso Outotec continues to explore opportunities in this regard. “Pellet plants are likely to play a prominent role in the future and what can be done to support a carbonneutral future as far as this particular technology is concerned?” Sneyd says. “Things that we consider are alternative burner fuels such as biofuel and hydrogen in pellet plant

COMMODITY SPOTLIGHT

powering, process modifications for energy efficiency and new hoods for electrification – all of these things are under development are being considered.” Metso Outotec has added a digital solution to its iron ore pelletising process with the aim to improve production capacity and quality, while reducing energy and costs. The company has iron ore pellet plants in Brazil, China and Africa but not Australia, according to public contracts. Hydrogen is a hot topic in the mining industry as the green push strengthens, yet there are still unanswered questions that encircle the resource. At this point in time, hydrogen is expensive to produce, difficult to transport and store, and highly flammable and dangerous. Deeming the obstacles as opportunities not impossibilities, there are already initiatives in play which are aiming to further unlock the resource. In November, the Western Australian Government awarded a contract to GHD Group to investigate the role the state’s iron ore can play in the global green steel movement, unpacking hydrogen capabilities as part of that.

PELLETISING IS IMPORTANT TO THE GREEN STEEL VALUE CHAIN.

In partnership with ACIL Allen, GHD Group will initially identify opportunities and current barriers for WA to support this revolution. The next step will be to examine infrastructure needs, market dynamics and policies to solidify the state’s understanding of the green steel value chain.

Minerals Research Institute of Western Australia (MRIWA) chief executive officer Nicole Roocke says the state’s examinations would be centred around its Pilbara and Mid West regions. “(By analysing future market dynamics) we’ll be looking at what the demand for low-grade and high-

grade ores are going to be into the future, and look at the jurisdictional and mineral endowment differences,” Roocke, speaking at the AusIMM conference, explains. “Also, to understand that if hydrogen is to be part of the solution, where does it have a role to play and what do production costs need to be to be able to make it economic.” Roocke says the examinations will establish the clarity Western Australia needs to explore a green steel opportunity intelligently and efficiently. “The whole intention of doing this work is to be able to ensure that both from a Western Australian Government and industry perspective, we have an understanding of what the opportunity is, and we have a better understanding of what the risk is to the state,” she says. Having brushed off the toils of 2021’s closing months, Australia’s iron ore industry can expect more trying enquiries from sustainably-minded steelmakers in 2022. Nevertheless, with the green steel movement in play, iron ore has the opportunity to evolve and prove the viability of a new direction – one that seems to be inevitable in a lowemissions future. AM

The KCA Carbon Converter Recover Gold From Your Carbon Fines On Site

Kappes, Cassiday & Associates (KCA) now has three carbon converters successfully operating, at mines in Armenia, Argentina and Nevada. These units take carbon fines and dirty, wet waste carbon at gold leach plants, thoroughly ash it and remove all mercury. Recovery of gold and silver into bullion is typically 99%. For waste carbon loaded to 200 grams gold per tonne, operating cost is $6.00 per gram, or 11% of the value of the recovered gold. Often waste carbons are loaded much higher - the cost per gram drops accordingly. Mines with the Carbon Converter can recover their gold quickly without the Chain-of-Custody problems of shipping carbon to outside processors. Shipping mercury-contaminated wastes off-site incurs large risks of environmental contamination, and the Carbon Converter eliminates this risk. Having the Carbon Converter on site allows the operation to explore various process optimization techniques. For example, carbon fines below 30 mesh are usually lost to tailings in CIL plants, because such fines cannot be recovered cleanly. These losses can account for 1% of the gold fed to the plant. The Carbon Converter can process them. Another opportunity exists where process facilities periodically discard a portion of their coarse carbon in order to maintain optimum carbon activity. With the Carbon Converter, this carbon can be consumed on site and the contained gold recovered economically. The installed cost of the Carbon Converter is about US$1 million including site services, a building, and infrastructure. For mines which generate at least 50 tonnes/year of carbon wastes and fines, payback is typically less than one year.

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MINING EQUIPMENT

AUTOMATED GROUND SUPPORT A BOLT FROM THE BLUE A BESPOKE CABLE BOLTING SOLUTION IS SET TO REVOLUTIONISE GROUND SUPPORT FOR UNDERGROUND MINES, WITH THE STAMP OF APPROVAL FROM NONE OTHER THAN NORTHERN STAR RESOURCES.

angecon has carved a path for itself in underground project construction since it began in 2014 under the watchful eye of mining engineering John Devereux and his business partner Nic Hicks. Both men, directors of Rangecon, recognised a hole in the underground mining market for an affordable solution to automate the cable bolting process. Through a partnership with global mining machinery and technology company Normet, Rangecon developed the Groutmec automated cable bolting machine. Hicks says it took just 18 months to turn the machine from conception to commercialisation. “We came to Normet with a requirement and they had the skills, the engineering and the IP to deliver that,” Hicks tells Australian Mining. “There’s been lots of tweaks along the way, but we have worked closely with them to develop a concept and eventually a commercially viable machine.”

The Groutmec takes Normet’s Charmec machine – originally designed for explosive charging – and reconfigures it to enable automated cable bolting. This includes the cable bolt installation, tensioning and the grout installation to finish. “What is normally done in a basket with three workers, we can now complete with two workers thanks to more automation from Normet, as well as a bunch of bespoke parts to facilitate that process,” Hicks says. The benefits of such innovation are numerous, as described by those at Northern Star Resources who were happy to take on the next step in ground support technology. The gold miner implemented Groutmec at its Kundana operations in Western Australia, as well as the Mount Charlotte mine at its Kalgoorlie operations. Northern Star managing director Stuart Tonkin highlights what he’s found to be the biggest advantage of the machine. “This advanced technology has lifted safety, quality and productivity

for this important ground support method,” Tonkin says. “It eliminates arduous manual handling exposure, while ensuring the consistent quality of grout mix and volumes for reliable strength and design. “The process has materially reduced time to install, which improves the unit cost and reduces time at the location.” Safety will always rate highly as a priority for mining executives and the Groutmec vastly reduces the risk of injury by simply removing the number of workers on hand. Hicks says traditional cable bolting methods can be a common cause of injury where ground support is required, inspiring Rangecon’s latest creation. Outside of safety, the Groutmec also achieves about double the linear metres of cable bolt achieved by traditional methods. “We currently have one in production in the Western Australian Goldfields, which consistently achieves 10,000 to 12,000 linear metres of cable bolt per month,” Hicks says.

RANGECON’S GROUTMEC CABLE BOLTING MACHINE IN ACTION.

AUSTRALIANMINING

FEBRUARY 2022

“From the research we’ve done we haven’t found a comparable machine that would be able to compete with ours.” As Australian mining battles skills shortages due to COVID-19 restrictions, any machine which reduces the labour required is likely to tick boxes for resources companies. Hicks says Rangecon is in the process of delivering another Groutmec to North America where similar constraints are being faced. “Timing is everything. This product has come at the right time as we have a crisis of labour shortage in this space as it reduces labour by one third,” Hicks says. “You only really need one really experienced operator plus the person up the back who mixes the grout, makes sure there’s enough grout for operation and keeps the rig clean.” And while the Groutmec reduces cable bolting crews by one third, the benefits to the remaining two workers are clear. As miners get older, Hicks says they increasingly appreciate any automated machinery that comes their way. “Operators have definitely embraced it. As a company, we provide all kinds of help that constitute ground support. So, from shotcreting to general underground construction work, we certainly get a lot of interest from senior personnel wanting to operate the Groutmec,” Hicks says. “From a fatigue perspective, it’s pretty light on and it’s something different for them. A lot of these workers are chasing a new challenge and we’ve had no issue with presenting it as an opportunity to progress a career in underground mining.” Tonkin agrees, saying his operators at Northern Star continue to show positivity towards the Groutmec, as it takes the load off them and into the ground. “Specialised skills need focussed specialised operators and Rangecon are ahead of the street in advancing cable bolt installation technology,” Tonkin concludes. “You can’t unsee success, and the acceptance from operators that have performed this task manually has been key to proving its benefit.” AM

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MINING EQUIPMENT

EPIROC FINDS A SOLUTION TO IMPORT DELAYS WHEN ALKANE RESOURCES’ TOMINGLEY GOLD MINE IN NSW NEEDED NEW MACHINERY TO BETTER SUIT ITS UNDERGROUND OPERATIONS, ORIGINAL EQUIPMENT MANUFACTURER EPIROC DELIVERED.

hen a mine site needs new equipment to facilitate a change in operations or an upgrade in equipment, delivery needs to be on schedule to reduce downtime and loss of production. However, with the majority of original equipment manufacturers (OEMs) based overseas, the recent international border closures have made importing equipment and machinery difficult. Freight costs have increased and other factors, including union action on some wharfs in Australia, have caused delivery schedules to blow out and cause headaches for operations all over the country. Tomingley gold mine general manager of operations Jason Hughes says the site needed to upgrade its underground fleet, which included four underground trucks from Epiroc. “Two were ejectors and two were tipping trucks, and like most people we wanted the trucks yesterday, if possible,” Hughes says. “Epiroc, rather than building the entire truck over in Europe and shipping them over, were able to get the trucks sent over in kit form and assembled them at their facility in Tasmania. “They were then able to freight the new trucks directly to site, which allowed us to receive them in a very reasonable time frame considering the circumstances that have been happening around the world.” Epiroc New South Wales regional manager Alan Sharpe says the MT65 trucks had the right size, speed on grade and manoeuvrability to assist the Tomingley site with its operations. “Manoeuvrability is a really key factor of the MT65 - its ability to move around in a five to five-anda-half metre drive makes it a leader in those areas in the 60-plus tonne capacity truck,” he says. “It has great articulation abilities and carrying to abilities to work in the size that Tomingley were operating in, which sets it above the current products that are out there.

THE MACHINERY WAS ASSEMBLED IN TASMANIA.

“The MT65 also represents quite a significant difference in payload. I worked closely with Jason to give them the confidence that they would be able to take them underground and put them straight to work.” Epiroc Australia and Asia-Pacific electrified solutions product and sales support lead Brett Kenley says the company shipped three containers per truck (two kit trucks and four trucks in total), which were unloaded in Melbourne. The company then loaded the chassis, tub, power frame and load frame onto flat beds which were shipped to Burnie in Tasmania. “We put the power frame and load frame into the workshop in Burnie, then we basically built the trucks from that,” Kenley says. “We essentially had to put all the components into the truck by following a step-by-step procedure that the company works to over in Sweden. AUSTRALIANMINING

“We were able to do the build in about five weeks – we normally take two to three weeks to do local modifications but in this case as we built it, we added the local modifications as well and were able to put the trucks together quite quickly.” The trucks are also equipped with Epiroc’s Certiq technology, which utilises GPS and on-board diagnostics (OBD) to monitor trucks and equipment. Kenley says this technology is able to record vital information for a mine site. “It receives all the machine information, so it is able to record speed on grade, fuel burn over its operations, the number of tonnes per dump box, so it basically analyses a shift of work,” Kenley says. “It shows any faults as well so we are able to actually view those trucks online to see how they are going and so can the customer.

FEBRUARY 2022

“That helps the client identify their cycle time which is an important piece of information that they can actually monitor.” Considering the challenges that Epiroc faced in getting the equipment into Australia, Kenley says he is extremely proud of what the company was able to achieve. Hughes says he was impressed by Epiroc’s commitment to keeping the delivery date of the trucks on schedule. “To see that kind of assembly here in Australia, at that kind of level, is really pleasing to see,” he says. “Since the trucks have turned up they have been brilliant – they have far exceeded our expectations. “Just the coordination from Epiroc was outstanding; nobody on our site had any experience with Epiroc equipment, but they were able to get the trucks on site as well as the training for operators and all the spare parts we needed.

MINING EQUIPMENT

MANOEUVRABILITY IS A KEY FACTOR OF THE MT65.

“It all happened very smoothly and working with the Epiroc team has been brilliant.” Since supplying Tomingley with the trucks, Sharpe says Epiroc is now planning on shipping more equipment to Australia in kit form,

including its loaders. “We will be doing our full underground fleet assembly where required to match the current mining energies for new equipment in Australia,” he says. “There is still plenty of

equipment coming out of the factory, this is just to supplement getting the gear into the country earlier for our clients. “When you are dealing with highend minerals the miners want the equipment as soon as possible, so it

is up to us at Epiroc to do what we can to fast-track delivery. “It is still very early in the process of bringing in equipment like this, but the opportunities to further grow and enhance that side of the business - and support the factory in these high-demand times - is beneficial for both the company and the clients.” The Tomingley extension project is expected to extend its gold operations mine life to at least 2031. “When we first started we used all second-hand gear that was either reconditioned or brought in as-is to get it through that original three-year mine life,” Hughes says. “Over those years we were able to increase the resource, as well as the reserves, and we were able to increase the mining rate. “Underground is now mining at just under a million tonnes per annum, the open pit has started again with a small cutback and we have got a whole new deposit down the road. “Our sites are going really well, we have got a big future ahead of us, so it is an exciting time for Tomingley Gold and Alkane.” Alkane’s target for Tomingley in the 2021-22 financial year is 55,000 to 60,000 ounces of gold at an all-in sustaining cost (AISC) of $1450 to $1600 per ounce. AM

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MINING EQUIPMENT

SWEDISH STEEL A SUPERIOR SOLUTION FOR SCHLAM BEHIND THE INCREASING PRODUCTION OF AUSTRALIAN MINES ARE RELIABLE EQUIPMENT MANUFACTURERS LIKE SCHLAM. AND BEHIND SCHLAM’S MARKET-LEADING DUMP BODIES IS THE STRENGTH OF SSAB SWEDISH STEEL. HARDOX 500 TUF CAN REDUCE WEIGHT OR INCREASE SERVICE LIFE.

hese two companies have been aligned for several years, allowing for faster delivery of products and expertise. Schlam’s Hercules dump bodies are going from strength to strength, owing to SSAB’s supply of its Hardox wear plate for extreme abrasion resistance. Schlam sales manager Tom Smith says the foundations of their longstanding relationship was not a signature, but simply reliable steel. “The relationship with SSAB started because they’ve got a fantastic name in the marketplace,” Smith tells Australian Mining. “We’ve explored what they can do for us and over time they’ve become our primary supplier. There are no agreements between our companies to formalise this. “We use them because they have a great product, a great reputation, and they look after us with both collaboration and fantastic technical support.”

The latest addition to the Hardox range is Hardox 500 Tuf, well-suited to all kinds of dump bodies, buckets, containers, and other equipment exposed to heavy wear in the mining and agriculture industries. Smith says he couldn’t believe how well Hardox 500 Tuf performed. “The transition from Hardox 450 to 500 Tuf has been an exciting one,” Smith says. “SSAB released it to the market a few years ago, and personally, I was one of the most sceptical of the product on the advertised benefits of Hardox 500 Tuf. “It didn’t sit right with me; it didn’t seem real. But we’ve tested it extensively at Schlam and it has performed as advertised and, in some applications, it actually exceeded expectations.” Hardox 500 Tuf builds upon its predecessors in a few key areas – chiefly, material grade. Smith explains there are three things that matter in the body design for a customer: body weight, floor AUSTRALIANMINING

thickness and material grade. “We strongly believe we cannot be matched by our competitors, and our steel selection and body design are the reason why,” he says. “The unique design of Schlam’s Hercules HX dump body allows us to reduce weight whilst keeping the steel thickness where it is required, namely in the floor.” Simply, if a miner has less weight in the truck body per load, they won’t require as many truck hours, Smith explains. “We’ve found removing an additional five tonne per load on a typical 240-tonne truck generally saves upwards of $50,000 per year in operating costs,” he says. “By utilising the Hercules, you can potentially upgrade your floor from 20 millimetres (mm) quenched and tempered 450 to 25mm Hardox 500 Tuf without increasing body weight, meaning you increase service life and reduce the carbon impact of your dump body without sacrificing payload.”

FEBRUARY 2022

While the end user receives major benefits from the use of Hardox 500 Tuf, manufacturers like Schlam are also largely improved by its use. SSAB area sales manager for Australia and New Zealand, Matthew Spiteri, describes how Hardox 500 Tuf makes Schlam’s life easier. “The Hardox 500 Tuf workshop properties are very close to Hardox 450 grade, so Schlam doesn’t have to change welding, pressing and cutting procedures, which are vital in an efficient production environment,” Spiteri says. “Not only that, but our plate compared to other quenched and tempered manufacturers has tighter welding tolerances to benefit end users. “This means the pre-heat thickness is single plate, reducing the time of pre-heating for Schlam which can improve costs on gas, time and production.” These efficiencies are equally beneficial to the end user, manufacturers and the environment, as it is becoming increasingly important for all parties within the mining industry. “We find it to be the next step for the likes of Schlam as it not only improves production, but it improves emissions for increasingly eco-minded mining companies due to the reduced body weight,” Spiteri says. Also in sustainable steel production, SSAB developed the first fossil-free steel in August 2021 and is continuing to partner with companies globally for its supply over the coming 12 to 18 months. Spiteri says SSAB achieved its green steel goals far sooner than it hoped. “By 2026, we aim to have it manufactured quite freely with good, designated partners around the world,” he says. Without wanting to give too much away, as is the key for any industry leading business, Spiteri says Hardox 500 Tuf wasn’t the last we would be hearing from SSAB. “We’re always looking to improve our products and so there will be more products that have the Tuf aspect to them in the future,” he concludes. AM

WE’RE BREAKING NEW GROUND REMU RECYCLING BUCKETS Remu Screening Buckets are an ideal recycling solution. A multifunctional tool for padding, mixing, separating and crushing. These buckets are used in situ for council recycling collections, greenwaste, bio waste, manure, builders rubble, gyprock, landscaping, asphalt millings or shoreline cleanups. Whether you are a contractor, roadbuilder, pipeliner, landscaper or in mining, Remu has several options to choose from. Interchangeable sized rotors enable various sized products to suit your needs.

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MINING EQUIPMENT

THE VALUE OF VALVES FROM COAST TO COAST THE VALVE COMPANY HAS GROWN FROM STRENGTH TO STRENGTH SINCE THE PANDEMIC BEGAN IN EARLY 2020, OPENING A NEW BRANCH IN BRISBANE THAT IT WILL USE AS A SPRINGBOARD FOR EXPANSION ALONG AUSTRALIA’S EAST COAST.

IAN HAWKINS AND TVC CAN’T WAIT TO VISIT CLIENTS ONCE MORE.

s Australia’s sole distributor of DeZURIK valve products, The Valve Company (TVC) recognises the importance of equally servicing the many mining hubs scattered across the country. Having established itself in Western Australia in 1994, TVC took the next step in Queensland during 2020 with a view to benefit a wider range of mining customers with quality valve products. Such is the customer-focussed ethos of TVC, a new branch was hardly about enhancing the company name. Rather, it enabled TVC to take on the renowned DeZURIK name in a whole new way. TVC business development manager Ian Hawkins is one of the inaugural staffers at the new Murarrie facility outside Brisbane. He explains TVC’s approach in taking on the East Coast. “We bought the previous East Coast distributor’s inventory, we bought all of DeZURIK Australia’s inventory, we then bought another $1 million worth of additional inventory, plus we still have all of our WA inventory,” Hawkins tells Australian Mining.

“Something I love about TVC is that the leadership team recognises we are a stockist, and they back up our commitment to the brands we serve by holding inventory.” The need for extra inventory heightened during the onset of the pandemic as supply chains were universally disrupted and lead times suffered. Despite this, Hawkins says the past couple of years have been transformative for TVC. “Our inventory has helped us grow – we had a phenomenal first year in the 2021 financial year – and we expect 2022 to come up even better,” Hawkins says. “The first goal we kicked was a halfa-million-dollar order last financial year with the M1 upgrade project on the Gold Coast.” Another benefit of having significant inventory on hand is the ability for customers to trial DeZURIK products. Hawkins says this allows customers to understand the value of what they might receive should they opt to work with TVC. “These trials will depend on the client,” Hawkins says. “Normally, we’d mock up a purchase order for them AUSTRALIANMINING

to understand how the process would work, they use it for about six months, and if they’re happy we can lock in an order.” It’s this customer-friendly take that allows TVC to build strong relationships, which in turn enable better use of DeZURIK products. Hawkins says there’s nothing better than visiting a customer’s operation to discuss their valve application, answering any questions they might have. “In mid-2021 we made a lot of inroads with a client in Mount Isa where our relationship basically allowed us to walk up and tour their site to investigate where we can optimise their equipment,” Hawkins says. “The number-one goal of selling this equipment is being able to help people, make their lives better in some way, and maybe teach them something along the way. “We’re frequently identifying problems in customers’ applications. We don’t always get the sale but we’re always looking to help out for the betterment of the client.” Examples of DeZURIK valves include its flagship KGC-ES Knife Gate, which sets the brand apart from its competitors. With a 100 per cent port size and a design built for longevity in a hard-

THE VALVE COMPANY HAS BECOME SYNONYMOUS WITH DEZURIK VALVES.

FEBRUARY 2022

wearing mining industry, Hawkins says the KGC-ES represents why he loves his job. “What I really like about being a valve salesman is identifying the unique features and benefits of each individual brand,” he says. “This isn’t just another valve which has copied all the features of the next brand, but it’s got its own real benefits that set it apart.” TVC’s other highlights include DeZURIK’s KUL non-discharge urethane-lined slurry Knife Gate valve, or the traditional sleeved slurry Knife Gate. Both of which are customer favourites, accoding to Hawkins. “We have sleeved slurry Knife Gate stocked up to 24 inches,” he says. “Sometimes when we mention this to customers, I have to return to the office to take a picture because they won’t believe me.” Looking forward, TVC is eager to build upon the growth enabled by its new Brisbane facility. Hawkins says he’s excited to get back on site where he and TVC do their best work. “The first thing we’re looking forward to in 2022 is regional visits across eastern Australia and especially in mining-heavy areas. We will also be looking to grow our sales team to ensure all of eastern Australia is well looked after,” Hawkins concludes. AM

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FUTURE OF MINING EMISSIONS

POWERING TOWARDS A SUSTAINABLE FUTURE TRADITIONALLY ONE OF THE LARGEST PRODUCERS OF GREENHOUSE GASES, THE AUSTRALIAN MINING SECTOR IS NOW LEADING THE CHARGE TO KEEP THE NATION ON TARGET FOR NET ZERO EMISSIONS BY 2050.

ast year, the Australian Government pledged to act in a practical, responsible way to deliver net zero emissions by 2050, while preserving Australian jobs and generating new opportunities for industries. A large part of this saw Prime Minister Scott Morrison and Minister for Industry, Energy and Emissions Reductions Angus Taylor release Australia’s Long Term Emissions Reduction Plan. The technology-driven plan sets out a credible pathway to net zero by 2050, establishing Australia as a leader in low emissions technologies. In his address to the COP26 Glasgow Climate Summit in Scotland, Taylor outlines the ways in which Australia would reduce its emissions, using a range of new and future technologies which will advance through continued development in these sectors. “We estimate the six priority

areas for investment in the Roadmap – clean hydrogen, energy storage, low carbon materials including green steel and aluminium, carbon capture technology, soil carbon measurement, and now ultra-low cost solar – will deliver around half of the reductions we still need to realise to achieve net zero by 2050,” Taylor says. John Curtin Distinguished Professor Peter Newman from the Curtin University Sustainability Policy Institute says the whole private sector is now moving quickly towards net zero emissions. “That means by 2030 the private sector will have to have made a very substantial move which means they have to start now,” he tells Australian Mining. “I did the Western Australian State Sustainability Strategy working in (former WA Premier) Geoff Gallop’s office for three years from 2001 to 2003 and the leading companies at that stage were the mining companies. AUSTRALIANMINING

“At that time, Rio Tinto was the leader and they helped me produce a set of case studies on what we called ‘sustainability hope’ and they helped to make that available to the public.” Newman says the destruction of Juukan Gorge in Western Australia’s Pilbara region has proven a catalyst for an increased focus on environmental, social and governance (ESG) from mining companies around Australia. “That to me was a turning point in history, certainly in Western Australia but in many other parts of the world as well,” he says. “To see a 60,000-year-old relic demolished was a wake-up call to everybody that this has to be an issue that is taken seriously from here onwards. “So ESG went from being something you could report on and tick off, to becoming something that is absolutely essential.” Despite the relatively recent focus on ESG from mining companies, Newman believes there is a wealth

FEBRUARY 2022

of knowledgeable people already working in the industry with ideas on how to achieve sustainable goals. “So many of the younger engineers have been ready and waiting for this opportunity, so when they get asked how they are going to achieve these goals they already have the plans ready and are able to show that it will actually be cost effective,” he says. Newman believes that while there is great potential in hydrogen fuel cell technology, it will not be costeffective and the industry will be better off focussing on the benefits of battery technology. “All of the land transport is going to be battery-electric, so every train, truck and piece of mining equipment will be able to switch to batteryelectric or running directly off the main power supply,” he says. “Batteries are getting lighter and they now have a more extensive range. The battery chemistries are constantly being upgraded which is giving them more power.

FUTURE OF MINING EMISSIONS

“There are also so many different types of batteries for different purposes, including what is happening with lithium batteries, and these appear to be moving on a curve that is getting more and more efficient.” However, it is not just the major miners that are contributing to Australia’s target of net zero emissions. The nation’s Mining, Engineering, Technology and Services (METS) sector is also playing a significant role in the industry’s low-carbon ambitions. METS Ignited is part of the Australian Government’s Industry Growth Centres Initiative from the Department of Industry, Science, Energy and Resources. The organisation works with Australian suppliers to the mining industry, global miners, research organisations and capital providers to improve the global competitiveness and productivity of the sector. METS Ignited chief executive officer Adrian Beer says the recent focus on ESG is similar to another important mining trend from last century. “I would liken the recent uptake of ESG in the industry to the focus on safety in the 1990s,” he says. “The competing mining companies would unashamedly collaborate around safety because protection of workers was, and still is, a common interest. “That collaborative nature and spirit is now in place in regards to everything ESG. “Then we also have this collaborative competition around the way in which Australia goes about processing minerals relative to other parts of the world that may not do it

MINING IS LEADING THE WAY IN SUSTAINABLE PRACTICES.

in a way that is as environmentally, socially or ethically responsible.” Beer says now that the entire sector is willing to collaborate on ESG through advancing technology and research development, providing solutions to net zero emissions is becoming more readily available. “Here at METS Ignited, we are finding that there so much investment in social license and sustainability - or in mineral deposits that are going to sustain this new technology – that we are finding it difficult to keep up with the advances, which is a great problem to have,” he says. “All these big miners are looking for the technology that they know exists, but they can’t find the companies that have it in their hands. “So, the investors are cashed up and looking for places to invest, so it is just a matter of connecting them with the right solution.” One example of this collaboration is the Electric Mine Consortium (EMC), a group of more than a dozen mining and service companies that have joined forces with the ambition to accelerate progress towards fully electrified mining operations. Beer says the EMC is a great example of collaboration that is mutually beneficial but can also influence zero emission goals for other industries. “Mining is definitely leading the way and I think the recent advances we have made in the METS sector is helping to push that goal and leading by example,” he says. “Battery technology is not just limited to mining, it has applications that can be used in a number of industries including agriculture, defence and it even has potential in the space sector.

METS IGNITED CHIEF EXECUTIVE OFFICER ADRIAN BEER.

“When a different industry demands a similar product but with a slightly different variation, they also start innovating much faster.” Beer believes while Australia’s target for a 26-28 per cent reduction in emissions by 2030 will be difficult to attain, the nation’s 2050 plan is certainly achievable. “I don’t think net zero for 2050 is far-fetched at all, but it doesn’t necessarily mean it is a walk in the park,” he says. “Collectively, the combination of all these factors - the research, the technology, the public pressure, the demand for sustainability, the use of batteries – these are all contributing to changes in the way that the industry operates. “Optimising current mining processes won’t get us to net zero, so we will ultimately have to start doing things differently, because if we wait until there is one solution available, we won’t achieve this goal.” AM

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CRUSHING & SCREENING

A BUSINESS BUILT ON EXPERTISE AND ACCESSIBILITY THROUGH ITS RELATIONSHIPS AND INDUSTRY REPUTATION, DM BREAKER HAS BECOME A MAINSTAY FOR MINING’S CRUSHING AND SCREENING ENTERPRISES.

rading since 1997, DM Breaker Equipment has earned a reputation as a trusted supplier for a variety of sectors, including mining, construction, farming and civil engineering. The company originally supplied rockbreakers for industry use, but the business has grown since then, becoming the sole Australian distributor of the reputed DNB attachments range, while also branching out to distribute attachments from the likes of MB Crusher, Remu and Movax. DM Breaker’s work with MB and Remu has seen it provide solutions for crushing and screening – two critical steps in the ore reduction process. The partnerships have been about more than just supplying a part; DM Breaker has assisted mining companies and contractors to achieve critical ambitions in the field. “Five years ago, DM Breaker took on the MB Crusher dealership for Western Australia and Northern Territory, seeing an opportunity to assist companies and contractors in the mining industry to not only save them costs, but also to reduce the impact on the environment made by mining and earthmoving,” DM Breaker managing director Marion Marriott says. With more than 60 years’ experience in the field, MB is at the forefront of research and technology in crushing and screening. Over the years, the company has developed buckets that reduce the environmental footprint of operators and contractors alike, enabling the recovery of materials in situ. “MB emphasises increased productivity in mining applications, such as increased production in gravity plants, MRP (materials requirement planning) applications and on-site processing,” Marriott says. “The crusher buckets have the capability to add more value to mining operations and already existing tools at the job site.” It’s no question crusher buckets play a vital role in the mining industry, and Marriott suggests the by-products created from crushing and screening

DM BREAKER DEPLOYS MB AND REMU BUCKETS ALL ACROSS AUSTRALIA.

processes hold untapped potential that some mining operators or contractors might not be aware of. “Crusher buckets are very evolutionary for the mining industry and can change the way miners work. They create more versatility in handling a job, such as working in limited access areas where only an excavator can move in or crushing material immediately to optimise space and load factors on site,” Marriott says. “Often it is just a matter of changing perspective; not only understanding that crushing and screening waste is not really waste, but realising that it is actually a huge resource, still to be exploited.” After securing its MB dealership, DM Breaker established a relationship with Finnish crushing and screening manufacturer Remu. Today, DM Breaker supplies Remu’s screening buckets for mining companies and contractors, another attachment that has proved its worth environmentally. “Remu Screening Buckets are an ideal recycling solution – a multifunctional tool for padding, AUSTRALIANMINING

mixing, separating and crushing. The Remu buckets are being used for recycling landfill, composting, padding pipelines, backfill for underground mining and drying out tailings,” Marriott says. “Each rotor has a direct drive radial piston motor to divide the power of the bucket equally. Interchangeable sized rotors enable various sized products to suit the required needs.” Marriott says Remu and MB buckets are currently in operation across Australia, offering solutions for varying requirements. The buckets are being used in the Tanami region of Northern Territory to dry out tailings, are working in nickel mines in the Goldfields region of Western Australia, processing gypsum in WA’s Mid West region, and completing remediation and utilising waste for road haul base in the Pilbara region of WA. The current deployment showcases the versatility of the buckets, providing solutions for all manner of conditions and demands. And such expansive commission couldn’t be made possible without

FEBRUARY 2022

the communication and collaboration between different parties in the supply chain. DM Breaker believes cooperation is imperative in ensuring everyone is on the same page and that no work falls between the cracks. The company is constantly engaged with Remu and MB at the original equipment manufacturer (OEM) level as the buckets are constantly finetuned to maintain their applicability in the field, while its exchange with contractors and mining companies is never stagnate. And when DM Breaker isn’t maintaining liaison throughout the supply chain, the company is on the ground providing maintenance through its field service teams and dedicated workshops. A resolution is never far away. A family-owned and operated institution, DM Breaker is underpinned by friendly and proficient customer support. It’s a business built on approachability and accessibility – two traits never undervalued in the mining industry. AM

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CRUSHING & SCREENING

THE POWER OF COLLABORATION BOTH CRITICAL COGS IN THE MINING SUPPLY CHAIN, LINCOM AND DARACON HAVE FORGED A STRONG RAPPORT OVER THE YEARS. AS THE MINING INDUSTRY CONTINUES TO EVOLVE, THE RELATIONSHIP KEEPS BLOOMING.

incom has established a reputation for its work in the mining supply chain, delivering machinery from the likes of McLanahan, Thor Global and Powerscreen to mining companies and contractors. The company recently distributed a fleet of Powerscreen crushers and screeners to New South Wales’ Daracon Group to supply road base, gravel and stemming materials at mines in the Hunter Valley. Powerscreen’s Premiertrak 400X jaw crusher, Maxtrak 1300 cone crusher and Chieftain 2100X 3-deck screener have enabled mining operations to remain on track, exceeding expectations and highlighting the importance of relationships and cooperation along the way. According to Daracon maintenance operations manager Mick Hingerty, the machines went through a judicious selection process before being selected for use, which included considering whole-of-life costs. Powerscreen is a familiar original equipment manufacturer (OEM) to Daracon, and while a recognisable name always helps, the power of collaboration in the supply chain cannot be understated. This is where Daracon’s strong connection with Lincom has proved vital. “From our perspective, the Powerscreen product is well known to us. We’ve got a great depth of knowledge about the product and we’ve been on a bit of a journey over the last couple of years where Lincom have really partnered with us to provide direct feedback back to the factory,” Hingerty says. “We’re really trying to create that continual improvement through Lincom to Powerscreen and we’re starting to see some of those initiatives flow back through some of the machines. There’s a lot of product improvements that we’d flagged with the manufacturer. “We’re seeing some good payback in terms of the effort we’ve collectively put in.” Hingerty believes that across the journey, Lincom has become more than just a supplier to Daracon.

POWERSCREEN’S MACHINES HAVE BEEN A CRITICAL ASSET TO THE HUNTER VALLEY MINING INDUSTRY.

In an industry as scrupulous as mining, the importance of optimising productivity, safety and everything between has seen relations elevate beyond just a transactional connection. “When you’ve got a big reliance on a supplier like Lincom like we do, you’ve got to treat them as more than a supplier; they definitely have to become a partner,” Hingerty says. “They’re a part of our business. We have monthly supplier meetings – we’re very disciplined on that. We have actions out of every meeting and every person that participates in those meetings has one thing in mind and that’s to improve the Powerscreen products, and increase efficiency and uptime for Daracon.” A key consideration in the continual improvement of Powerscreen’s machines is the need to ensure they are compliant with a constantly evolving and demanding mining industry. Lincom’s equipment is mine spec compliant to Australian Standards, as well as MDG 15 compliant on all Hunter Valley mine sites. This further consolidates the importance of collaboration and

AUSTRALIANMINING

communication between more than one party. “You cannot work on a mine site without meeting various regulations. Those three machines are probably among the first machines in the crushing industry at least that are fit-for-purpose, out of the box,” Hingerty says. “Lincom has learned a lot over the last couple of years. The company is very proficient and knowledgeable about the mine site compliance requirements. “A lot of the initiatives we are seeing Lincom present with its new machines now are all a result of us working together and us educating them on what we require.” Daracon contract crushing manager Wayne Roberts says improving conveyor guarding is one part of this development process, again with mine spec compliance as the ultimate goal. Each of Powerscreen’s Premiertrak 400X, Maxtrak 1300 and Chieftain 2100X 3-deck machines have conveyor guards which are installed to protect workers, whether it be from rogue material flying off the fast-paced machinery or to prevent employees

FEBRUARY 2022

from entering the danger zone. “One of the big things about working with Lincom and Powerscreen is that we can have these guards put in place, but unless they’re in the correct place, most times they’re only going to be a hindrance to the actual operation,” Roberts says. “So over time we’ve been able to work with Lincom and Powerscreen and have these guards designed so they’re fully compliant with safety.” Roberts says that not only have the companies collaborated to redesign guards to ensure safety, but adjustments are being made end-toend, spanning components such as belt covers, skirting, dust suppression and beyond. Both family-owned businesses, Daracon and Lincom share the humility and understanding to enable open communication and collaboration. It’s a relationship of constant improvement and development. Not always is an objective achieved first go. But it’s only inevitable a likeminded partnership will achieve the desired outcome, and Daracon and Lincom have that down to a tee. AM

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MINING EQUIPMENT

THE BACKBONE OF CRUSHING IS CUSTOMER-FOCUSSED THYSSENKRUPP DESIGNS ITS CRUSHERS TO REMOVE ANY EXTRA STRESS FOR THE OPERATOR, WITH AN UNDERSTANDING OF THE SHEER NUMBER OF PROCESSES INVOLVED IN AN UNDERGROUND MINE.

ineral processing is just one of Thyssenkrupp’s specialties in the mining space, with a range of equipment to cater to the vast array of environments and materials presented by the industry. One of the most demanding applications these machines excel in is Australia’s iron ore industry where some of the most difficult conditions in global mining is found. Thyssenkrupp product line manager for mining, Luke Bennett, tells Australian Mining the company’s vibrating grizzly feeder (VGF) is just one example of its crushing prowess, with a reputation to match. “This machine has been the backbone of primary scalping for many years in the Australian iron ore industry,” Bennett says. “With multiple installations, including the largest VGF installed in iron ore, and continual rotable machine demands, our clients request these machines because they know they will perform and last.” Another example of the company’s crushing expertise is epitomised

by its jaw gyratory crusher (JGC). Bennett says Thyssenkrupp sets itself apart by continuing to develop its existing portfolio of equipment while also introducing new technology as customers request it. “The jaw gyratory crushers have been leading the way in block cave mining operations with the largest feed opening on the market,” he says. “A client wanted a machine they could feed from both sides so Thyssenkrupp designed it for them.” In response to the broader needs of its clients, Thyssenkrupp also designed the eccentric roll crusher (ERC). The ERC is designed for greater efficiency and productivity using a roll mounted eccentrically between the crushing chamber and the integrated screening chamber. This optimises mining operations for better integration and automation. Bennett also says the machine’s reduced size – up to 50 per cent – allows it to suit a wider range of mining scenarios. “Our machines not only look at the process they are involved in, but the effect on our clients’ overall projects,” he says. “The ERC not only delivers the

THYSSENKRUPP’S VIBRATING GRIZZLY FEEDER HAS BENEFITTED SEVERAL IRON ORE JOBS.

AUSTRALIANMINING

THYSSENKRUPP’S CRUSHERS CATER TO A WIDE RANGE OF MINED MATERIALS.

product our clients require, which can be achieved from other machines, but also reduces the size of the underground cavity, or height of the crushing wall which has significant savings to the overall project.” In all these crusher models and more, Thyssenkrupp ensures a formula for robust and simple operation. Bennett says the less Thyssenkrupp customers must worry about the state of their machinery, the better. “Robustness is one of the biggest considerations for our customers,” he says. “This gives them peace of mind so that they can simply turn the machine on and all they need to worry about is replacing a liner in 12 months’ time, for example. They can rely on this happening year after year as the machine operates.” This customer-centric consideration is a key pillar of Thyssenkrupp, supported by its number of service centres and approach to customer service. Thyssenkrupp sales and service director Uwe Zulehner says all the aspects and disciplines of Thyssenkrupp’s customer’s operations are considered.

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“In order for Thyssenkrupp to improve our products and services we need to understand the demands of our clients in a challenging and changing environment,” Zulehner says. “The constant contact to our customers is fundamental for our business and the development of our support offerings. “This goes for all different levels in their organisation, from the planning to the operational departments, as we listen to what clients have to say and where their challenges are.” Thyssenkrupp operates multiple service centres near its customers’ sites, including in Port Hedland and Perth in Western Australia, and in Brisbane and Mackay in Queensland. “These service centres provide continuous support to customer operations for shutdowns, maintenance and off-site repairs,” Zulehner concludes. “Having a strong and stable workforce helps us to deploy the same personnel to the same sites and machines. “This increases their knowledge of specific sites which results in more effective on-site support and potentially reduces shut down times.” AM

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CRUSHING & SCREENING

FLSMIDTH ZEROES IN ON SUSTAINABILITY AS THE WORLD SCURRIES INTO ACTION TO REACH NET ZERO EMISSIONS BY 2050, FLSMIDTH IS TACKLING THE CEMENT AND MINING INDUSTRIES.

LSmidth is bringing its A-game when it comes to reducing emissions, using unmatched technology and knowledge to enable mining and cement companies to be part of the solution, not the problem. With sustainability at the forefront of FLSmidth’s ethos, its MissionZero ambition was born to reduce emissions in mining and cement to zero by 2030. The fundamentals of MissionZero are FLSmidth’s goal to offer customers sustainable solutions that enable zero water waste, zero emissions and zero energy waste by 2030. MissionZero utilises FLSmidth technology and products that allow miners to implement solutions that assist in reducing emissions across its flowsheet. “You need mining for the clean energy revolution to go forward, so how we help our customers is absolutely critical to support mining in reaching net zero,” FLSmidth regional president Tamer Eid tells Australian Mining. “The majority of Scope 3 emissions are from our customers, so the biggest impact we can have as a provider is helping our customers reduce their emissions, water and energy waste.” There is no silver bullet to deliver MissionZero. Mining is complex and there are different solutions that need to be applied depending on the commodity and needs of the region. Loading and hauling is one of the biggest sources of greenhouse gas

What beneﬁts could the MissionZero Mine deliver?

Reduce GHG emissions by more than 100,000 tonnes of CO₂e per year

MISSIONZERO IS FLSMIDTH’S MAIN FOCUS OF 2022 AND BEYOND.

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45% reduction in grinding energy per kWh/t 30% overall energy consumption reduction

30% increase in plant throughput

35% reduction in grinding energy per kWh/t

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emissions from a mine, and tailored solutions for in-pit crushing and conveying can significantly reduce those emissions. “When you go to ship out the rock from the pit, in some places mines are so deep that the truck can take well over an hour to get to the top and the same to go back down,” Eid says. “Think about that from an emissions perspective; that’s a huge amount of emissions just to get around the mine. But what about if you could crush it and ship it on a conveyor straight out of the pit where you’ve done the work?

TAILORED SOLUTIONS FOR IN-PIT CRUSHING CAN REDUCE EMISSIONS.

AUSTRALIANMINING

“In-pit crushing and conveying means you can send it out ready to be used at the next stage of the process, which reduces the amount of trucks, thereby taking out one step of emissions creation.” Grinding is another large source of greenhouse gas emissions, however, technology breakthroughs like coarse flotation and fast flotation machines can reduce the energy needed to grind ore by up to 30 per cent, improving recoveries and producing a cleaner product. FLSmidth aims to put a sustainable package forward to customers which enhances productivity but reduces environmental impact at the same time. In July 2021, FLSmidth agreed to acquire thyssenkrupp’s mining technologies business, thyssenkrupp Mining, with integration expected in the second half of 2022. “The thyssenkrupp Mining acquisition is really important for us, it is a transformational deal that will set up FLSmidth as an even stronger mining sustainability innovator,” Eid says. “This creates a stronger value proposition for our customers, as we will become a true leader in global mining with a complete pit-to-plant range of technology, equipment and service expertise.

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We modelled what the impact would be if you replaced a traditional wet milling SABC circuit, standard ﬂotation cells and cyclone sand tailings dam with the MissionZero Mine ﬂowsheet for a 100,000 tpd plant.

“We will also be able to offer bestin-class digital solutions, covering continuous mining, mineral processing and mining systems.” The thyssenkrupp Mining acquisition will complement FLSmidth’s work with MissionZero as thyssenkrupp Mining has a strong in-pit crushing set up which will add to FLSmidth’s existing product range. MissionZero is FLSmidth’s main focus of 2022 and beyond as the 2030 deadline looms. “We’re confident knowing 2030 is a pretty short timeline, because we have these products available right here, right now. They’ve been used. They’ve been proven. It’s a particularly exciting time,” Eid says. “For us it’s imperative that we help our customers achieve their goals with the products and technologies that are ready to go.” As FLSmidth looks to the future, the company’s focus is to be the partner of choice for its customers, increasing productivity and profitability with sustainable solutions. “It’s important to practice what we preach, so we are going full steam ahead down our MissionZero path as well, it’s not just about saying ‘this will work for our customers’, we also have to walk the talk,” Eid concludes. AM

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CRUSHING & SCREENING

THE VALUE OF THE CRUSHER OUTWEIGHS ITS COST MINPROVISE GENERAL MANAGER OF ENGINEERING AND VALUE-ADDED SERVICE, JOHN MINNAAR, EXPLAINS WHY THE HIGH CAPACITY OF THE KAWASAKI ZI-2100 CONE CRUSHER’S CHAMBER RESULTS IN A REMARKABLE IMPROVEMENT IN CRUSHING CAPACITY.

he crusher is one of the most important pieces of machinery in mining. It is responsible for breaking rocks and ore to produce a product that is suitable to be exported and sold or used in downstream processing. The method used by some conventional crushers is to maximise crusher throughput. Their large eccentric settings result in a significant amount of material being recirculated through the circuit before it reaches the required size. Improving on this method, Earthtechnica, a subsidiary of manufacturers Kobe and Kawasaki, has created the ZI-2100 cone crusher, which is distributed in Australia by Minprovise. As Minprovise General Manager of Engineering and Value-Added Service, John Minnaar, explains, the ZI-2100 cone crusher stands apart from the competition by the way it processes material. “It produces more material closer to the client’s desired size, per crusher pass,” he says. “The ZI-2100 uses a smaller eccentric throw that means more precise crushing and less energy use.

USING ZI-CONE CRUSHING TECHNOLOGY COULD INCREASE THE PLANT OUTPUT BY APPROXIMATELY TWO PER CENT.

The rocks are more rounded through inter particle crushing, resulting in less recirculating load and reduced degradation when shipping the product.” Degradation refers to the change in size of the product between the mine site and its final destination – normally overseas. “When rocks break in the crushing chamber, they end up with jagged or splintered shapes that can be worn down during the transport and handling process,” Minnaar says. “Degradation creates a significant difference between the weight of acceptable product on departure compared to its arrival at its destination. This can, and usually does, result in penalties for producers. Something the ZI-2100 crusher can reduce.” Minnaar says crushers are generally selected in terms of throughput, but clients don’t make money with crusher throughput – they make money on the product produced, and that’s where the ZI2100 excels. “Say, for example, a crusher processes 500 tonnes per hour. Of that 500 tonnes passing through the machine, maybe 150 tonnes per hour are not quite the client’s desired size, so it has to go back into recirculation,” he explains. “Whereas with the ZI-2100, because of the slightly taller chamber, material stays in the chamber longer for more breakage, which means that of the 500 tonnes, less than 100 tonnes per hour are recirculated. This unlocks capacity potential in the circuit for more product to be produced and uses less energy.” Minnaar says this increased efficiency has the potential to provide huge economic benefit, especially in the iron ore industry that has seen major price fluctuations over the past 12 to 18 months. More overall product can mean millions of dollars in additional revenue. “As another example, say a plant produces 10 million tonnes per AUSTRALIANMINING

THE ZI-2100’S CRUSHING CHAMBER IS SLIGHTLY LONGER THAN OTHER MODELS.

annum of product, common in the Pilbara, using ZI-Cone crushing technology could increase the plant output by approximately two per cent,” he says. “That is more or less another 200,000 tonnes per year extra product. At $100 per tonne the two per cent adds an additional $20 million revenue to the bottom line. So, imagine what would happen if the increase was five per cent? This can be quantified through test work”. Looking at another feature, the crushing liner nip angle on the ZI-2100 is optimised compared to conventional crushers. “Because the ZI-2100’s crushing chamber is slightly longer, it can have a more gradual increase in angle and never exceed the material’s natural nip angle,” Minnaar says. “If you have a very short crushing chamber, you need a large angle to go from the closed-side setting to the feed opening. This large angle is usually close or larger than the material natural nip angle causing the liner to wear very quickly, especially

FEBRUARY 2022

in localised areas resulting in liner belling.” Minnaar says a longer chamber results in less downtime, less maintenance time and clients often gaining financially as liner changes are less frequent. “With the ZI-2100 you can generally get a longer life out of a liner set,” he says. “We do see in our industry that focus is on the pricing of crushers and liners more than the value they can offer. Decisions on models are made by comparing crushers on throughput and seeing that one model costs less than the other. “However, clients may be losing out on millions of dollars a year in additional revenue because selection of a specific crusher is not based on its value. “For us it’s important to distinguish the difference between a crusher price and the value that a crusher adds to the process. Minprovise assist clients with data and information to evaluate and select based on value”. AM

A SMALL STEP ON OUR PATH TO CHANGE

FROM 2021, ALL CASTROL PRODUCTS WE SELL IN AUSTRALIA WILL BE

COMMITTED TO CARBON NEUTRALITY IN ACCORDANCE WITH PAS 2060** A SMALL STEP TOWARDS A MORE SUSTAINABLE FUTURE

* **

in accordance with PAS 2060, see www.castrol.com/cneutral for more information. The C02e emissions are calculated in accordance with the Greenhouse Gas Protocol’s Product Life Cycle Standard and includes life cycle emissions. The demonstration of carbon neutrality will be assured by an Independent Third-Party and certified to BSI’s PAS 2060 carbon neutral specification. See www.castrol.com/cneutral for more information.

CRUSHING & SCREENING

SEARCHING FOR SAFETY: BOOST SAFETY AND EFFICIENCY WITH DIAGNOSTIC TOOLS HAVER & BOECKER NIAGARA PARTS AND SERVICE MANAGER WILM SCHULZ EXPLAINS HOW VIBRATING SCREENS AND THEIR PROPER MAINTENANCE CAN MAKE OR BREAK AN OPERATION.

HAVER & BOECKER NIAGARA PARTS AND SERVICE MANAGER WILM SCHULZ.

vibrating screen is the heart of steady operations, as the deciding factor in mined products meeting specifications. Deadlines and quotas might tempt producers to overload the screen while attempting to increase their bottom line. However, this contributes to downtime due to premature wear and might create safety hazards for workers near an unbalanced screen. And just as monitoring a heart rate is an essential for optimal health, the same idea applies to a mining operation. Think of manufacturers as an operation’s cardiologist, there to diagnose and remedy operating issues before they become a safety hazard or halt production altogether. They provide producers with the necessities to streamline an operation and minimise downtime or injury. And, these days, that starts with diagnostics. Like a house-call from a doctor, onsite diagnostics enhance aggregate operations through vibration analysis service programs without having to transport the equipment into a shop. These programs offer producers insight on their screen’s performance to achieve optimum efficiency and ensure

minor operating issues don’t become major hazards. For the first time ever, manufacturers’ service programs provide producers the opportunity to monitor screening performance in real time. And recently, some manufacturers advanced these systems by using wireless technology. These advancements offer a handsoff approach to analysing screening equipment by allowing operators to stand out of harm’s way — from a potentially off-balanced screen — when performing diagnostics. In addition to safety, wireless technology offers operators remote, real-time monitoring, which ensures equipment is properly maintained and running optimally. This means less risk that strain is placed on the screen or other parts of the operation to maintain production quota. This increased efficiency and enhanced safety is the healthy choice for all areas of the operation. Sound interesting? Here’s how it works: It all begins with a close relationship with the original equipment manufacturer (OEM) and is enhanced by real-time equipment monitoring. Finding a key partnership where an OEM approaches the application as a solution provider rather than an equipment supplier is key to productivity and success. If your OEM isn’t providing consultative advice and real-time proactive monitoring, it might be time to seek another solution. A key aspect to safety is having equipment that runs at peak performance and knowing when and how to maintain it. The more time spent fixing and maintaining the equipment heightens the risk of injury. That is where real-time monitoring comes in handy. An advanced vibration analysis program specifically monitors the health of vibrating screens. That real-time feedback ensures optimised screen performance and equipment durability. AUSTRALIANMINING

HAVER & BOECKER NIAGARA’S PULSE VIBRATION ANALYSIS PROGRAM MONITORS VIBRATING SCREENS.

The hands-free system uses a wireless, industrial-grade tablet computer and eight tri-axial sensors to detect abnormalities the human eye cannot, such as a hairline crack in a side plate or an uneven or twisting motion. Even the slightest irregularities can result in diminished performance, decreased efficiency and safety risks for the operator. The programs use wireless accelerometers to detect any irregularities, allowing operators to stand as far as 100 metres out of harm’s way. Each sensor attaches to key places on a machine to send 24 channels of data to the tablet via WiFi — illustrating the machine’s orbit, acceleration, deviations and more. After the sensors record the data, trained and experienced engineers review, study and interpret the results

through the system’s database. This provides the engineers and producer with a detailed report of any concerns. If an irregularity is detected, the service team travels to complete onsite service, which keeps producers on top of preventative maintenance and ensures a safe operation that runs at maximum efficiency and lower risk. Some vibration analysis systems store each machine’s historical data, which allows for quick comparison over time and easy troubleshooting. More and more often, producers rely on diagnostics for safer work environments and a streamlined operation. Its hands-off approach offers producers a healthy operation, running at peak performance, which helps them efficiently meets deadlines and produce quality product for their customers. AM

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FEBRUARY 2022

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PROFILE

CUSTOMER CENTRICITY A FOCUS FOR WALSH WEIR MINERALS APAC REGIONAL MANAGING DIRECTOR KRISTEN WALSH HIGHLIGHTS THE IMPORTANCE OF WORKING IN PARTNERSHIP WITH CUSTOMERS TO SOLVE THEIR BIGGEST OPERATIONAL CHALLENGES SAFELY, EFFICIENTLY AND SUSTAINABLY.

ast year saw the Weir Group celebrate its 150th anniversary, giving them an opportunity to reflect on a long history of innovative engineering which began in 1871 when two engineers, brothers James and George Weir, developed a way to improve steamship performance. For newly appointed Weir APAC regional managing director Kristen Walsh, recognising the significant milestone, gave her a chance to connect with her teams to get a deep understanding of the culture and values that have delivered the company so much success. “Reflecting on our 150 years of knowledge and leadership, really gave us a chance to also look forward and focus on where the company is going - ultimately it’s about continuing to care for people as well as bringing value to our customers,” Walsh says A trained engineer, Walsh says an attractive part of working with Weir is to support the company’s local presence. “We have a big operation and footprint. Across our APAC region alone we have 23 service centres, 4 R&D centres and 9 manufacturing centres (including the largest ferrous foundry in Australia – in Artarmon, Sydney). Our engineered solutions and technical teams that support them are some of the best in the world. And we also have unrivalled support from our extensive global network in over 70 countries. “With such big teams, across different locations it’s important that I have strong engagement to ensure our people feel connected to our growth strategy and understand how their role contributes to looking after our customers. “Our customers are at the heart of our business, so I have been spending time meeting with many of them so that we can continue to understand their needs and make sure their requirements are being met.” Walsh says one of the Weir

WEIR MINERALS APAC REGIONAL MANAGING DIRECTOR KRISTEN WALSH

Minerals focus areas in 2022 will be on supply chain and building stock within the region to make sure customers can have reliable access to the equipment and parts they need to operate smoothly. “Weir Minerals is an original equipment manufacturer in the truest sense – we develop, design and make the end-product. We make the critical components and spare parts for our products. And we make them all from materials that we develop and manufacture AUSTRALIANMINING

ourselves, in order to improve our equipment’s wear life and reduce the total ownership cost of our products.” “We are working hard to provide our customers with an integrated solution. While we have always had a reputation as original equipment industry leaders, we are increasingly focused on how we can deliver efficiency, productivity and sustainability improvements for our customers,” she says. “Often this is an outcome of

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Weir providing an increased level of onsite support, particularly during significant maintenance projects or sites being recommissioned. “I hope to leverage my service background to encourage more site-based support to customers, so we can understand what our customers need in real time and help develop solutions, whether it is recommissioning, troubleshooting or making improvements to existing facilities and processing circuits.” Walsh accepts her new role will provide challenges. This includes the high volume of technology and innovation that Weir brings to the resources industry. “Because we have design centres across the world, there are new product enhancements and offerings that are happening all the time, that are fantastic innovations for customers,” she says. “Our APAC team contributes directly to the Weir global product roadmaps and this helps our team be proactive and bring new offerings to our customers early.” Walsh says the company’s plans for 2022 include the opening of a site in Port Hedland. “I recently spent time in Kalgoorlie at our new service centre and visiting customers and witnessed the importance of a local presence for our customers. The strategic location of our manufacturing sites and service centres allows us to meet the specific needs of our customers,” Walsh said. One of the company’s principles is to work in partnership with customers to solve their biggest operational challenges safely, efficiently and sustainably. “As well as a focus on people safety, there is also the opportunity in environmental and social governance (ESG) in how we can reduce water consumption, power consumption and emissions both for our own business and also for our customers,” she says. “We have the engineering expertise to make a real difference and our job is to bring global best practice to the industry.” AM

DIGITAL MINING

TAKING BELT CLEANER MAINTENANCE TO ANOTHER LEVEL FLEXCO INDUSTRY MANAGER FRANKLIN MOORE HIGHLIGHTS THE FOUR KEY PAIN POINTS OF BELT CLEANER MAINTENANCE THAT CAN BE ALLEVIATED THROUGH THE COMPANY’S LATEST SOFTWARE OFFERING – FLEXCO ELEVATE.

arryback is one of the main causes of conveyor issues at mining operations. It can lead to faster belt wear and additional clean-up activities, with both translating to further downtime and a loss of production, which is critical in the resources sector. Flexco industry manager Franklin Moore says carryback is often thought of as an unavoidable reality for belt conveyors at cement operations, but it doesn’t have to be. “If not given the full attention it requires, carryback can threaten the productivity and safety of an operation,” Moore tells Australian Mining. “When not addressed, it can reduce potential throughput, require frequent cleanup, pose slipping hazards for employees, and even cause premature belt wear. “While it can be easy to overlook belt cleaners as just one small piece of a much larger puzzle, they play a critical role in minimising carryback and its negative effects on an operation.” Moore says the best defense to the threat of carryback is an effective maintenance strategy for belt cleaners supported by remote belt cleaner monitoring technology. Flexco has just released its latest technology, Elevate, a new software that allows customers to monitor their belt cleaners from anywhere. Elevate’s predictive, data-driven engine lets customers move from traditional methods of monitoring cleaner performance to a new way that empowers operations for the future. Moore says this technology employs devices attached to belt cleaners throughout an operation to monitor cleaner performance and transmit data to the cloud in real time. “In a true remote belt cleaner monitoring system, this data is interpreted in the form of critical insights and predictive analysis that can help optimise productivity, streamline operations and heighten operational efficiencies,” Moore says. He highlights four primary pain points of traditional belt cleaner

THE FLEXCO ELEVATE I3 DASHBOARD PROVIDES OPERATORS INSIGHTS AT THEIR FINGERTIPS.

maintenance that can be alleviated through using Elevate.

Keeping cleaners engaged and working properly

For belt cleaners to work effectively, they need to be properly engaged with the belt and maintain proper tension levels. “Because cleaners can become disengaged over the course of normal operations, it is essential that they be monitored and maintained regularly,” Moore says. “If not, excessive carryback and buildup of debris on belts can lead to wear and tear, poor tracking, and seized idlers.” Elevate can significantly improve an operation’s ability to track belt cleaner effectiveness and address maintenance needs in a timelier manner.

Manual maintenance and repairs compromise safety

Moore says carryback is one of the greatest threats to employee safety on a belt conveyor. “While there is a critical need for

proper belt cleaner inspections and maintenance on conveyors, both of these tasks present safety challenges of their own by placing employees close to the moving belt and often in confined spaces to access the cleaners. “A belt cleaner monitoring system lets operations remotely gather critical data and perform real-time analysis of belt cleaner performance. “This can significantly reduce the reliance on manual inspections and the possibility for injury they present.”

Labor hours and wasted costs

Manual inspections require a significant use of manpower for an operation. This includes hours walking the belt or even driving to the site to conduct the inspections. Moore says once repairs are identified, additional time is required to coordinate with a purchasing department to secure any necessary parts. “Allowing operations to better evaluate belt conveyor health anytime, anywhere, without dispatching a crew to the physical belt location is a

THE FLEXCO ELEVATE I3 DEVICE SIMPLY ATTACHES TO FLEXCO BELT CLEANERS WITH A 42-BOLT CLAMP.

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significant advantage to remote belt cleaner monitoring,” he says. Elevate can not only help reduce the need for belt cleaner monitoring, but it can provide insights to other areas of belt performance that can improve overall maintenance efficiency.

Accurately timing maintenance

Scheduling belt cleaner maintenance on a belt conveyor can pose a number of challenges. If problems are not caught soon enough, what could have been solved with routine maintenance can lead to equipment failure, downtime and even potentially catastrophic events. “In an ideal scenario, necessary maintenance work is identified in a timely manner and scheduled for upcoming planned downtime,” Moore says. “However, even this situation can result in equipment being replaced prematurely, resulting in unnecessary costs for an operation.” Elevate delivers valuable insights remotely and in real time. These insights provide a detailed view of the belt cleaner performance and allow maintenance teams to better realise several factors such as cleaner engagement, belt and cleaner run times, tensioning reminders, and urethane and carbide blade wear. Elevate can also detect abnormal events in overall belt performance that could indicate a more significant problem to come, including those that might not even be caught by the naked eye with a physical inspection. AM

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DIGITAL MINING

MACRO LEVEL ADVANCEMENTS FOR MICROMINE TECHNOLOGY IS ADVANCING BEFORE OUR EYES, WITH BIGGER AND BETTER CAPABILITIES AND EACH SUPERIOR TO THE LAST.

ining software is no different, and as technology progresses, there is no limit to what can be done on a

mine site. Micromine has taken the evolving industry in its stride and given itself a complete rebrand to increase its focus on new processes and opportunities unlocked by mining innovations. The Micromine rebrand will give clients more clarity on which product is the right one for them and their particular mine. “We have more offerings now, so the rebrand is about showing our clients what the product is, who it is for, the problem it is solving and where it fits in the value chain,” Micromine chief strategy and product officer Kiril Alampieski says. Micromine revealed the rebrand at its industry event Micromine Momentum in November 2021, a virtual conference for geo-professionals

and mining specialists, and the event also saw the release of Micromine Nexus. Micromine Nexus will be released early this year, and is designed to connect and orchestrate workflow tools, while providing data security across the entire ecosystem. “What we’re hoping with Micromine Nexus is to connect users and the data across the whole value chain so that everyone is singing from the same hymn sheet; working from the same set of data and collaborating around that to understand how they impact each other,” Alampieski says. “By improving these decisions and outcomes, it will also have less of an impact on the environment and the community by getting it right the first time.” After recently acquiring Alastri Software and Precision Mining’s mine scheduling software, Spry, Micromine is focussed on integration and making the companies mesh together as seamlessly as possible.

“With the acquisition of the two new businesses, it helps us clarify where our offerings fit in and what value they are delivering for our clients that’s the key driver of the rebrand,” Alampieski says. The two products created from the acquisitions are Micromine Spry and Micromine Alastri. Both are mine scheduling software, however Micromine Alastri specialises in open pit metals and iron ore while Micromine Spry specialises in open pit coal. The company has also revamped its namesake product, splitting it into two separate products - Micromine Origin and Micromine Beyond. Micromine Beyond does everything around designing and simulating the mine, including long-term scheduling or strategic scheduling. Micromine Origin is a comprehensive exploration and 3D modelling solution that allows you to integrate, validate and interpret critical exploration data. MICROMINE NEXUS WILL BE RELEASED EARLY THIS YEAR.

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“Micromine has a product covering almost every need of every user in the mining value chain,” Alampieski says. The vision is clear for Micromine moving forward. The company intends to work even closer with its clients to be able to give them the best mining solutions it possibly can. “The focus is really listening to what our clients are saying and thinking about what the underlying issues are,” Alampieski tells Australian Mining. “It’s not just solving the problem that’s right in front of our clients, but developing a technology solution that unlocks that next step – to the next generation technology for mining,” Micromine is helping mines go digital across their whole operation as quickly as possible, utilising all the different parts of the value chain through the technology, which significantly scales up the client’s capabilities in their mining operation. “This year is very much about facilitating collaboration between users by simply providing them with a technology platform that’s integrated,” Alampieski says. With physical separation among mining and exploration teams becoming more commonplace, seamless transfers of knowledge and effortless data management is more critical than ever. Micromine Nexus brings teams together through the latest cloud technology and direct integration into Micromine Origin. Onsite exploration teams can utilise Micromine Nexus to collaborate with city-based resources or geographic information system teams, ensuring tighter version control of data and projects. “We’re focussed on making sure that there is fluidity of data sharing and collaboration across the value chain so that it’s as seamless as possible to work with their colleagues, whether they’re in the same building, in the same team, or on the other side of the planet,” Alampieski says. In the wake of the pandemic, many mining companies are enthusiastic about technology and how it, combined with better communication, can improve the future of mining, and with Micromine they have a one-stop-shop solution. AM

The ZI-2100 is here! Australia’s leading supplier of crushing equipment and services is proud to announce that the ZI-2100 Cone Crusher is now in stock, in Perth. Proven Japanese engineering and design quality from Kawasaki Heavy Industries, supported locally by Minprovise.

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DIGITAL MINING

WIRELESS MONITORING IMPROVES SAFETY AND PRODUCTIVITY EQUIPMENT IN THE MINING AND QUARRYING INDUSTRIES IS SUBJECT TO HEAVY USE, DIRTY ENVIRONMENTS AND HIGH TEMPERATURES. BSC LOOKS AT THE VALUE OF WIRELESS MONITORING IN THIS ENVIRONMENT. ABB IS DELIVERING SMARTER OPERATIONS TO THE MINING INDUSTRY.

ear and tear from these challenges and other pressures is unavoidable – but becomes crippling if it causes a machine’s rotating components to fail. “The major pieces of equipment in a quarry or mining operation are rotatorbased,” BSC’s national engineering manager Anthony O’Keefe says. “Think of crushers, combiners, rollers, pumps – these and others are the fundamental pieces of equipment needed to get the job done.” The reliability of rotating components is paramount in ensuring facility output is maintained without disruption. “Take a crusher, for instance. Big rocks need to be crushed down to size. If that crusher’s rotating component fails, then the crusher is out of action and the whole process comes to a halt. If you can’t crush rock, there’s no production,” he elaborates. “So, we need to make sure such equipment lasts as long as possible – and to know where the machine is at in terms of maintenance and when it needs to be replaced. This might range

from simple lubrication every now and then, to as much as a complete rebuild or equipment overhaul. “How do you ensure reliability? By monitoring the condition of your equipment. This won’t come as a revelation to anyone.” And essential to condition monitoring is vibration analysis – the process of monitoring levels and patterns of the various vibration signals in all types of components – so that abnormal vibration events are detected, and existing or oncoming problems identified and fixed before it’s too late. “Vibration analysis is not a revelatory new discovery either,” he continues. “Everybody does it. But not everyone conducts wireless vibration analysis. And this is key – because they should. “Wireless vibration is not a new technology, but the mining and quarry industries have some catching up to do, which is completely understandable, because the pace of technological improvement and increasing cost-effectiveness has happened so fast – especially recently – that it’s just not on people’s radars yet.” At the moment, the standard AUSTRALIANMINING

practice is for individuals to go to sites and manually conduct vibration analysis. “Operations rely on individual data collectors to go to a site with their equipment, plug it into each asset, and do a series of data collections,” O’Keefe explains. “Then they will sit down and have to analyse that data.” The whole process is very time consuming, with individuals – or even teams of individuals – walking through a whole plant, collecting data, analysing it, then returning to the main office to deliver reports on what has been found out and what actions might need to be taken. “This is why we at BSC find ABB wireless monitoring devices so helpful – they make the case for mining operations to switch to wireless,” O’Keefe says. “ABB remote wireless monitoring devices – the ABB Ability™ Smart Sensor is a great example – remove the need for individuals to walk around the plant.” Using ABB’s remote wireless condition monitoring devices, companies can improve safety – as individual assessors are not exposed

FEBRUARY 2022

to risk; receive data in real time over the internet cloud – instead of receiving once-monthly reports from individual assessors; and access more and better data for greater reliability. What goes along with these improvements and savings is greater capacity for analysis – and training in analytical trends – so that personnel can determine what equipment needs to be fixed, removed, or overhauled ahead of time. O’Keefe sums it up as safer machines, safer workers, better data, better predictive ability, no surprises and no disruption. “Customers can be confident in us as a supplier of wireless condition monitoring devices,” he concludes. “We have many supply options available, including ABB products; access to different technologies – and the competence to assist in choosing and implementing the right one. “As part of Motion Australia, BSC is a big company with a great service offering. And that is matched by a big company like ABB, which has the resources to invest in R&D and produce the best devices – like the ABB Ability Smart Sensor.” AM

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WATER MANAGEMENT

REDEFINING UNDERGROUND WATER MANAGEMENT THROUGH THEIR NEW PC PUMP STATION, XYLEM AND SEEPEX HAVE BUILT A COMPACT UNIT PERFECT FOR FIXED AND MOBILE MINE DEWATERING APPLICATIONS UNDERGROUND.

t is Xylem’s mission to solve the world’s most challenging water issues, no matter the situation or environment. Through its many brands and partnerships, Xylem has cracked the most difficult codes to ensure water is safely, sustainably and efficiently managed across industries. Xylem has been at the forefront of evolving water management and its next advancement has it diving deeper into underground mines with a new compact pump station fit for the narrowest spaces. The company’s partnership with leading pump technology specialist Seepex has seen the two create a progressive cavity (PC) pump and hopper package designed for use in mobile and fixed mine dewatering applications. Xylem product and marketing manager, Australia and New Zealand, Cameron Pate says the pump station was built with the confines of an underground mine in mind. “It’s a lower, more narrow space underground so the design of the pump station is built around being compact and mobile and easy to install and move around,” Pate says. “We also made these units safer for underground by not having ladders go up to the top of the tank.” Some underground pump stations can be two-to-three metres tall, requiring workers to scale ladders in slippery conditions. The compact design makes it easier and safer to complete the daily inspections and servicing. “Part of the daily inspection is for someone to physically climb up to the top of the tank and hose out all of the sediment that builds up in the bottom of the tank, so we’ve tried to engineer a solution to minimise the height in which people have to climb,” Pate says. Xylem business development manager mining, metals and industrial, Himanth Prathap, says the quality of the PC pump station has resulted from the unique expertise Xylem and Seepex have brought to the partnership. “Seepex is a well-known brand in the progressive cavity pump (PCP)

XYLEM AND SEEPEX HAVE CREATED AN ERGONOMIC, USER-FRIENDLY PUMP STATION.

space and has been making PCPs for a long time now,” he says. “This particular model was specifically developed for mining and there was a fair bit of work that had been done by Seepex themselves to understand what the typical challenges are with PCPs. “It was based on that feedback from customers that they came up with this particular design and when we came into the picture with the Seepex partnership, we were able to build on those features to come up with an improved pump station design.” Developing a unique and innovative product can be one of the biggest challenges in manufacturing. Having competitive awareness is critical to gaining an edge. Constructed to be more ergonomic and user-friendly than the competition, Pate says the PC pump station also excels when it comes to maintenance or rebuilds. This is made possible with Seepex’s ‘Maintain-In-Place’ (MIP) technology, which greatly improves the pump’s repairability, whereby the rotor-stator AUSTRALIANMINING

cartridge can be replaced in-situ without disconnecting the pipework. Seepex’s NSM70-12V pump (an attachment to the PC pump station) is significantly lighter than competitor models, while even wall stator technology allows the one pump model to cover a range of duty points that would otherwise require multiple competitor models. The capability of the pump station isn’t just the perception of Xylem and Seepex either, verification is also coming from the field. A well-known underground mining operation in Kalgoorlie took on the pump station as part of a threemonth trial in August. The company was so happy with the product compared to its current units that it signed a long-term contract with no designated end date. “We have had a few units go out to site now and the feedback so far has been, these pump stations are really compact and really easy to manage – these are the words from the customers themselves,” Prathap says. “The fact that it’s compact

FEBRUARY 2022

really makes a big difference because real estate is limited in the underground mining space, so every time there is an opportunity to have a compact and more manageable asset underground, the end users would prefer that over the larger alternative.” With its new PC pump station gaining traction, Xylem continues to evolve the concept and possibility of water management in mining through its end-to-end focus. “We’ve managed to build a product portfolio that offers solutions at every stage of managing water – whether it be how water is sourced, then moved, tested, treated and then discharged back to where it was sourced from,” Prathap says. “And given how much of an emphasis there is today around how water is being managed on mine sites, the PC pump station is just another valued-added solution that we’ve been able to bring to the customer, to complement all of the existing solutions that we have around water management.” AM

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WASTE MANAGEMENT

DIGERO REDUCES MINING TO ASH WITH INCINER8 THIS NEW ZEALAND-BASED DISTRIBUTOR IS DIVING INTO THE WORLD OF AUSTRALIAN MINING WITH ITS FLAGSHIP LOWEMISSION INCINERATORS.

igero has become a key distributor for Inciner8 products in the South Pacific region after experiencing success in waste management for a range of other industries. The Inciner8 brand was developed in the United Kingdom to address the pollution caused by some current waste disposal practices like landfill. The product’s main goal upon development in 2003 was ease of installation for remote operations, with minimal operator input and an affordable, environmentally friendly design. As a growing family-owned business, Digero has been proud to take this on over the past three years and has achieved success in its distribution for Australia, New Zealand and Papua New Guinea. Digero managing director Mark Courtney says the Inciner8 range is well-suited to Australia’s mining industry and he’s looking forward to growing the brand’s presence in the region. “The mining industry has been of real interest to me because currently I believe they still bury a lot of their waste and that’s obviously not very good for the environment, so we’re looking to get our foot in there,” Courtney tells Australian Mining. “As environmental regulation tightens around dumping rubbish in the ground, I believe mining companies are going to be looking for solutions and this is a great way to still dispose of rubbish on site in a responsible way.” The Inciner8 range has a few environmental benefits compared to landfill, such as no water contamination, fewer greenhouse gases and a physical footprint only as wide as the incinerator itself. Digero stocks several Inciner8 products to suit a number of applications throughout the mining industry, offering a range of burn rates from 100 to 1000 kilograms per hour. Courtney envisions these incinerators to be ideal for mining villages where rubbish from potentially hundreds of miners is created every day. “They can be especially helpful

for mine villages because, if miners are living on site, not a heap may be getting recycled. So, anything they can’t recycle they can just incinerate with no worry about pollution either,” Courtney says. Taking the i8-1000G as an example, the 21-tonne machine heats to 850 degrees Celsius and leaves an average ash residue of just 3 per cent the original weight of the rubbish. Courtney says incineration can even add value for the operator, as ash residue can be used in other applications. “After burning, the leftover ash has had all the harmful elements removed so it is essentially inert,” he says. “Some larger operations have clients they can sell the ash to for use in road base and similar applications, providing a new life for otherwise disposable material.” Once the material is burnt, the harmful gases are treated in a secondary chamber, using seven low nitrous oxide (NOx) burners. These can either come as gas or oil-fired burners and take just

two seconds to reduce the exhaust fumes to meet European air quality guidelines – some of the most stringent in the world. “While a few gases are released by the end of this system, they are still well below the allowed amounts by law,” Courtney says. “If customers require more assurance and pollution reduction, there are two types of filters we can offer as options. “These are the ceramic and Venturi filtration systems.” The 15-nozzle Venturi gas scrubber creates a high-pressure water mist to capture smaller particles for collection as a sludge in a container. “The incinerator is already producing emission levels well below what’s allowed,” Courtney says. “But it generally comes down to who is giving consent to a customer to operate, and if they’re asked to attach a filtration system for extra assurance, it’s available to them.” “A lot of bigger operators do use them as they’re running the incinerators every day and they need

as much help as possible to reduce waste and emissions.” Courtney also explains how further costs can be saved using Inciner8 products in the form of energy and water. “You can even recover and reuse the energy created by our machines if you want to go down that track, further reducing energy costs,” he says. “This can be done by capturing the air and hot water created during incineration for use on site or around the village.” A final optional extra is for remote monitoring and proactive analysis of the incineration unit and process. A plug-and-play control panel comes as standard on several Inciner8 products for reliable use of the product. This can be upgraded to connect with the Inciner8 headquarters for constant condition monitoring. Inciner8’s team of engineers and technicians can advise of any faults or simply help to optimise the use of its incinerators, providing a clean service to an even cleaner product. AM INCINER8 PRODUCTS COME IN ALL SHAPES AND SIZES.

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MATERIALS HANDLING

RIO TINTO ENGAGES CONVEYOR SPECIALIST MASTERS IN CONVEYOR COMPONENTRY AND SPECIALIST MAINTENANCE, TS GLOBAL’S NEXT CHALLENGE IS WORKING ALONGSIDE RIO TINTO AT ITS IRON ORE OPERATIONS IN WESTERN AUSTRALIA.

S Global has been successful with a threeyear contract to supply conveyor components and associated maintenance for Rio Tinto Iron Ore (RTIO) in the Pilbara region of Western Australia. From its manufacturing facility in Newcastle, New South Wales, TS Global will provide conveyor and belt cleaning solutions to RTIO, reducing downtime and increasing productivity, with the company’s specialised experience to be a valued attribute in the partnership. TS Global is also building a dedicated team in Western Australia to ensure RTIO receives the necessary assistance and servicing to ensure its conveyor systems keep turning. During the contract tender process, TS Global’s reputation as experts in its field gave it the edge over the competition. “Product knowledge is key. The conveyor service industry has moved into an area where there’s a lot of generalists … and many of these companies are belt manufacturing or belt splicing companies that try to do a lot of mechanical work,” TS Global director Graham Holford says. “Our vision is to focus simply on our mechanical components and employ product specialists and knowledgeable people that specialise in our product – what’s required to make our product the best.” Holford says that becoming a master of your craft is an important consideration at TS Global, without this, the company would not be able to deliver its high-quality service. “At the end of the day, if we do our job well, our business is successful; if we don’t do it well, we haven’t got belt sales and belt splicing sales to fall back on,” he says. “It (mechanical components) is our core business, and we must be successful at it. And as a result, we’ve got good people with exceptional skills, delivering a great result to our clients.” Prior to securing the contract, TS Global was put through a series of performance tests to ensure

TS GLOBAL EXCELS IN ITS USE OF STAINLESS STEEL IN ITS STRUCTURAL COMPONENTS.

its offering was up to Rio Tinto’s standards. The company impressed at all levels. “The feedback was that we performed well which we’re confident of because all our products are stainless steel,” Holford says. “We believe the cushions we supply are the best worldwide and we’re pretty confident our tungsten tips – the bit that does all the cleaning – is equivalent to anything else on the market.” The exclusive use of stainless AUSTRALIANMINING

steel on structural components has been central to TS Global’s growing reputation – an innovative solution that was strategically employed following careful consideration of its competition. “The majority of our competitors put a mild steel product out into the marketplace and when we started TS Global in 2007, we were able to consider the positives and negatives of taking mild steel to the market versus doing everything out of stainless steel,” Holford says.

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“By the time we’d completed business cases around manufacturing out of stainless versus mild steel, the costs associated with blasting, painting and labour transporting to the painter was more expensive than paying the premium for the stainless steel.” TS Global gave itself an ultimatum and has stuck with it ever since. “We believe this has been to our clients benefit with a reduction in TCO (total cost of ownership),” Holford says. “We made the decision that everything we were going to make was out of stainless steel which gave us a product with a superior lifecycle, particularly in the coal industry where there’s a lot of moisture in the coal and you have ongoing issues with things seizing and rusting. “Stainless steel gives us a product structurally that should last for 20-30 years.” The Rio Tinto contract enables TS Global to continue expanding its capability and its team – something the company has become quite familiar with as it enjoys a period of significant growth. “Six to 12 months ago, TS Global was based in New South Wales; we employed approximately 30 people,” Holford says. “In the last 12 months, we opened the branch in Emerald. We’ve opened a branch over in WA. We’re employing probably 70 people now and have positions open for another 30. We’re on the way to tripling in size in under 12 months.” The company also continues to invest heavily in research and development (R&D). “We’ve got a lot of R&D projects on the go currently and we’re expecting a range of smart belt clamps and belt lifters to hit the market into the new year. These coupled with our newly developed range of pulley lifting beams all focussed on improving safety associated with conveyor maintenance. “These new products are on the way, and I think we’re finding a strong place in today’s mining practices.” AM

We show the future so you can solve it We believe in progress. Going further. Enabling the future. As we’re creating next generation technology for mining to empower the leaders of tomorrow, we’re also evolving the way we present ourselves to the world. Our suite of products is now clearly designed to fit into an integrated solution and become part of your everyday workflow. Find out more today at micromine.com

MINING SERVICES

BSC AND TIMKEN TAKE LEAD ON ENGINEERED BEARING SURFACES AUSTRALIAN MINING HAS SEEN TREMENDOUS GROWTH THIS YEAR, WITH THE PRICE OF IRON ORE REACHING RECORD LEVELS, WITH A SIGNIFICANT INCREASE IN DEMAND ON PRODUCTION OPERATIONS, HIGHLIGHTS BSC’S TONY TORMEY.

ines have been challenged to keep up with demands at an all-time high, according to BSC product manager for industrial bearings, Tony Tormey. “And one of the biggest challenges for us at BSC has been keeping mines up and running while achieving optimal performance on all of their equipment,” he says. “In that same vein, mine site operators have been exceeding their expectations in terms of historic bearing demands and sacrificing bearings on critical pieces of equipment, for more production,” he continues, “This would not typically be considered good practice, but does open the door for BSC and Timken to seek ways to prolong the lifespan of equipment and reduce the total cost of ownership.” In tandem with an increase in production demands, BSC has seen a jumpstart in innovation from suppliers and manufacturers behind the bearings and bearing components that go into the equipment on mine sites. “Bearings are an integral part of our business offering, so we are constantly striving to stay on top of the latest maintenance trends and bearing technology as they become available to the market,” Tormey says. “I think we have had a lot of success in accommodating recent challenges, and part of our success can be attributed to working with premium bearing suppliers like Australian Timken. BSC and Timken have been partnering for 70-plus years to offer bearing solutions for mining applications.” Significantly, the Timken Spherical Roller Bearings (SRB) offer a range of solutions for rotating mining equipment, with the bearing housing, sleeve and sealing components available in a single brand solution to the customer. “Timken SRBs have some of the highest load and speed ratings when compared to other SRBs on the market,” says Tormey. “They are available with steel and brass cage designs, with Timken’s

INNOVATION HAS EMERGED IN THE DEVELOPMENT OF BEARINGS.

total steel cage range hardened to produce a more resilient bearing. They were designed and built to handle tougher applications in heavy industries like mining, with advanced technical features that lead to a longer service life.” One of the more recent innovations for the Timken Spherical Roller Bearing range is the capacity to add “Engineered Surface Technology” to the bearings. National mining manager for Australian Timken, Mark Davies, discusses how engineered surface technology is changing the bearing landscape and how Timken is supporting the mining market by advancing this surface treatment technology. “The demand right now for bearings is very high with OEMs and at the after-market customer level,” Davies says. “End users of our bearing products have been pushing for more life from their equipment. They want to increase their uptime as much as possible and extend the life of their bearings.” Designed for harsh conditions, the bearing surface technology used in making Timken’s ES302 Spherical Roller Bearings assists in extending the bearing life.

AUSTRALIANMINING

“The ES302 Spherical Roller Bearings use Physical Vapor Deposition (PVD) technology, which is a thin coat of engineered ceramic and a polymer over the finished surface of the rollers,” explains Davies. “PVD bearings really come into their own on rolling applications when the lubrication starts to age and with the presence of contamination particles, the rolling surfaces of the bearing can have metal to metal contact. When this occurs, the ES302 surface treatment works as a dissimilar metal, protecting the raceway and minimising smearing of the race material. ES302 bearings can extend operating life due to their greater resilience compared to a standard bearing due to its protective coating.” According to Davies, the ES302 Spherical Roller Bearings have been specifically designed for applications where conditions would not normally be ideal for an extended bearing life, in particular on both fixed and mobile mining equipment. “The PVD bearings are best for applications where contamination and lubrication damage has been observed in a previous failure inspection” Davies explains, noting as a matter of interest that outside of the mining industry they are also being used in

FEBRUARY 2022

the construction of renewable energy wind turbines as an industry solution to a known SRB damage mode from excessive thrust loading, which speaks to the capacity of the bearing and effectiveness of the ES302 coatings capacity. Tormey and the rest of the team at BSC are well versed in the range of Timken SRB solutions being offered to heavy industry and, according to Tormey, they keep a good amount of stock ready across their network of distribution channels to better assist in solving equipment issues in a timely manner. Additionally, Timken engineers work actively with BSC to do joint site calls together, which allows BSC to better facilitate the appropriate training on correct bearing sealing and fitting practices for Timken SRB products. “The quality of Timken SRB products has certainly given us an edge when assisting customers in contending with the current extraordinary levels of demand on their production facilities. The better quality the bearing on a piece of equipment, the longer the bearing maintenance interval, and the greater the ability to extend the life and performance of a piece of equipment,” Tormey concludes. AM

REGIONAL SPOTLIGHT

THE TREES AREN’T ALL THAT’S GREEN IN TASMANIA THE FOCUS IS THROWN TO ANOTHER OF AUSTRALIA’S QUIET ACHIEVERS WHERE COLLABORATION IS KEY AND ‘NET-ZERO’ IS EFFECTIVELY A WAY OF LIFE. THE CONTRIBUTION OF TASMANIA’S MINING INDUSTRY IS WORTH FAR MORE THAN THE LAYMAN MIGHT REALISE. HENRY BALLARD WRITES.

GRANGE RESOURCES PRODUCES SOME OF THE HIGHEST QUALITY IRON ORE PELLETS.

any people might hear Tasmania and think seafood, wine, forestry, or tourism upholds

the state’s economy. But in the 2021 financial year (FY21), Tasmania mined and processed about $2.8 billion worth of product, with $2.3 billion of that being exported. This accounted for 61 per cent of Tasmania’s exports. In November, the state clocked a fourth consecutive month maintaining 12-month export figures above $4 billion, underpinned by mined materials and metal scraps. The Tasmanian Minerals, Manufacturing and Energy Council (TMEC) is a membership-based organisation representing the state’s mining exploration, extraction and processing businesses, energy consumer sectors, advanced manufacturers and associated supply chains. TMEC chief executive officer Ray Mostogl tells Australian Mining he is

very optimistic for the future of the region. “The last 12 months have been incredibly positive and all the signs are that the next 12 will also be strong,” Mostogl says. “The drivers for the big uptake in Tasmanian mining was the rise in iron ore price, and the aluminium and zinc prices have also been favourable for our minerals sector.” The sector has also been bolstered by some significant investment from the state government in the 2021-22 Budget. The Exploration Drilling Grant Initiative (EDGI), for example, received $1.5 million to stimulate greenfields drilling projects, while the Geoscience Initiative received $2 million to better understand regional mineral systems. The Budget also includes $6 million to deliver the final three years of Tasmania’s first Trade Strategy, plus $450,000 is allocated to a Diversity Action Plan to increase gender and cultural diversity in forestry and mining. AUSTRALIANMINING

Mostogl says all this investment is welcomed by the industry as it continues to grow. “We’ve seen a big uptick in exploration with double the number of applications in 2021 compared to 2020,” he says. “The state government has continued on with their incentive program to offset some of the costs and we’re really appreciative of that.” But financial investment isn’t the only thing attracting people to the Tasmanian mining industry, as TMEC continues to reposition the narrative around mining with a new slogan of ‘cleaner, smarter, diverse and proud.’ This has included an extensive program in schools since the start of 2021 which Mostogl says has started to turn some attitudes around. “We had people who just did not understand mining in Tasmania which caused us to get very active in schools,” he says. “We’ve visited almost every high school in the last 12 months to promote the manufacturing and mining industries and raise people’s awareness of their importance to the region.” One of the major selling points for mining in Tasmania is a state-wide claim to fame – net-zero emissions. Tasmania has been carbon neutral in six of the past seven years thanks to its abundance of forests and an electricity grid run completely on renewable energy since 2020 – mostly hydropower and wind. This allows mines to produce some of the greenest minerals in the world, according to Mostogl, but it’s not without its difficulties. “We’re very fortunate to have the hydro and wind power assets to allow us to do that,” Mostogl says. “We expect to navigate challenges involving the renewable energy sector because Tasmania has a legislated objective to become 200 per cent renewable, and some potential wind farms are located above protected mineral resources. “Just as in New South Wales where the farming industry sometimes takes precedence over the coal mining

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industry, I am concerned something similar may occur in Tasmania.” One Tasmanian miner embracing the pillars of TMEC’s campaign is Grange Resources. Grange has operated the Savage River iron ore mine for 53 years and produced over 2.5 million tonnes of iron ore pellets in 2021. The company’s chief operating officer Ben Maynard says his company is keen to embrace whatever technologies allow Savage River to uphold Tasmania’s green reputation. “We’re moving into this interesting time where the world is realising its fragility over a number of issues and we’re now embracing our response to climate change,” Maynard says. “We’re now looking at the other ways and things we can do to adapt our industry to become net-zero. As an industry, we realise we need to change and implement new technologies, so we are positioned to maintain this netzero status for the state.” Grange takes the iron ore from Savage River and transports it 85 kilometres north to its processing facility in Port Latta on Tasmania’s

THE SAVAGE RIVER IRON ORE MINE AT DUSK.

REGIONAL SPOTLIGHT

northwest coast. Here, the iron ore is turned into pellets, and as Maynard explains, it’s one of the best in the world owing to Tasmania’s unique geological composition “We’re the most experienced magnetite producer with some really positive aspects to our pellet,” Maynard says. “It’s got the lowest phosphorus in the world giving it very low impurities. It’s thought of as a naturally fluxed pellet and so it’s quite sought after as a premium iron ore and steelmaking input.” To power the processing of these pellets and contribute to Tasmania’s renewable credentials, Maynard suggests some alternatives to traditional methods. “The use of hydrogen is quite a big one the government has put some support behind,” Maynard says. “We’ve been doing a feasibility study to understand if we can replace the use of natural gas as an energy source to create pellets at Port Latta. “I think there’s some great aspects on the horizon there and that ‘green steel’ or ‘green minerals’ angle is another upsell for the mining industry and Tasmania as a whole.” Miners and industry bodies alike hope that with all the community engagement and ethical operation, more workers will be encouraged to call Tasmania home. With a range of industries operating in unison and collaboration across the west coast of Tasmania, Mostogl says making space for all businesses and employees will be key to the state’s growth. “Part of our community

CATALYST METALS’ HENTY GOLD MINE.

engagement focusses on housing and accommodation on the west coast,” Mostogl says. “We want to understand what the industry can do to create a network of likeminded business across industries, because there is more to the west coast than mining. “There’s going to be a requirement for additional workers for probably the next 15 years, so we see it as an opportunity for an innovative way to set the accommodation up in a way that all these communities and industries can benefit from.” Catalyst Metals is a far newer player than Grange in the Tasmanian mining industry, but an equally important one as the state’s only major gold producer. The Henty gold mine began operations in 1996 and has produced 1.4 million ounces of gold since, but

AUSTRALIANMINING

Catalyst took ownership of Henty in 2021 and has warmed to the region well in its first year. “Operationally, Henty has exceeded our expectations and been very consistent,” Catalyst chief executive officer John McKinstry says. “One of the trademarks of Henty over the last few years has been the inconsistency, but we’ve been able to really bed it down and we’ve inherited some good people as well.” McKinstry says Catalyst is very focussed on giving back to the community in which it operates. “What we don’t want to do is set up any kind of miner camps because it sees the miners come and go without spending any money in the town,” he says. “We don’t want them just seeing it as a bed and room while they’re at

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work. Instead, our model is a better one for everyone where people miners live in the town, eat in the restaurants and buy in the shops.” Benefitting Tasmania’s pitch for the ‘live and work’ lifestyle is the state’s handling of the COVID-19 pandemic. At time of writing, the state has had 247 cases of the virus compared to Australia’s 250,000, and the certainty that brings for miners has had its benefits, according to McKinstry. “We’re finding Tasmanians migrating back to Tasmania,” he says. “This is positive not only because they’re good, skilled workers but because they’ve seen first-hand how major mining communities and operations work, and they return with good standards.” And with the right people on board, the state will be set to become an even more important piece in Australia’s mining puzzle. In fact, Mostogl says he’s hearing that many previously unrecognised resources would come into play as Australia positions itself to become more self-serving. “All the noise around critical minerals is that the sector is about to fire up,” Mostogl says. “Within the Federal Government’s critical minerals portfolio, there’s a level of interest to say every state should have some sort of mineral processing capability. “So, we see Tasmania as a potential tungsten processing facility for local and national producers.” Yet another of the state’s niches to be developed into the future as cleaner, greener mining is recognised as vital to its growth and support. AM

2021

AUSTRALIAN MINING PROSPECT AWARDS

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TECHNOLOGY

SMARTER, SAFER AI-DRIVEN MINING FLEETS THE DEPLOYMENT OF ADVANCED DATA ANALYTICS, ARTIFICIAL INTELLIGENCE (AI) AND INCREASED CONNECTIVITY THROUGH THE INTERNET OF THINGS (IOT) ARE KEY DRIVERS OF THE DIGITAL REVOLUTION IN THE MINING SECTOR. ONE AREA WHERE MACHINE LEARNING CAN PLAY A BIG ROLE IS FLEET MANAGEMENT.

he Australian mining industry has one of the highest fatality and injury rates of any industry. A combined total of 2808 working days per year are lost due to injuries alone. This makes it easy to see why mining companies have a lot to gain from this advanced technology and why rates of adoption continue to grow. There’s an urgency to ensure mine site safety and maintain regulatory compliance, which has resulted in a need for mining companies to become more proactive in managing daily operations to mitigate risk.

BY ANALYSING ENGINE DATA, FLEETS CAN GET MORE PRECISE AND PREDICTIVE THAN EVER BEFORE.

Why AI is the future of fleet management

The use of AI can allow for a deeper analysis of fleet operations as well as more accurate and specific predictions than have been seen before. Thanks to AI, mining fleets can improve the accuracy of telematicsderived data related to driver behaviour, asset tracking, fleet utilisation and overall fleet operations which, in turn, can improve site safety, driver safety, productivity and costefficiency.

Automated decision making

AI-driven automated decision-making is also becoming more common when it comes to fleet maintenance issues. Many fleets today practice preventive maintenance – for instance, sending a notification or alert every 10,000 kilometres to change the vehicle oil to prevent future engine problems. By analysing engine data, fleets can get more precise and predictive than ever before. Not every vehicle needs its oil changed at 10,000 kilometres – where, how and how frequently depends on factors like the way a vehicle is driven and the condition of the oil. Telematics data pulled from the engine and analysed can give a more precise picture and enable fleets to predict exactly when maintenance is needed to suit a particular circumstance. You can see how such a process would

lead to better efficiency, greater vehicle uptime and increased productivity. Preventive fleet maintenance is where AI can really shine.

Making fleets safer

Another feature of AI that could help in making mine fleets safer is facial recognition. In-cab cameras are a big growth area in telematics. According to Berg Insight the market for video telematics will grow by 22.2 per cent between 2020 and 2025, to 3.2 million subscribers. Video telematics can reduce collisions by 60 per cent and the related costs by 75 per cent. Visual evidence collected by in-cab cameras is a powerful tool for insurance claims and driver safety training. What’s more, video telematics is increasingly being used in combination with AI technology to help provide visual context. This helps to determine the circumstances around specific events such as on-site crashes. AI-powered video eliminates the time-consuming task of sifting through hours of footage to find the precise event a fleet manager needs to review and makes AUSTRALIANMINING

any video snippet available in near real-time. The technology has garnered a significant reputation for its ability to increase safety and efficiency within fleets of all sorts, making AI ideal for the mining industry. In-cab cameras can also provide important proactive safety benefits – models that can detect a driver falling asleep while driving or an imminent crash that then triggers audible in-cab warnings to help prevent a crash from occurring. Machine vision technology, powered by AI, can also be used to streamline driver ID and security processes. For instance, you could use facial recognition to unlock or start vehicles (to prevent, for example, unauthorised usage), or enable auto-login to your telematics system.

Challenges that AI-powered video can help mining operators to solve The benefits of using AI-powered technology can include (but are not limited to): •R eduction in speeding through increased awareness of road safety behaviours.

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• I dentifying at-risk drivers and taking relevant actions to assist them. • Locating drivers at all times. •P roviding direct real-time feedback for operators and their control centres on road conditions. •R educing fuel usage, thus lessening environmental impact. Using AI alongside video telematics can help manage driver distraction, fatigue and other potential safety threats in real-time to prevent potential crashes and the resultant injuries. Safety incidents can be significantly reduced through the identification and monitoring of high-risk drivers, locations, times and shifts. In turn, action plans can be implemented to train drivers on how to avoid safety hazards, allowing for improvement to take place on a continuous basis for long-term results. The more data you have, the smarter you can be about making decisions that improve performance, efficiency and most of all safety. Generating actionable insights will be the key to success in this brave new world of AI-enabled fleet management. AM

PRODUCT SPOTLIGHT

GLOVES BY NAME, GLOVES BY NATURE NITRILE GLOVES ARE THE TOUGHEST IN THE BUSINESS, AND THE GLOVE COMPANY IS AN AUSTRALIAN DEVELOPER OF THESE HIGH-PERFORMANCE PRODUCTS.

name says a lot, and with The Glove Company, you know what to expect – the highest quality hand protection gloves, which is the core focus and specialty of the company. The Glove Company introduced TGC Black Nitrile Disposable Gloves to Australian shores more than 15 years ago, revolutionising the industry and setting a new benchmark for safety. The company has maintained its spot at the top of the industry ladder through constant improvements to make sure its gloves continue to stand out. “We put a lot of effort into innovation, and we won’t just make the same disposable gloves as everyone else – ours are known for being higher quality and higher performance,” The Glove Company national sales manager Ben Kessey tells Australian Mining. “If you see a TGC box on a workbench, you know it’s going to be high quality – you know you will get your money’s worth.” On a mine site, disposable Black Nitrile Gloves can be used across different operations, including the

BLACK NITRILE GLOVES ARE PUNCTURE AND CHEMICAL RESISTANT

automotive and mechanical aspects in any workshop and anywhere that there might be a high risk of contact with hazards. Nitrile disposable gloves have an extremely low allergy rate, especially when compared with latex, and prior to The Glove Company introducing its TGC Black nitrile gloves to Australia, there weren’t really any other options to latex. “Nitrile gloves are a superior alternative to latex, at the moment we have over 12 different types of disposable nitrile gloves that set the benchmark in the industry,” Kessey says. The TGC Black Nitrile Gloves have a low-sweat technology that allows it to adapt to the user’s PH levels and reduce the amount of sweating.   “We can manipulate the way the glove reacts with the hand through our low sweat technology, which will increase the length of usage, comfortability and reduce breakage,” Kessey says. The technology behind The Glove Company’s top tier nitrile gloves is the company’s best kept secret, with owner and chief executive officer Grant Staples creating his own formula AUSTRALIANMINING

exclusive to TGC, fortifying its position as the industry leader. Using disposable nitrile gloves on a mine site isn’t only for safety, it also reduces the number of pairs used in a day due to its durability, and with the gloves costing approximately $0.35 each, there is the cost benefit to using them. “If you use reusable gloves, protecting your hands against chemicals, solvents, grease and oil

becomes difficult, because these substances can soak into the glove,” Kessey says. “With disposable nitrile gloves, if you get hazardous materials on them you can identify it immediately, safely remove the glove, dispose of it and grab a new one and it will only cost $0.35, rather than a costly reusable glove that would also have to be thrown out if a hazard gets on it.” The Glove Company is currently on a strong growth curve, with the pandemic bringing disposable gloves to the forefront of everyone’s minds, giving the company more opportunity to innovate and continue to better the products it offers. “We have recently released a glove that has a raised grip on it, if anyone is wearing these gloves and they’re handling oily or greasy parts, it gives them better grip and better control,” Kessey says. “We always go for stronger, better and more comfortable. We’ve got the world’s toughest disposable glove, but we will always continue to enhance that to make the world’s toughest disposable glove 2.0.” All of the gloves have been independently tested by Vic Labs, a National Association of Testing Authorities accredited company, to ensure the highest quality is maintained. “Black Nitrile Gloves are known as the toughest; they’re the longest lasting, highest performing, and we do it the best,” Kessey says. AM

THE GLOVE COMPANY INTRODUCED NITRILE GLOVES TO AUSTRALIA

FEBRUARY 2022

PRODUCT SPOTLIGHT

RUNNING A PIPELINE? THINK LAYFLAT AUSTRALIAN MANUFACTURER CRUSADER HOSE HAS THE SOLUTION FOR THE QUICK AND EASY DEPLOYMENT AND RETRIEVAL OF PIPELINES ON MINE SITES: LAYFLAT HOSE PIPELINE SYSTEMS.

ll mining projects strive to remain efficient. Engineers measure efficiency in terms of volume and plant downtime. These two KPIs also gauge water logistics, a vital part of all mining projects. Crusader Hose understands the importance of effective project management by working closely with the mining industry and has developed layflat pipeline dewatering systems to support productivity. The Waterlord mine dewatering system is valuable to any mine’s water logistics plan. Tough and durable to withstand high pressures and rough handling, Waterlord layflat large diameter hose can move water up to 500 litres per second. Crusader Hose pipeline systems will help move water easily and efficiently with customisable reels and turntables. The Waterlord reeling system will also help keep any mine operational. Waterlord is a heavy-duty and reliable layflat mine dewatering hose. It is constructed by weaving a tight polyester reinforcement and using a thermoplastic polyurethane (TPU) through-the-weave extrusion process. It comes in a range of diameters from 40 millimetres to 305 millimetres. Although manufactured in standard 200-metre lengths, the continuous length hose is available in longer, customisable lengths. Its exterior is abrasion-resistant

when appropriately handled, making it suitable for the rugged terrain typical to the mining industry. Most recently, a mine in Western Australia urgently needed to move large amounts of water over four kilometres. Traditionally reliant on conventional poly pipe for temporary pipelines, the mining engineers knew time was of the essence. Crusader Hose came to the assistance with 4000 metres of 12inch Waterlord with a turntable and couplings. Wound on reels, the compact layflat

hose was dispatched on a single truck. Once it arrived at the mine, the four-kilometre Waterlord dewatering system was rapidly deployed by only three operators over two days, much faster than if they had used poly. Relieved at the speed at which the mining project could continue, the engineers hailed it as a life-saver. Crusader Hose is a world-leading manufacturer of layflat hose, and is recognised as having rapid and efficient dewatering systems. The company’s warehouse has large diameter Waterlord and other industrial layflat hose in stock. Based

in Victoria, the experienced staff are ready to find solutions for all pumping needs. “We are proud to be the only manufacturer of mine dewatering hose in Australia and with our capabilities, support the mining sector with world-standard high-quality products in a timely fashion,” Crusader Hose managing director Francois Steverlynck says. “There are many benefits in using flexible layflat hose, and we are eager to assist more mining engineers in finding the right solution for their dewatering requirements.” AM

THE WATERLORD LAYFLAT DEWATERING HOSE IS A CRITICAL ASSET ON MINE SITES.

T AC NT OW CO S N U

LEGENDARY DEWATERING PUMPS EXPERIENCE THE DIFFERENCE Truflo Pumps is an investment in superior design and quality. Manufactured in Australia to exacting standards and to your specific needs, you can have confidence that your Truflo Pumps equipment can handle any challenge that is thrown its way. FREECALL

1800 813 677

www.truflopumps.com.au AUSTRALIANMINING

FEBRUARY 2022

PRODUCTS

A VEHICLE FOR ANY NEED

PUMP UP YOUR BRAND

Europcar WA in partnership with AUS Fleet Solutions group is your onestop shop for fleet solutions throughout WA. Europcar offers a wide range of long and short-term rentals, as well as being equipped to service, repair and custom fit parts to suit any business needs. Europcar’s fleet range extends itself to cars, trucks, buses, 4WDs, vans and even hybrids. Europcar have all vehicles and services to suit you and your business needs. After recent expansion, Europcar WA has 13 locations: Bassendean, Welshpool, Osborne Park, Fremantle, Bunbury, Busselton, Kalgoorlie, Geraldton, Paraburdoo, Port Hedland, Onslow, Newman and Karratha. Get moving your way and visit one of these 13 locations today, or contact 1300 HIRE ME.

Why blend in when you can stand out? Turn your new pump into an industrial billboard aimed to turn heads and get your brand noticed on the worksite. A value-added service from Truflo Pumping Systems when you purchase a new Silent Pack, offers the opportunity to utilise a blank canvas of a Truflo Pumps’ Silent Pack to your advantage. Elevate your organisation’s presence in the field with a graphics package that reflects ownership and participation in the industry. It’s your choice – use a creative approach or claim ownership over an operation – this hassle-free branding value pack is perfect for expressing your brand and effectively promote it to all that see your pump. Designs for branded wraps are created inhouse by Truflo Pumps’ marketing department to suit your individual needs and goals.

• europcar.com.au

• truflopumps.com.au

GENERATING INNOVATIVE SOLUTIONS

LIEBHERR UNVEILS LATEST AUTONOMOUS SOLUTIONS

Atlas CEA offers an extensive range of Atlas Copco generators, lighting towers and portable air compressors. Finding innovative solutions for providing portable energy, the team at Atlas CEA prides itself on its level of technical knowledge, offering customers information and support to determine suitable products for unique applications, and to suit even the harshest of conditions. Atlas CEA supports many of Australia’s largest mining, civil, construction, industrial, rental and government organisations. With a reputation for consistently supplying world-class quality products, parts and service, while offering exceptional customer support, Atlas CEA also prides itself on the level of technical knowledge it provides to customers assisting in their decision around suitable products for unique applications. If you’re in the market for generators, lighting towers or portable air compressors get in touch with the team today.

Liebherr premiered its new Mining Technology Product portfolio at MINExpo 2021, comprising new autonomous haulage solutions and excavator automation with a focus on safety and productivity. Showcasing the flexibility and scalability of its range of equipment, technology and services, the Liebherr portfolio includes machine automation, digital services and assistance systems, and on-board analytics product lines. Liebherr’s autonomous haulage solution is the next generation of on-board intelligence system, reducing the dependency on site infrastructure and paving the way for increased safety and productivity. The autonomous solutions provide an eight-layer safety concept in combination with the latest on-board perception technologies for long-range, high-resolution and 360-degree coverage. • liebherr.com

• atlascea.com.au

AUSTRALIANMINING

FEBRUARY 2022

PRODUCTS

EPIROC RIG REVEAL ADDS MUSCLE

ORICA’S EXPLOSIVE NEW TECHNOLOGY Orica has launched 4D, its latest bulk explosives technology enabling customers to target specific blast outcomes in real-time. Delivering improvements in fragmentation, bench productivity, and reducing overall drill and blast costs, 4D is built for anticipation, functionality and proactivity. Suitable for both pumped and augered loading methods across dry, wet and dewatered hole conditions, 4D combines emulsion blended with ammonium nitrate porous prills. This results in greater bench productivity by Orica’s fleet of 4D-enabled Mobile Manufacturing Units (MMU), without the need to change raw materials in the MMU. Orica’s 4D enables a broader range of applications, promising up to 23 per cent more relative bulk strength for hard rock applications and up to 43 per cent reduction in soft rock. • orica.com

Epiroc has released the Pit Viper 291 drill rig and two Boltec rock reinforcement drill rigs, the M10 and the E10. The Pit Viper 291 is the latest in a reputable line of drill rigs, now with the ability to drill larger diameters in soft to medium-ground conditions. The 291 can be configured with Epiroc’s Rig Control System (RCS) to allow for fully autonomous drilling, while options like AutoDrill and AutoLevel provide further productivity enhancements. Underground, the Boltec M10 and E10 rock reinforcement drill rigs are wellsuited to medium and large-sized tunnels. Similar to the 291, the Boltec rigs can perform autonomously, with single and multi-bolt installation available. • epiroc.com

FERROCER INCREASES RECLAIMER LIFE, REDUCES WASTE

ALEMLUBE REELING IN SAFETY Alemlube’s new HR90000 series is a more durable and functional hose reel for mine sites. Stiffening ribs allow for product longevity while flanged edges consolidate the sturdiness and versatility of the hose reel. Safety is a big consideration when it comes to Alemlube’s EL series. Each reel features a protective outer shroud reducing potential accidental injury, while 50 per cent less rewind speed facilitates greater control and enhances hose longevity. A new innovative latching solution enables the hose to be stopped in multiple positions as required, while effortless, smooth hose extraction and retrieval further improves ease of operation and operator safety. Alemlube’s HR90000 series is suitable for the transfer of oil, grease, air and water, while the adjustable arms mean the reels can be mounted on the floor, wall or ceiling.

FLSmidth has created an innovative, long-lasting modular wear panel that continually performs well above all expectations. They’re called FerroCer wear liners and an iron ore major in the Pilbara recently used them to extend the wear life of its reclaimer buckets from 48 weeks to 116 weeks. A unique combination of ceramic and ductile iron, the patented, Australian-made, easy to install, modular panels can be fitted to crushers, chutes, hoppers, or any application where ceramics are breaking, or where steel liners are wearing out too quickly. As fewer wear liners are required over a longer period, FLSmidth is contributing to a reduction in waste for any operation which takes advantage of FerroCer wear panels. • flsmidth.com

• alemlube.com.au

AUSTRALIANMINING

FEBRUARY 2022

EVENTS

CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@AUSTRALIANMINING.COM.AU

The Australian Gold Conference Sydney | February 10-11 The Australian Gold Conference will take place across two days in 2022 at Crown Sydney, kicking off with an ‘Introduction to Gold’ pre-event hosted by The Perth Mint on February 9. From there, a two-day symposium will be held – bringing together every aspect of the precious metals investment industry to promote and help educate everyday Australians, as well as those already invested in the sector. Keynote speakers will present their investment views and look at how we can grow and protect our wealth going forward. Bullion dealers will also be on hand to help you understand how. • g oldindustrygroup.com.au/events/ industry-event-2021-australian-goldconference Austmine Mining Innovation Roadshow Newcastle | February 24 This full-day conference will rehash concepts discussed at Austmine’s biennial conference and exhibition from May 2021. Conversations surrounding sustainability and innovation will be driven by keynote speakers Mick Buffier, Glencore; Stuart Sneyd, Metso Outotec; Cam Halfpenny, Bengalla Mining Company; and Belinda Grealy, Orica. New topics will also be discussed which relate to the local mining and METS industry, including safer and more productive coal mining, opportunities for diversification into metals mining and other industries, the role of innovation in driving sustainable processes and

effective stakeholder engagement. Roundtable interactions will present an excellent opportunity to network with senior industry leaders, researchers and a range of METS company delegates. • i nnovationroadshow.austmine. com.au International Women’s Day Brisbane, Sydney, Melbourne, Adelaide and Perth | March 4-11 Returning to Brisbane, Sydney, Melbourne, Adelaide and Perth in March 2022, AusIMM will present another forward-thinking event as it continues to raise the profile of women in the resources sector. As part of its 2021 International Women’s Day event series, AusIMM welcomed 1600 people from across Australia to applaud the achievements of women in the resources sector and hear from inspiring keynotes about their own journeys on challenging bias and inequality. Women were provided an important platform to tell their stories and express their concerns, paving the way for the continued evolution and equality of the resources sector. The series welcomed respected industry speakers such as human rights lawyer and hostage survivor Rabia Siddique, Australia’s chief scientist Dr Cathy Foley AO, South Australia’s chief scientist Prof Caroline McMillen AO, success coach Yemi Penn, and company director, author and leadership expert Dr Kirstin Ferguson across the five locations in 2021. • ausimm.com/conferences-andevents/international-womens-day AUSTRALIANMINING

Australian Mining Prospect Awards Brisbane | March 17 The most esteemed and prestigious awards for the Australian mining and minerals processing industry, the Australian Mining Prospect Awards return in March of 2022. Mining has always been a part of Australia’s landscape, playing a major part in the development of this nation from its early days. The sector remains vibrant and innovative, and for more than a decade the Australian Mining Prospect Awards have been the only national awards program to stop, take a look at what the mining industry is doing, and reward those who are excelling and going above and beyond, recognising and rewarding innovation. The Australian Mining Prospect Awards were established in 2004 to recognise and reward excellence and innovation across the Australian mining industry. • prospectawards.com.au Queensland Mining Industry Health and Safety Conference Gold Coast | August 21-24 Representing an initiative to promote health and safety in the Queensland mining industry, the conference provides attendees with the opportunity to exchange information, network, and foster proactive health and safety management techniques. This year, the event returns with the theme “Together we collaborate, innovate and educate”. The conference will retain presentations planned for

FEBRUARY 2022

2020 and promote the ingenuity of home-grown safety. It follows a bumper year for conference attendance, with almost 1000 people joining the event when it featured seven keynote presentations, 50 concurrent presentations and 60 trade displays in 2019. Held at The Star Gold Coast this year, the Queensland Mining Industry Health and Safety Conference will conclude with a Safety Innovation Health Awards and gala dinner. • qmihsconference.org.au BULK 2022: Australian Bulk Handling Expo Melbourne | August 24-26 The Australian Bulk Handling Expo, conference and awards will take place in 2022 to bring together the bulk handling industry into a standalone exhibition that shares the same location as MEGATRANS, which integrates intrinsically with the logistics and multimodal freight sector. It is supported by the Australian Society for Bulk Solids Handling (ASBSH), which will host an industry conference, while the trade expo will showcase the latest in bulk materials handling equipment and technologies. Exhibitors include VEGA, SEWEurodrive, Mideco, Bonfiglioli, Minprovise and ESS Engineering. BULK2022 will take place at the Melbourne Convention and Exhibition Centre over a period of three days. BULK2020 and BULK2021 ticketholders will be able to use their tickets to join the rescheduled expo. • bulkhandlingexpo.com.au

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Australian Mining February 2022

Articles inside

EVENTS

PRODUCTS

MINING SERVICES

PRODUCT SPOTLIGHT

REGIONAL SPOTLIGHT

TECHNOLOGY

MATERIALS HANDLING

WASTE MANAGEMENT

WATER MANAGEMENT

DIGITAL MINING

MINING EQUIPMENT

INDUSTRY OUTLOOK

NEWS

FUTURE OF MINING EMISSIONS

COMMENT

CRUSHING & SCREENING

COMMODITY SPOTLIGHT

PROFILE