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TECHNOLOGY MINING CONTRACTORS VOLUME 112/2 | MARCH 2020

UNDERGROUND MINING

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TECHNOLOGY MINING CONTRACTORS VOLUME 112/2 | MARCH 2020

UNDERGROUND MINING

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COMMENT

THE SUPPLY CHAIN’S ROLE IN MODERN MINING BEN CREAGH

Ben.Creagh@primecreative.com.au

AN ANNUAL REPORT ON MINING TRENDS HAS HIGHLIGHTED THE CHANGING CONTRIBUTION NEEDED FROM THE SUPPLY CHAIN IN TODAY’S INDUSTRY.

ame, same but different – that could be a way to describe many of the latest trends that are shaping the mining industry. Each year, Deloitte releases its Tracking the Trends report, which explores key trends for companies in their pursuit of productivity, financial discipline, operational excellence and sustainable growth. The 2020 edition includes some familiar themes – collaboration and partnerships, innovation and technology, the environment, workforce and community engagement, and risk management. What’s different is how these themes are affecting mining in a changing world with broader expectations of the industry. Mining’s role in managing the environment, such as techniques for decarbonisation, have become more defined in 2020, for example. With Australian Mining’s target audience extending across the complete supply chain, from the major miners to the smallest of service providers, a chapter on partnerships spikes particular interest. How collaborative partnerships help progress technology and innovation projects, environmental management at mine sites, and community engagement efforts are a focus across the trends. In describing how large companies can work with juniors, Deloitte manages to flesh out ways to ‘lay the proper foundation,’ ‘select the right partners’ and ‘adopt the right KPIs’. These principles are relatable throughout supply chain partnerships, including the

CHIEF EXECUTIVE OFFICER JOHN MURPHY PUBLISHER CHRISTINE CLANCY MANAGING EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALISTS VANESSA ZHOU Tel: (03) 9690 8766 Email: vanessa.zhou@primecreative.com.au SALOMAE HASELGROVE Tel: (03) 9690 8766 Email: salomae.haselgrove@primecreative.com.au

compliance matters within major contracts that are formed and the need to find partners that are the right cultural fit. It is evident that today’s major companies increasingly target partners that share the same desire for innovation, diversity and inclusion, decarbonisation, and opportunistic risk taking. Original equipment manufacturers and service providers, along with local communities and governments, are all part of this emerging model where partners are asked to share assets and liabilities across the supply chain ecosystem. Fittingly, we look into the supply chain in this edition with a special feature on mining contractors. It is clear profiling these companies that their role serving the mining industry is more than transactional, but instead also follows these themes. The supply chain is introducing the same technologies as the major miners. It is also pursuing a new standard of environmental management and looking at risk management as a positive function that opens up opportunity.

In this edition, we analyse the latest Deloitte Tracking the Trends report, including a focus on building better partnerships. This issue looks at Epiroc’s journey towards integrating battery electric machinery with new technologies in underground mining. Australian Mining talks to a number of mining contractors and how they are developing products and services for leading operators. We also highlight the role of renewable energy in the future of mining in an interview with Total Eren. And as usual, we review the latest mining equipment and technology in our regular products spread.

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Ben Creagh Managing Editor

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CONTENTS MINING EQUIPMENT

TRACKING THE TRENDS

14-15 ASTEC BACKS CONVENIENT DESIGNS Mine Runner a preferred underground machine

TWO ARE BETTER THAN ONE Joint ventures, partnerships ease up boundaries

40-41

UNDERGROUND MINING

MINING CONTRACTORS

43-53 FORCES GROWING AUSTRALIA MINING’S FUTURE Partner companies provide solutions to problems

EPIROC LINES UP UNDERGROUND ARSENAL Electrification strengthened by battery machines

17-18 REGIONAL SPOTLIGHT

SUSTAINABILITY

20-22 THE RACE TO VICTORIA’S GOLDEN RESERVES Gold companies hunt for central Goldfields riches

FACING ENVIRONMENTAL CHALLENGES Mining companies manage drought season

55 COMMODITY SPOTLIGHT

MINERALS PROCESSING

24-26

THE POWER TO ELECTRIFY Lithium more than a short-term phenomenon

CDE ON A SUSTAINABLE PATH The clever use of resources not thought useful

PROSPECT AWARDS

AUTOMATION

28-30

A TECHNOLOGY FOR THE AGES Sandvik and Northparkes pioneer underground mining’s future

READY TO GO IN 2020 A new decade for the Australian Mining awards

FUTURE OF MINING

UNDERGROUND MINING

60 SUSTAINABLE FORCE POWERING MINES Total Eren highlights Australia’s renewables readiness

MINNOVARE USHERS IN NEXT TECH LAUNCH Production Optimiser makes grandstand entrance

33-34 TECHNOLOGY

PRODUCTIVITY & EFFICIENCY

LINX TAKES ON VIRTUAL REALITY Training in the face of high-risk environments

MAXIMISING UNDERGROUND ORE RECOVERIES Minova extracts value at unchartered depths

36-37 INDUSTRY OUTLOOK

INDUSTRY COMMENT

URANIUM POTENTIAL TAKES CENTRE STAGE AusIMM makes its case for nuclear power

AUSTRALIA’S CRITICAL FUTURE The possibilities of an Australia-US alliance

38-39 REGULARS NEWS 9-12

PRODUCTS 64-65 AUSTRALIANMINING

EVENTS 66

MARCH 2020

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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. WA GIVES FORTESCUE GREEN LIGHT FOR ELIWANA RAIL CONSTRUCTION

FORTESCUE HAS AWARDED OVER $1 BILLION IN CONTRACTS FOR THE ELIWANA IRON ORE MINE AND RAIL PROJECT. IMAGE: FORTESCUE METALS GROUP.

The Western Australian Government has granted a special rail licence for the construction and operation of Fortescue Metal Group’s Eliwana iron ore mine and rail project in the Pilbara region. Fortescue chief executive officer Elizabeth Gaines, chief operating officer Greg Lilleyman and Western Australian Premier Mark McGowan visited Pacific Industrial Company (PIC) in Kwinana where the announcement was made. PIC is one of many Western Australian companies that has benefitted from the $1 billion in contracts awarded by Fortescue for the Eliwana project.

Fortescue has spent 82 per cent of its project expenditure with 290 Western Australian businesses and a further 9 per cent with other companies across Australia. “It’s outstanding to see the majority of the work on this mammoth $1.7 billion project is happening here in Western Australia,” McGowan said. “Eliwana is a huge project not only for Fortescue but for a lot of small to medium enterprises in Western Australia and for the 2400 workers in total who are expected to get jobs out of it.” PIC is manufacturing more than 2600 tonnes of fabricated structural steel into rail and road bridge girder

modules for the Eliwana project. The road and rail bridge girders are the largest and heaviest to ever be constructed in Western Australia, according to PIC managing director Marco Mosole. “With all the steel manufactured and fabricated in Australia, it has enabled the industry to demonstrate the capacity and capability that exist here to undertake these sizeable projects,” he said. Gaines said she was pleased Fortescue could award so many Eliwana contracts to local companies. “As a proud West Australian company, we are pleased to provide opportunities for local small- and

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medium-sized businesses,” Gaines said. “Importantly, we are proud to support Aboriginal participation in the resources sector, with the Eliwana project awarding 19 contracts worth a total of $25.5 million to Aboriginal contractors as part of our pioneering Billion Opportunities program.” The Eliwana mine and rail project includes 143 kilometres of rail development and a 30 million tonnes a year dry ore processing facility. Once complete, Eliwana will continue Fortescue’s low-cost iron ore producer status and maintain its overall production rate of 170 million tonnes a year for 20 years.

RIO TINTO AWARDS MONDIUM $400M CONSTRUCTION CONTRACT Rio Tinto has handed Mondium a major $400 million design and construction contract for the Western Turner Syncline phase two (WTS2) mine in Western Australia. Mondium, a joint venture between Monadelphous and Lycopodium, will complete all engineering, design, procurement and site construction at the Pilbara site. Works include designing and constructing the process plant, overland conveyor and other nonprocess infrastructure.

Mondium, which is set to start work in the first quarter of this year, expects to create 450 jobs through the contract. Rio Tinto and Mondium intend to work closely to ensure the project boosts local and indigenous employment in the region. Mondium’s design and construction works at WTS2 are expected to complete in 2021. Rio Tinto iron ore chief executive Chris Salisbury said the two companies share the same values AUSTRALIANMINING

of creating local and Indigenous employment opportunities. “We’re committed to supporting Western Australian businesses, buying locally and supporting our communities through the creation of jobs,” Salisbury said. “We’re continuing to invest in Western Australia and have a number of development projects in the pipeline that will continue to provide opportunities for local companies.” Mondium managing director

MARCH 2020

Andrew Carnie said the contract was a major strategic milestone for the company’s growth strategy. “We are thrilled to be making great strides in our growth strategy and to have secured this significant contract with Rio Tinto,” Carnie said. “Mondium has been working hard to execute projects successfully and prove our capability.” The WTS2 project is part of Rio Tinto’s Greater Tom Price operations, which had a $1 billion investment approved last November.

NEWS

BMW TO SOURCE LITHIUM FROM AUSTRALIAN MINES The BMW Group has signed a contract with Ganfeng Lithium to receive its supply for the batterymaking ingredient from Australian mines. This entails a projected order volume totalling €540 million ($872.8 million), representing 100 per cent of BMW’s lithium hydroxide needs for fifth-generation battery cells in its high-voltage batteries, according to BMW AG’s board of management member Andreas Wendt. “With the signing of this contract, we are securing our lithium needs for battery cells,” Wendt said. “We aim to have 25 electrified models in our line-up by 2023 – and more than half will be fully electric. Our need for raw materials will continue to grow accordingly. “By 2025, for lithium alone, we expect to need about seven times the amount we do today.” BMW plans to double its electric vehicle sales between 2019 and 2021. The contract runs for a five-year term. The German group stated sustainability was at the core of the expansion of electromobility, and Ganfeng extracted lithium by mining hard-rock deposits in Australia under the strictest sustainability standards. Ganfeng has offtake agreements with Pilbara Minerals and Altura Mining in place.

BMW FORECASTS AN INCREASING NEED FOR RAW MATERIALS FOR ITS UPCOMING 25 ELECTRIFIED MODELS.

STANWELL RE-SIGNS DOWNER WITH $600M MEANDU CONTRACT Downer EDI has won a five-year contract for mining services at the Meandu coal mine in Queensland worth $600 million. Under the contract, Downer will complete full mining services, including operating the coal handling and preparation plant at the mine, which is owned by Stanwell Corporation in the South Burnett region. This contract extends Downer’s

current operations at the mine, which started in 2013 and will expire in June. The new contract will commence in July. Stanwell chief executive Richard Van Breda said the two companies would work together to build on lessons learned between them from the past seven-and-a-half years. “Downer’s reappointment supports the long-term future of Meandu mine and the Tarong power

stations,” Van Breda said. “Over the next five years, significant changes will occur within the national electricity market and it is important we are in a position to respond to these changes. “The cost of coal is a significant portion to the total cost of running the Tarong power stations, it is therefore important for us to undertake these market reviews to ensure we are operating as

cost-effectively as possible.” The contract renewal comes as Downer has revised its net profit after tax and amortisation (NPATA) down to $300 million for the 2020 financial year. This reflects delayed project commencement in mining, project underperformance, lower revenue and unbudgeted restructure costs in engineering, construction and maintenance (EC&M).

MINING GIANTS SUPPORT NATIONAL BUSHFIRE RELIEF Mining companies such as BHP and Rio Tinto have responded to Australia’s fire crisis by donating millions to the Red Cross. The BHP Foundation donated $2 million, while Rio Tinto increased its contribution by $750,000. Rio Tinto previously donated $250,000 to the Red Cross to

support emergency relief efforts in November last year. Bushfires have (at time of writing) burnt through 5.8 million hectares across Australia, destroying more than 1700 homes and displacing regional communities. “The (BHP) Foundation’s donation will help Australian Red Cross AUSTRALIANMINING

provide immediate support through evacuation centres, psychological first aid and emergency assistance including cash grants to people who have lost homes as well as support longer-term recovery programs in fireaffected communities,” BHP stated. Newcrest Mining pledged $200,000 to the New South Wales

MARCH 2020

Rural Fire Service and $200,000 to the Victorian Country Fire Authority (CFA). This adds to the gold miner’s commitment to match up to $200,000 of employees’ donations. Mineralogy chairman Clive Palmer also made his helicopter, pilot and sea vessels available for any type of rescue during the national fire crisis.

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NEWS

PERTH MINT SHOWCASES RARE ARGYLE DIAMONDS

THE COINS FEATURE ARGYLE PINK DIAMONDS. IMAGE: THE PERTH MINT.

The Perth Mint has released Jewelled Tiger coins featuring rare pink diamonds from Rio Tinto’s Argyle mine in Western Australia. Its most significant release for 2020 incorporates nearly three carats of fancy vivid intense pink diamonds from the Argyle mine, making up a finely

structured three-dimensional 18-carat rose gold tiger pavé. Two emeralds from Colombia’s Muzo mines feature as the tiger’s eyes, while the coin is crafted from 10 ounces of 99.99 per cent pure gold. The Perth Mint only issued eight Jewelled Tiger coins, which are priced

at $259,000 each, recognising the significance of the number eight in Asian cultures and its association with luck and prosperity. “Our 2018 Jewelled Phoenix and 2019 Jewelled Dragon coins sold out within weeks of their respective release dates. We expect the Jewelled Tiger

will be similarly sought-after among the world’s diamond connoisseurs and collectors of luxury items,” Perth Mint chief executive Richard Hayes said. Each Jewelled Tiger coin is presented in a display case with 18-carat gold furnishings inset with two additional Argyle pink diamonds.

RED RIVER TO RESTART HILLGROVE GOLD MINE IN 2020 Red River Resources plans to start producing from the Hillgrove project in New South Wales this year to take advantage of high gold prices. The decision was made on the back of metallurgical testwork carried out by engineering consultant Consep and metallurgical development specialist Core Resources, which demonstrated

the viability of treating Bakers Creek waste dump material. This will go through the existing Hillgrove Mill, with total gold recovery to saleable gold doré produced on site estimated to be 75–80 per cent. The results from Hillgrove show that Red River can restart gold production from existing onsite

material, according to managing director Mel Palancian. “Having only acquired Hillgrove in August 2019, we are pleased that results to date have validated our strategy to expand our operations and we are progressing our plans to restart Hillgrove production before the end of 2020,” Palancian said.

Work has commenced on flowsheet to maximise the gold recovery using existing plant and infrastructure on-site. Red River plans to load and truck material from Bakers Creek Waste Dump 4.2 kilometres to the Hillgrove Mill, where it will be crushed and ground.

SIEMENS KEEPS CONTRACT WITH ADANI DESPITE PUBLIC BACKLASH Siemens has maintained its rail contract with Adani Mining despite protests from the general public, including climate activist Greta Thunberg. The company completed a due diligence report to back this decision and secured the right to pull out if Adani violates environmental obligations. “The Adani mining project has been approved by the Government of Australia, the Highest Courts and, very importantly to us, the indigenous

Wangan and Jagalingou people,” Siemens chief executive Joe Kaeser said. “The local and federal governments approved the project based on the Environmental Protection and Biodiversity Conservation Act 1999, as well as hundreds of pages of environmental impact statements. “Given the importance of legitimate environmental concerns, we have secured the right to pull out of the contract if our customer violates the very stringent environmental AUSTRALIANMINING

obligations.” Adani contracted Siemens to deliver rail signalling systems for the Carmichael rail network in the Galilee Basin, Queensland in December, which was met with public backlash. Shortly after the contract announcement, Kaeser announced that Siemens would review the contract and respond to the protestors. Thunberg expressed her disapproval of Siemens teaming up with Adani via social media platform Twitter, prior to Kaeser announcing his decision.

MARCH 2020

“It seems that Siemens have the power to stop, delay or at least interrupt the building of the huge Adani coal mine in Australia,” Thunberg tweeted. Siemens made a significant commitment to help tackle climate change in 2015, being the first global industry company of its size to pledge to become carbon neutral by 2030. Its latest sustainability report shows the company has slashed its carbon dioxide emissions by 41 per cent since that time, and by 2021 it will have reduced its emissions by half.

We had a ground man that did nothing but constantly clean up; that was his job. Now we don’t have a ground man. We haven’t shoveled the tail wheel or cleared anything out from under the conveyor since we installed these cleaners. I’m amazed by CleanScrape®, it’s been on for a year now and I haven’t touched it. This material is sloppy, it’s just muck that we’re running. And then you look at the return side of the belt and the proof is right there. Absolutely phenomenal. Try it out for yourself, it’s amazing. – Trey Poulson | Fairplay Gold Mine, CO, USA

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TRACKING THE TRENDS

BETTER PARTNERSHIPS, THE SOCIAL INVESTOR LEAD 2020 TRENDS THE 12TH EDITION OF DELOITTE’S TRACKING THE TRENDS REPORT HAS HIGHLIGHTED THE IMPORTANCE OF PARTNERSHIPS AND HOW THEY AFFECT A COMPANY’S AMBITIONS TO DELIVER SOCIAL VALUE AND TECHNOLOGY PROJECTS. BEN CREAGH WRITES.

or many years mining companies have been urged to improve how they collaborate in the industry and their supply chain through joint ventures and partnerships. This advice has resonated with companies and resulted in a wave of new joint venture activity between large, mid-tier and junior miners across the industry, according to Deloitte’s 2020 Tracking the Trends report. On a global scale, for example, former Kalgoorlie Super Pit partners Barrick Gold and Newmont have taken their relationship to another level by combining Tier 1 assets in Nevada, United States as a way to accelerate growth. Locally, several of Australia’s leading operators have increased investment or ramped up activity to identify the next generation of deposits in metals such as gold, copper and nickel. They are commonly working with junior companies by providing crucial funding that would have otherwise been difficult to source. As is the case in Nevada, gold has been central to a number of joint ventures, with Newmont and Newcrest Mining teaming up with junior companies to advance exploration opportunities in northern Australia. Rio Tinto, meanwhile, has been progressing its future copper potential in the Paterson Province in Western Australia through a JV with Antipa Minerals. Recognising these moves, Deloitte has identified ‘getting partnerships and joint ventures right’ as a key trend for mining companies in the 2020 report. According to Tracking the Trends, mining companies have looked back on partnerships and JVs they have formed and realised that many have failed to deliver the value originally envisaged. Deloitte Australia mining and metals leader Ian Sanders believes a solid foundation, selection of the right partners and key performance indicators (KPIs) are the major factors of a successful JV or partnership. “The majors are looking at diversifying some of their risk, whether

that means taking a stake in a mid-tier operation or it being a stepping stone to a future acquisition,” Sanders tells Australian Mining. “I think we are going to see more of it as industrial metals like copper and nickel continue to face supply issues. “Mining companies in particular currently have strong balance sheets relative to four or five years ago and need to find a good home for their cash flow that sustainably grows the business.” The need for better partnerships goes beyond joining forces with junior and mid-tier explorers; METS (mining equipment, technology and services) companies also have a role to play in today’s collaborations.

WITHOUT PEOPLE YOU ARE NOT GOING TO GET THE CHANGE AND EFFICIENCY YOU ARE LOOKING FOR, OR THE ENGAGEMENT OF THOSE PEOPLE.” Mining companies require effective partnerships that enable them to drive social value, deliver technology projects or shape the makeup of their future workforce – all key themes of the 2020 report. The so-called ‘social investor’ and

ENVIRONMENTAL FACTORS CONTINUE TO GROW IN PROMINENCE.

AUSTRALIANMINING

MARCH 2020

their demands for mining companies to deliver more social value through initiatives such as decarbonisation is a trend that is pushing for collaboration within the supply chain. “Sustainability teams within our mining organisations do not have the bandwidth or depth to be able to achieve their stated objectives,” Sanders says. “That’s not because they don’t want to, but because those objectives are so significant and vast, i.e. different examples of mining companies talking about their decarbonation footprint to 2050. “To get there they are going to need to be talking right through the supply chain on scope one and two emissions

TRACKING THE TRENDS

DELOITTE SUGGESTS COMPANIES RETHINK HOW PARTNERSHIPS ARE STRUCTURED.

and what can be done.” Deloitte regards decarbonisation as a priority in 2020 that will elevate Australian miners in the eyes of the social investor. Sanders also believes this focus is changing how mining companies are working with supply chain partners to achieve their goals. He says companies are being proactive in how they approached the supply chain to meet their social targets. “What does that mean? … You as a supplier of (a mining company) will have ethical sourcing including the

people that you use and the suppliers you use, first and foremost,” Sanders says. “Secondly, how can we work collaboratively together to create a greater product that is going to satisfy environmental stewardship and carbon emissions for both of us and ultimately then help us with our customers.” From a technology perspective, Deloitte highlights ‘the road towards intelligent mining’ by taking advantage of digital technologies, artificial intelligence and analytics solutions. The report reinforces the

AUSTRALIANMINING

need for mining companies to modernise core technologies, while also understanding the impact digital initiatives can have on their workforce, leadership and the communities in which they operate. “Digital investment alone isn’t enough to achieve the step changes,” Sanders says. “What’s really needed is where you conceptually focus across broader transformation, coupled with digital investments and innovation, along with people skills. “Without people you are not going to get the change and efficiency you are looking for, or the engagement of those people. “Some companies have therefore left some opportunity on the table because they have not put all of that together.” Getting partnerships right is,

again, a way for mining companies to ensure their technology projects and initiatives reach their potential. Deloitte identifies an emerging partnership model is to allocate project assets and liabilities across a full ecosystem of partners, including mining companies, original equipment manufacturers and service providers, to local communities and governments. Sanders says the creation of trust and collaboration between organisations will lead to unique insights into what might be possible. “I think those barriers that may have existed in the past are slowly coming down where organisations are seeing the competitive advantage they are going to get when they collaborate and work together,” Sanders concludes. AM

DELOITTE’S 10 KEY TRENDS FOR 2020 - T he social investor. The drive towards social value is no longer limited to environmental activists. Civil society and investors are demanding greater transparency around the environmental, sustainability and governance principles. - Getting partnerships and joint ventures right. In the next year more companies will be looking to explore joint ventures and partnerships in the execution of their strategies. However, looking back, many of these JVs and partnerships have failed to deliver the kinds of value originally envisaged. - Seize opportunity amid uncertainty. Commodity prices rise and fall in tune with economic trends, which are currently foreshadowing a potential downturn or lower growth environment. Deloitte identifies five bold plays so companies avoid being blindsided. - Dynamically managing risk. As global volatility rises, mining companies can no longer rely on their risk registers to identify danger areas. Deloitte explores how companies can embrace more strategic risk management practices. - The path to decarbonisation. Driven both by pressure from stakeholders and the strengthening business case for decarbonisation, mining companies are taking steps to reduce their greenhouse gas emissions. - On the road towards intelligent mining. Digital technologies, artificial intelligence, and analytics solutions have the potential to transform mining. While many companies have launched digital programs, companies often are not deriving the value they hoped for. - Modernising core technologies. Many legacy systems introduced by companies now need to be modernised. This raises considerations such as moving to the cloud, adopting sound cybersecurity strategies, managing data and choosing the best approach for revitalising core systems. - The intersection of talent and community. To capitalise on the digital revolution, companies need to drive radical change both internally and within surrounding communities. This requires a thorough understanding of the impact that digital transformation can have on work, the workforce, and the workplace, and in turn on the communities in which they operate. - Leadership in an Industry 4.0 world. There are four drivers reshaping today’s leadership landscape: the emergence of non-traditional teams; the creation of exponential roles; the proliferation of data; and the imperative to embrace greater diversity and inclusion. - Tax tribulations. Various global tax measures potentially could create serious constraints on mining economics. To mitigate any unexpected tax obligations, mining companies should be aware of these changes, understand how they could impact their tax affairs, and take steps now to mitigate tax risk.

MARCH 2020

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UNDERGROUND MINING

EPIROC SETS PATH FOR UNDERGROUND INTEGRATION THE ORIGINAL EQUIPMENT MANUFACTURER IS ON TRACK FOR THE FUTURE OF UNDERGROUND MINING WITH AN ARSENAL OF PRODUCTS THAT OFFERS MINING COMPANIES OPPORTUNITIES FOR ELECTRIFICATION AND AUTOMATION. BEN CREAGH WRITES.

lectrification and automation are shaping as the next frontiers of an underground mining industry determined to make safety, environmental and productivity improvements. For Epiroc, the integration of both into future models of its underground fleet has become the company’s ultimate goal. The Swedish original equipment manufacturer (OEM) is making significant progress on the electrification of its machines in particular, with global companies now investing in the latest models. Epiroc celebrated orders of its second generation battery electric mining equipment from Finland, Australia and Canada last September, less than a year after releasing the new machines. In Finland for example, Agnico Eagle Mines ordered the Boltec E Battery rig for its Kittilä gold operation. The Boltec joined a Boomer E2 Battery rig that had already been at the site for months. Agnico has been an important partner for Epiroc during development of its battery electric machines. The Canadian company has also tested

EPIROC’S TRIO OF SECOND GENERATION BATTERY ELECTRIC MACHINES ARE GATHERING INTEREST.

the Minetruck 42-tonne hauler and Scooptram 14-tonne loader at Kittilä for the Sustainable Intelligent Mining Systems (SIMS) project. Epiroc is serving as a coordinator of SIMS, which is part of Horizon 2020, the most extensive research and innovation program ever conducted by the European Union. Agnico highlighted the successful testing of the truck and loader a few months after the machines arrived at the site in August. Epiroc business line manager – underground rock excavation, Shaiful Ali, believes the SIMS project has reinforced the potential of the OEM’s battery electric machinery at mines around the world. He says Epiroc’s first battery electric machine destined for Australia will leave the company’s factory in the second quarter of this year, before delivery in the following quarter. “We are seeing good progress in regards to Epiroc providing a more environmentally-friendly underground solution,” Ali tells Australian Mining. “The tests show the machines are performing as we have said after we made quite a few upgrades with the battery packs since inception.” Epiroc’s upgrades have not only improved performance but also AUSTRALIANMINING

helped to reduce industry concerns about the capital costs involved with introducing battery machines over diesel alternatives. A key development that lowers the CAPEX is Epiroc’s Batteries as a Service solution, which gives the OEM ownership of the batteries being used on its underground machinery. Previously, battery electric machines would cost mine operators around double that of a diesel model. But with Batteries as a service, initial

THE SCOOPTRAM ST14 BATTERY LOADER.

MARCH 2020

capital outlay would be significantly reduced, according to Ali. He says the innovative service also provides mining companies with the comfort that Epiroc will look after the battery from “cradle to grave” and be with them for its lifetime. “When we first did a cost analysis the difference was quite significant,” Ali says. “The cost to operate a battery machine is not as much as a diesel, but the capital constraint from day one was something that a lot of

UNDERGROUND MINING

THE BOOMER E2 BATTERY DRILL RIG.

people were nervous about. “Now the price of buying the battery, storing the battery, technology advances with battery upgrades, battery removal and disposal – those are items that are taken away by Batteries as a Service.” With electrification comes a stronger opportunity to introduce automation at mine sites. A 2019 Ernst & Young (EY) report expects electrification will accelerate automation and the Internet of Things in the mining industry. “…more reliable electric motors require less maintenance and intervention,” according to the EY report. “With electrification, automation through drones, autonomous vehicles and remotecontrolled operational systems will be rolled out more widely across mining operations.” Epiroc has become an industry leader in automated surface drill rigs and plans to replicate this success with its underground machinery in the coming years. The OEM combines its underground automation offering with information management through an initiative coined, 6th Sense, which now features a range of products. They include Scooptram Automation Regular and Total, technologies for a single loader up to an entire fleet. Epiroc has deployed Scooptram Automation at a high-profile underground mine in Australia and has moved the project into the commissioning phase. The OEM’s team that executed a surface automation project with BHP in the Pilbara, Western Australia has focussed on the underground

opportunity since 2018. Epiroc Rocktec division regional applications centre manager Rohan Anderson has been involved on the surface and underground automation projects in Australia. He says with the progress Epiroc has made with its surface drills the next priority for the OEM will be to improve the effectiveness of its autonomous systems for underground mining. “There are plans to get people out of that environment by replacing them with computer algorithms and sensors and have the people operating the machines from the surface,” Anderson says. “We’ve had four software developers working there and

an engineer looking at data, developing dashboards that monitor performance. “By analysing the data, it is helping us find where the gaps in performance are and also looking for opportunities for improvement.” Epiroc is complementing its ambitions for electrification and automation underground with information management solutions. The company has a series of industry collaborations that are supporting its efforts to develop the systems, including a partnership with Saab and Combitech to develop safe mining digitalisation concepts. Together, the trio has created a traffic management system that effectively allows Epiroc’s machines

to talk with each other, reducing the risk of accidents and lowering traffic congestion underground. The addition of Mobilaris Mining Intelligence to the Epiroc suite of products has also proven to be a point of difference for the OEM. Mobilaris has launched its Onboard solution in past year to solve some of the navigational challenges in underground mining. The solution runs on a modern tablet computer mounted inside a machine’s cabin and enables any underground miner to know what is going on in the mine. Mobilaris Onboard collects all of the real-time information about personnel, equipment and vehicles from the centralised Mobilaris Mining Intelligence software. The information, including mine maps, is shown in 3D and is stored locally so operators can use it even when they are outside of network coverage. As each of these elements for underground mining evolves, they are combining to create Epiroc’s vision for a safer and more sustainable underground environment. “The hope is to integrate everything, having an automated battery machine is probably the ideal angle we want to achieve. We know we have the battery machine and automation system – it is just a matter of how we integrate them with each other,” Ali concludes. AM Epiroc will highlight its expertise in electric vehicles, automation and information management systems at the 2020 Underground Operators Conference at the Perth Convention and Exhibition Centre on March 25–27.

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REGIONAL SPOTLIGHT

DIGGING DEEPER FOR VICTORIA’S GOLDEN REWARDS

THE CASTLEMAINE AND SOUTH MUCKLEFORD PROJECTS HAVE BECOME KALAMAZOO’S PRIORITIES.

THE UPWARD SPIRAL IN PRODUCTION AND GRADES AT THE FOSTERVILLE GOLD MINE HAS REIGNITED INTEREST IN THE RICHES THAT THE CENTRAL VICTORIAN GOLDFIELDS OFFER. VANESSA ZHOU WRITES.

entral Victoria has not only delivered to the gold mining sector during past centuries but is also emerging as a thriving region for the miners of today. The romanticism of Victoria’s gold rush in the 1850s may even go to another level with the wave of discoveries that modern companies are threatening to make. According to Victorian Department of Jobs, Precincts and Regions head of resources John Krbaleski, the state’s gold sector is booming with more gold being found every year and more companies searching for the next viable deposit. “Geological evidence suggests there may be as much as 32 million

ounces of undiscovered gold across the Bendigo region,” Krbaleski tells Australian Mining. Kirkland Lake Gold’s resounding success at the Fosterville mine is a clear indication of the potential in central Victoria. Though the much-celebrated Fosterville mine commenced operations back in 2005, it has only truly made headlines as Victoria’s largest gold mine in recent years. The abundance of gold has always been there. What’s different is Kirkland Lake’s audacious commitment to drilling. “A lot of it owes to the hard work of drilling we’re putting into Fosterville,” Kirkland Lake vice president, investor relations Mark Utting says. “(The previous operator) already AUSTRALIANMINING

knew the grade was improving in traditional sulphide mineralisation as they were drilling deeper, and there was also a sense there was a different kind of mineralisation starting to appear at depth. “But at the end of the day, you’ve just got to get into it and drill it to know exactly what you have.” Kirkland Lake invested $US25 million ($37.4 million) in exploration drilling in the first year after the company’s completed its acquisition of Newmarket Gold in 2016. The budget was more than what had been invested in exploration at Fosterville for a number of years, potentially going back to around when the underground mine opened, according to Utting. Still, the Canadian company has continued to lift its exploration

MARCH 2020

budget since, investing $US48.4 million in 2017, followed by a 38 per cent boost to $US66.6 million in 2018. “Our exploration budget for this year is $US70 million to $US80 million – the highest it’s ever been – and that was just based on what we see: a number of different potential targets with encouraging results,” Utting says. “We saw an opportunity to make an exploration campaign at Fosterville and we were willing to invest in it and prove it up. That’s been a character of Kirkland Lake and the success we’ve had.” Kirkland Lake’s tireless commitment to drilling wasn’t left unfounded to a geologist’s instinct but a due diligence study that validated the takeover decision:

REGIONAL SPOTLIGHT

Fosterville could become a more profitable mine. During its initial years, Fosterville’s gold was produced from near-surface, low-grade mineralisation. Kirkland Lake has since discovered the Eagle and Harrier zones, which contain high-grade visible-gold bearing mineralisation, and down-plunge extensions of the Lower Phoenix gold system. As Victoria’s leading gold operation, Fosterville boasted a reserve of 2.7 million ounces at 31 grams per tonne at the end of 2018. This figure has grown significantly from the reserve of 244,000 ounces at seven grams per tonne when Fosterville was acquired from fellow Canadian-listed Newmarket around four years ago. “It’s really the case of successful exploration leading to significantly higher grade and a much more profitable mine,” Utting says. “We just finished 2019 where we produced 619,000 ounces at Fosterville. When we acquired the mine in 2016, it produced 150,000 ounces. The gold is all in the ground. It’s all about proving what’s there.” The prominence of gold in central Victorian extends beyond what’s already unearthed from Fosterville. Kirkland Lake is investigating a sulphide structure at the Lower

AT THE END OF THE DAY, YOU JUST GOT TO GET INTO IT AND DRILL IT TO KNOW EXACTLY WHAT YOU HAVE.”

KALAMAZOO INSISTS IN FINDING PROJECTS OF AT LEAST 10 GRAMS A TONNE.

Phoenix system where it has extended mineralisation 950 metres down plunge of the bottom of the Swan Zone. Utting describes the structure as a “very large exploration target” to pursue. “We haven’t discovered the next Swan Zone yet, but we’ve had intersections of quartz with visible gold in it that suggest this is a very large area we’re going to be exploring,” Utting continues. Kirkland Lake has also identified

the Cygnet Zone, a structure that extends 650 metres along strike and intersected quartz with visible gold. This adds to another plunge from a different open pit which Kirkland Lake calls Harrier. Deep drilling at target is under way at Harrier, which Utting believes carries high potential. “We’ve got all areas on the mining lease property that are showing extremely profitable mineralisation that’s been intersected at various locations, and we’re following up on

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all of them,” Utting says. “In fact, we will be driving a twin drive from where the existing mine infrastructure is underground, which is going to help us with exploration and ultimately production. “That’s allowed us to investigate another very attractive exploration target in the Twin Phoenix where Swan and Robin’s Hill are.” Robin’s Hill, dubbed as potentially being Fosterville 2.0, has returned “very encouraging” results and could ultimately feed the existing Fosterville mill, which has capacity to accommodate an expansion. “If you were to draw a straight line to the Phoenix System where Swan Zone was discovered, Robin’s Hill mineralisation compares very favourably,” according to Utting. “That’s why we’re investing so much capital in drilling there this year. We’re confident there’s a lot more to be found in Fosterville and that we’re going to be mining

REGIONAL SPOTLIGHT

Fosterville for a very long time.” Fosterville has awakened industry interest in the high-grade gold projects that potentially exist in the region, particularly that of Kalamazoo Resources chairman and chief executive Luke Reinehr. “What’s interesting there is that (Fosterville) was a low-grade open pit operation that had been running for 15 to 20 years,” Reinehr says. “It was only in recent times that under the guidance of Kirkland Lake that they found incredibly high-grade mineralisation by drilling deeper and using new technologies, giving everyone an encouragement to find potential world-class gold orebodies.” Given the proximity of Kalamazoo’s exploration projects to Kirkland Lake’s mine (45 kilometres to be exact), the geological similarities between the junior’s Castlemaine and South Muckleford gold projects and Fosterville are undeniably appealing. The two exploration projects remain Kalamazoo’s priorities for 2020 with the maiden drilling program commencing in November 2019. “An exceptional high-grade intersection was reported in just the fourth hole of 1.42 metres

at 261 grams per tonne of gold from 100.3 metres, which not only provides further support of Kalamazoo’s model and strategy, but demonstrates its ability to potentially deliver a potential worldclass discovery,” Reinehr says. “This was followed with an $8 million investment by legendary Canadian gold investor Eric Sprott and Canadian gold explorer Novo Resources just weeks later.

WE’RE VERY CONFIDENT THAT WE’RE GOING TO BE MINING AT FOSTERVILLE FOR A VERY LONG TIME.”

“For the rest of this year, we have planned a further 14,000 metres of diamond drilling at Castlemaine and South Muckleford.” Yet Kalamazoo is hoping to expand its footprint in the state’s north central Goldfields area after lodging a tender in the North Central Victorian Goldfields ground release in February. Reinehr believes there is golden

potential in the region, describing the bidding areas as “very prospective”, with the closest of the land packages just 15 kilometres from Kalamazoo’s north-east tenement boundary. The Fosterville success has sparked international interest in exploring for gold in central Victorian, according to Krbaleski. Fosterville is not just a unique success story for the mining industry, but it is also a project that contributes to the community. “We think it’s a great win-win in terms of our willingness to invest and creating value for the company and for Victoria,” Utting says. Victoria’s newly introduced gold royalty of 2.75 per cent doesn’t deter Kirkland Lake from what it is pursuing either. The royalty simply represents “an additional cost” that has to go into the economic analysis, Utting says. “It doesn’t impact anything we’re doing today, but in terms of future exploration successes, we have decisions to make in future investments,” he says. “The royalty could impact that, only because it represents an additional cost that has to go into our economic analysis.” For Kalamazoo, Reinehr is

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AUSTRALIANMINING

MARCH 2020

GOLD DEPOSITS HAVE NOT RUN DRY IN CENTRAL VICTORIA.

confident in the company’s financial capacity should it be successful in transitioning into a producer. “We have a high-grade strategy only at Kalamazoo,” Reinehr says. “We’re looking at projects of not less than 10 grams a tonne, and even though the costs in Victoria can be elevated at times, if we find a worldclass gold resource, we’ll have the capacity to pay for that royalty.” It seems the prospect of rising costs won’t stop large or junior miners alike from flocking to central Victoria, a testament to how abundant its gold riches could again become. AM

COMMODITY SPOTLIGHT

LITHIUM HINTS AT RETURN TO POWER AS MARKET SHIFTS

PILBARA MINERALS’ PILGANGOORA LITHIUM-TANTALUM PROJECT.

IN A RAPIDLY DEVELOPING WORLD, LITHIUM WILL SOON BE AN ESSENTIAL COMMODITY TO POWER SMART PHONES, ELECTRIC CARS AND OTHER ELECTRONICS, DESPITE A DIP IN PRICES DUE TO WEAKER DEMAND. SALOMAE HASELGROVE INVESTIGATES THE MARKET.

n spite of lithium’s promise, the metal’s rise has been up against slowing electric vehicle (EV) production growth in China, putting Australian producers in a waiting game. The start of a new decade has, however, shown some positive signs for the material, which had been a commodity market darling up until last year’s woes. Lithium has started 2020 with more optimism and prices of lithium equities have risen, particularly Chinese powerhouse companies within the supply chain. Fitch Solutions predicted an improvement in lithium prices

and demand in December, as the Chinese Government strengthened its support for EV adoption, offering subsidies and forming strategic partnerships to boost vehicle sales. For example, Chinese lithium manufacturer Ganfeng Lithium, which has offtake agreements with Australian producer Pilbara Minerals, has signed a contract with automotive giant, the BMW Group to supply its product. The German car manufacturer plans to power its vehicles using lithium produced at Australian mines, including Pilbara Minerals’ Pilgangoora lithium-tantalum project in Western Australia. Pilbara Minerals chief executive AUSTRALIANMINING

Ken Brinsden says 100 per cent of the lithium hydroxide BMW needs for the fifth-generation battery cells for its high-voltage business is expected to come from sustainable and secure Australian hard rock lithium mines. “By 2023, the BMW Group aims to have 25 electrified models and by 2025 it expects to need seven times the amount of lithium compounds compared to today,” Brinsden tells Australian Mining. This is great news for Australian lithium producers, many of which have faced poor market conditions over the past year. Pilbara Minerals is one Australian lithium producer that slowed mining

MARCH 2020

activities at Pilgangoora in the second half of last year after the site had rapidly developed into a producing operation. United States lithium major Albemarle Corp fell victim to the market conditions in November, suspending operations at the Wodgina lithium joint venture with Mineral Resources until demand shifted. Joint venture partners Wesfarmers and Sociedad Quimica y Minera de Chile S.A. (SQM) have also postponed a final investment decision on the Mt Holland lithium project in Western Australia until next year. Despite the immediate concerns,

COMMODITY SPOTLIGHT

the Australian lithium industry remains well placed to feed Asian demand for the commodity over the long term. Pilbara Minerals and fellow Australian developer Core Lithium remain positive about the commodity’s outlook as the Chinese and European EV markets continue to grow. Core Lithium managing director Stephen Biggins points out that government-driven EV sales across Europe have increased by about 30 to 40 per cent year on year. Both Core Lithium and Pilbara Minerals also anticipate strong outcomes for lithium from other emerging opportunities that are appearing in the market, such as renewable energy. As Biggins explains, there has been a positive shift in demand for lithium batteries to power renewable energy supply, such as the 100 gigabyte Tesla battery built in South Australia during 2017. “There has been significant growth in lithium batteries for renewable energy supply and supporting electricity networks around the globe,” Biggins says. “We’re seeing now in the south west of Queensland there are plans to build an even larger lithium battery to support the electricity

INNOVATIVE MINING SOLUTIONS

THE PILGANGOORA PROCESSING PLANT.

network.” Lithium batteries, both primary (disposable) and secondary (rechargeable) lithium-ion models, are only just scratching the surface of the potential of the metal and its chemical compounds. The commodity has traditionally been used for a wide range of

chemical and industrial resources, such as heat-resistant glass ceramics, specialty glasses, enamels and lithium grease lubricants. Additionally, it can be used as a flux additive for the production of other commodities like iron, steel and aluminium. With this outlook, both Pilbara

Minerals and Core Lithium are focussed on expanding and developing their projects. Pilbara Minerals has a stage two and three expansion on the agenda at Pilgangoora, where it is looking to increase its mineral reserves to accommodate increased output. Throughout 2019, Pilbara

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COMMODITY SPOTLIGHT

LITHIUM RECOVERY IS A KEY CONTRIBUTOR TO ACHIEVING UNIT OPERATING COST REDUCTIONS AT PILGANGOORA.”

CORE LITHIUM EXPLORATION DRILLING IN THE NORTHERN TERRITORY.

Minerals made important progress to increase its recoveries through the Pilgangoora processing plant. Its recoveries reached an average of 55 per cent during the June 2019 quarter and increased as high as 70 per cent during campaign processing in the December quarter. “The company anticipates that with further plant optimisation and operating time, product recoveries will continue to improve,” Brinsden says. “Lithium recovery is a key contributor to achieving unit operating cost reductions at Pilgangoora. “We remain focussed on moving forward with key joint venture terms in place with our partner POSCO, for the development of a lithium chemical conversion facility in South Korea. “With this opportunity now firmly in our sights, we are positioned to be the first Australian spodumene

producer to enter this fast-growing market in South Korea.” Core Lithium, meanwhile, is moving quickly through feasibility studies at its Finniss project in the Northern Territory, with plans for starting construction of a mine as soon as this year. For Core, exploration at the project near Darwin has repeatedly delivered exciting drilling results, including 107 metres at 7 per cent high grade coarse spodumene. Biggins says the company is working on significant resource upgrades throughout the remainder of this quarter now it has returned the excellent drill results. “While undertaking additional mining studies on our expanded resources and reserves, we are working towards having the project construction ready by the middle of the year, including upgraded resources,” Biggins says. Core plans to complete mining AUSTRALIANMINING

and feasibility studies for the Finniss project in the first half of this year, while also progressing approval and financing discussions, so the construction decision can be made. Located just 25 kilometres from Darwin port, which is considered a key Australian gateway to Asian exports, Core also has convenient logistical connections from the mine to the market in place. This opens an opportunity for both Core and potential workers, having a world-class asset so close to an Australian capital city. “Finniss has an exciting incentive for workers’ wellbeing, as the company is able to leverage the existing infrastructure without the need to build camps or airstrips being less than an hour’s drive from an international airport,” Biggins says. “The project has the best location in regards to port infrastructure and the benefit of having our workforce based residentially in Darwin, since the project is only a 45-minute drive from town.” Fittingly for both companies, future estimates for EV and battery demand support their growth aspirations as lithium producers. For example, Benchmark Mineral Intelligence tips global EV sales to increase by 12.4 million units at a penetration rate of around 11 per cent by 2025, before further growth

to 54.3 million units by 2035 “Whilst it’s taking some time for the industry to readjust, the changes to the subsidy regime in China to favour the emerging highnickel cathode batteries will in time provide Australian hard-rock lithium producers with a significant competitive advantage,” Brinsden says. “In the medium-term, stronger support for lithium raw material demand growth is expected to occur as a result of the sourcing initiatives currently under way by battery and car manufacturers, which will lead to increased demand for lithium-ion batteries globally.” Biggins validates this, stating that as global markets continue to demand more lithium and spodumene products, lithium companies will see an increase in pricing. “For the European and Chinese markets in particular, the demand side of things is still very, very strong,” he says. “On a supply side, we’ve seen supply delayed and switched off, which is going to require some effort and incentive to switch back on again, so I would expect markets will need to see higher prices in spodumene and lithium to incentivise new lithium supply.” According to Biggins, as lithium operations slowed in Australia to counter the drop in demand, this could help to set up the resurgence. “In Europe, car manufacturers are already concerned there is not enough planned new lithium supply to be developed,” he concludes. “So now all levels in the supply chain, from car manufacturers to battery manufacturers all need to work out in coordinating their approach to ensure enough supply in the future.” AM

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AUTOMATION

SANDVIK AUTOMATION PARTNERSHIP PAYS OFF FOR NORTHPARKES NORTHPARKES COPPER MINE TOOK ITS FIRST STEPS TOWARDS UNDERGROUND LOADER AUTOMATION IN THE 1990S. MORE THAN 20 YEARS ON, IT HAS BECOME A GLOBAL SHOWCASE FOR THE SAFETY, MAINTENANCE AND PRODUCTIVITY BENEFITS THAT AUTOMATION CAN PROVIDE.

utomation is one of the most important trends in underground mining today. Operators across the planet are rapidly moving to automated systems to harness the productivity and safety gains achieved by removing humans from dangerous frontline operations. But it wasn’t always so. Back in the 1990s, the potential for automation was a huge unknown. Only the most future-focussed mine owners and contractors were willing to invest time and money into investigating the potential for the then fledgling technology.

That’s when Australian copper and gold miner Northparkes began its automation journey. In 1998, the operation began cooperating in early industry trials investigating the viability of automated load, haul, dump machines (LHDs). A little over 20 years on, the mine in New South Wales has become a shining example of all that automation can achieve. Since switching over to an automated Sandvik LHD fleet in its E48 block cave mine in 2015, Northparkes has boosted output by nearly 20 per cent. Daily loader productivity is up 24 per cent, costs per tonne are down 23 per cent, and

the problem of loader-operator head injuries has been eliminated. “Moving to automation at Northparkes was by far the best decision we ever made,” Northparkes mining operations manager Rob Cunningham says. “What we have today is a very successful solution with a very good partner that has achieved everything and more than we wanted right from the very beginning. It’s been very profitable to the business and it’s been in the best interest of our people as far as health and safety goes.” Established in 1993, the Northparkes operation is a joint venture between majority owner China Molybdenum

(CMOC) and the Sumitomo Groups. Copper concentrate mined and processed here is taken by truck and rail to Port Kembla on the coast south of Sydney, about 400 kilometres away. Northparkes initially made a name for itself by becoming the first miner in Australia to use the block cave mining technique. The approach involves undercutting an ore body and allowing it to progressively collapse under its own weight. Draw bells, (essentially, funnels), are established below the fracturing deposit and feed ore into extraction drives where LHDs convey it to be crushed and taken to the surface for further processing.

AN AUTONOMOUS LOADER WORKING UNDERGROUND AT NORTHPARKES.

AUSTRALIANMINING

MARCH 2020

AUTOMATION

WE’VE SEEN A REDUCTION IN OPERATING COSTS, A GREATER LEVEL OF PREDICTABILITY AROUND FLEET LIFE CYCLE MODELS AND THE PERFORMANCE OF THE ASSETS AND THAT BASICALLY PUSHES YOU INTO A MORE OF A PLANNED SPACE.”

SANDVIK’S RELATIONSHIP WITH NORTHPARKES HAS SPANNED SEVERAL DECADES.

Some 80 per cent of Northparkes’ production today comes from its E48 Lift 1 block cave mine, with the remaining 20 per cent coming from the E26 Sub Level Mine. In 2015, Northparkes achieved a major milestone when its E48 Lift 1 block cave mine became the first mine in the world to achieve full automation, outside of display mines. Six autonomous Sandvik LH514 loaders (five electric and one diesel) now operate 500 metres below the surface at Northparkes, tramming ore from the draw bells and dropping 11- to 12-tonne loads in the ROM bin for crushing.

Travelling at speeds of up to 21 kilometres an hour, the LHDs operate autonomously for 80 per cent of their cycle time and rest of the operation cycle is tele operated. Operators working in a screen-filled control room on the surface assume control only when the loader bucket needs filling. “The Sandvik AutoMine (Fleet) system controls the function of the loader from the draw point to the dump point, tips the bucket and then returns the loader to the draw point,” Northparkes underground production superintendent Tim Bray explains. “The automation operator then takes control of the loader, fills the

bucket and repeats the cycle.” Bray explains while the autonomous Sandvik LHDs are slightly more efficient than human operators on a tonnes-per-hour basis, the real productivity gains come from increased utilisation across the 24hour working day. Since 2015, Northparkes has moved more than 20 million tonnes of material under automation. In recent years, automation has allowed for production to be ramped up from 5.5 million tonnes annually to 6.5 million tonnes, a rise of 18 per cent. The switch to automated loaders has also reduced wear and the need for

maintenance, helping to push down LHD operating costs by 23 per cent. Northparkes mobile equipment maintenance superintendent Brad Goodfellow explains, “We’ve seen a reduction in operating costs, a greater level of predictability around fleet life cycle models and the performance of the assets and that basically pushes you into a more of a planned space.” Cunningham says the next step for Northparkes is fully autonomous operation of its loaders, something it hopes to achieve in 2020 through close collaboration with Sandvik. “What we want to see in the future is that the machine will come back

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AUTOMATION

THE NORTHPARKES CONTROL ROOM.

to the draw point, load itself, pull back and go to the ROM bin. So, everything’s controlled by the system.” While the benefits of automation to Northparkes are now crystal clear, it took tenacity to remain committed to the concept through various hurdles and partner changes. Following initial trials in the 1990s that proved the automation was viable, Northparkes trialled various automated loader systems throughout the 2000s. These efforts often involved pairing

Sandvik loaders with third-party automation systems. When planning and construction began on E48 Lift 1 in 2008, Northparkes felt technology was approaching the point where it could commit to full automation of an entire mine site. In 2011, it signed an agreement to partner with Sandvik in developing automation systems for E48. Together, Northparkes and Sandvik developed the required safety, productivity and

automation systems ahead of the commencement of production in 2012, and eventually implemented full loader automation in 2015. Sandvik support manager for mine automation in Australia Ty Osborne says there were a number of challenges along the way, which Sandvik and Northparkes collaborated to solve. An issue with repeated cabin damage due to operator error was remedied with enhanced automation software and hardware changes. “We

MAINTENANCE ACTIVITIES AT THE COPPER OPERATION.

AUSTRALIANMINING

MARCH 2020

also had an issue where the loader was sliding going into the draw points,” Osborne says. “Working with Northparkes, we came up with a solution to give more situational awareness to the operator up here on the surface, so they knew when the machine was sliding.” Meanwhile, fleet data management has also since been introduced via the My Sandvik Digital Service Solutions platform. The ongoing operation of Northparkes’ automation is now supported by team of five and LHDs by a team of 18 Sandvik specialists based on site and working on a roster of five crew at a time. Sandvik project manager of the service contract at Northparkes, Matt Plummer, says the Sandvik team is continually collaborating with the Northparkes team to find ways of making the operation more efficient. A recent breakthrough involved pushing out the maintenance interval on the loaders from every 24 hours by fitting a larger grease cannister. “We’ve now taken our service intervals out to 48 hours,” he says. Cunningham says the greatest strength of Northparkes’ relationship with Sandvik is the shared goal of achieving the best for the operation. “Issues have been always put on the table, managed in open discussion and worked to resolution,” he says. “And that’s fundamentally how it’s all worked all the way through. While we can have disagreement or we can have different views or ideas, we’ve always worked it out and we’ve always got the best outcome.” AM

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FUTURE OF MINING

RENEWABLES ARE A NO BRAINER FOR THE AUSTRALIAN MINING SECTOR WHEN EXPERIENCE IN THE RENEWABLES ENERGY SECTOR COLLIDES WITH EXTENSIVE KNOWLEDGE OF THE MINING INDUSTRY, CONSIDERABLE BENEFITS AWAIT THOSE THAT CAN EXPLOIT THE ADVANTAGE. TOTAL EREN EXPLAINS HOW. KIAMAL IN VICTORIA IS ONE OF TOTAL EREN’S LARGEST SOLAR ASSETS WORLDWIDE.

CLÉMENT FAURE OF TOTAL EREN.

he mining sector is heading into a new era of responsibility, with power generation taking a slice of it. While investors around the world are looking for environmentally-friendly companies to back, technology has made the use of renewable energy possible and at an increasingly affordable price. This allows mining companies to slash their carbon footprint at the same time. Founded in 2012 by Pâris Mouratoglou and David Corchia, French-based Independent Power AUSTRALIANMINING

Producer (IPP) Total Eren has an ambitious goal: achieve a gross installed renewable energy capacity of more than five gigawatts globally by 2022. A global leader active on the five continents in only seven years of existence, the Paris-headquartered company has a comprehensive grasp of all development stages of a solar, wind or hydro energy project. Today, Total Eren owns more than 2700 megawatts of renewable energy power plants in operation or under construction worldwide, supplying low carbon energy to major utilities and large private customers in Europe and

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the Mediterranean, Central Asia, Asia Pacific, Africa, and Latin America. Australian Mining speaks with Total Eren head of business development – mining and hybrids Clément Faure about how the company, in which Total S.A. holds a 30 per cent stake, helps mining companies around the world transition towards a more competitive and sustainable power supply.

Why do you think Australia is ready for the use of renewables?

With more than 14 gigawatts of solar and six gigawatts of wind capacity already deployed, contributing over 12

FUTURE OF MINING

per cent of Australia’s total electricity demand, figures speak for themselves. Over the past 10 years, renewables have become more and more competitive everywhere in the world, and Australia surely belongs to this trend with its tremendous wind and solar resources.

Why does renewable energy make sense for an Australian mine site?

On the other hand, security of supply has arguably not been as much of a driving force as it has been in places like Africa and South America, which also explains why Australia is slightly behind these other countries in implementing renewables for mining. It remains that renewables do make sense, and the Australian mining industry has already illustrated that there is a market for it. Take, for example, Goldfields’ Agnew solar and wind project in Western Australia, the latest of 20 hybrid projects involving solar storage happening in the state. Concurrently, mining operations connected to the grid can benefit from the ever increasing solar and wind capacity coming online, allowing for easier procurement similar to BHP’s tender mid last year.

What challenges can a mining operator expect?

Challenges are minimal, while opportunities are demonstrated. Renewables are very capital intensive. On the other side, you have very limited operating expenses in a solar or wind farm. With significant upfront investments, you need to have a mid- to long-term view to enjoy the plain value of renewable energy whether the mine decides to invest itself, or to enter into a medium to long-term Power Purchase Agreement (PPA) with an entity like us who will develop and invest in the renewable power plant. In addition, particularly for offgrid mining operations, the reliability and stability of their power supply cannot be endangered by intermittent renewable. But here again, the industry has already demonstrated its ability to successfully tailor the rightly balanced energy mix, from the Agnew project to our Essakane project in Burkina Faso. It’s important for the mine to contract an experienced independent power producer who understands how to smoothly, technically and contractually integrate the renewable energy plant in the global electricity supply plan of the mine. A lot of players say they know how to do it. We are part of the very few companies having a real track record. The last thing that needs to be kept

TOTAL EREN’S BIGGEST WIND FARM IN LATIN AMERICA IS UNDER CONSTRUCTION IN THE SANTA CRUZ PROVINCE IN SOUTHERN ARGENTINA.

in mind is that most renewable energy projects that have been financed all over the world were structured for a national or regional grid, with a sovereign risk around offtake and creditworthiness. Now looking at renewables for mines, investors and lenders will have to get comfortable with the mining operations and their ability to sustain commodity cycles. This is also where an experienced partner can structure the best financing scheme and tailor the optimal risk allocation between the investor, the lenders and the mine.

How does a mining operator ensure that a renewable project is as competitive as possible?

Mining operators need to understand the pros and cons of each renewable energy technology versus their specific power supply needs. The more renewables, the more competitive and clean energy and the bigger the hedge versus future grid or fuel price volatility. But also the more complex the energy management to deal with the intermittency. You need to find the right balance AUSTRALIANMINING

between daily power stability and your benefits on energy costs across the year, because you don’t want your mining operation to be disturbed. Tendering process is a standard way of sourcing the most competitive offers. Yet a lot of the value comes from the development as the right technical and commercial risk allocation is always the fruit of extensive discussions and has to be tailor made for and with each mine. This is because what looks good on paper is not always deliverable in reality, and you cannot put all what it takes in a tender. At the end of the day, the most important decision a mining operator has to make is who to partner with on their renewable energy journey. And one should not forget that time is of the essence as energy cost savings start upon commercial operation of the plant. Endless tender processes postpone the start of those savings and reduce the remaining life of mine.

Do all renewable energy companies not have the same capability? In a renewable energy market, there are lower entry barriers and lots of

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variety in the players’ profiles. You have very small-scale starters, which may not have the financial strength or long-term vision. And you have regional players which may not have the ability to source the best equipment globally. You need a renewable energy partner with an experience in the mining sector; an expert in renewables that can also cater for the needs and concerns of a mining operation. One thing to keep in mind is that contrary to a developer or contractor, an IPP never takes a short-term view. We do not promise what we cannot deliver and operate, simply because we recoup our investment over time, aligning our interests with the mine as an offtaker. And why would a mine talk to a developer that has no intent or means to invest and will thereafter come to us to “sell its project”? In Australia, Total Eren is building a 256.5 megawatts Kiamal solar project, soon to be the largest solar farm in Victoria once completed. Kiamal will provide low carbon energy to one large food manufacturer (Mars Australia), two energy retailers (Alinta Energy and Flow Power) and a collective of 13 leading Victorian water corporations (Zero Emissions Water). In Burkina Faso, Total Eren and its partner Africa Energy Management Platform (AEMP) developed, financed, built and now operate a 15 megawatts hybrid PV-HFO (heavy fuel oil) plant at the IAMGOLD Essakane gold mine in northern Burkina Faso, displacing six million litres of fuel and saving 18,500 tons (16,783 tonnes) of carbon dioxide per year. A unique project, and to date the largest unsubsidised solar hybrid project successfully brought into operation at an off-grid mining site: the Essakane solar plant represents a major step for the renewable energy industry and the mining sector. Building on these experiences among others, we are confident in our ability to deliver on complex project structures for the Australian mining sector, whether it be on the offtake, the technical or the harsh environmental and security constraints. With Total Eren, mining companies benefit from the support of a global company with an extensive trackrecord in providing reliable grid and off-grid renewable energy projects worldwide. In parallel Total Eren leverages the knowledge and experience gained in the mining sector through its shareholder Total S.A, who has grown for decades from being an industry partner in lubricants supply to one of the world’s strongest and most committed energy partners. Time has come to build on that mutual trust towards a more sustainable mining future. AM

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TECHNOLOGY

LINX CARGO CARE GROUP IS USING VIRTUAL REALITY TRAINING FOR STAFF ACROSS ITS OPERATIONS.

VR PREPARES LINX FOR DANGEROUS SITUATIONS, SAFELY LINX CARGO CARE GROUP IS USING VIRTUAL REALITY TRAINING TO PREPARE ITS WORKERS FOR HIGH-RISK ENVIRONMENTS IN A SAFE SPACE. AUSTRALIAN MINING SPEAKS TO THE COMPANY ABOUT HOW THE TECHNOLOGY HAS IMPROVED ITS TRAINING PROGRAM.

s an organisation with 4000 employees across 70-plus sites in Australia and New Zealand, training staff at LINX Cargo Care Group can be time-consuming. Since rolling out virtual reality (VR) training, however, the supply chain and logistics company has found that processes that once took days to complete have been cut to hours, in a more engaging environment. LINX Cargo Care Group business development manager Neil David and systems and governance manager health safety and environment Michael Kemp say the innovative style of training has been effective with the company’s workforce. Since procuring eight VR headsets, training has gone from a traditional paper-based environment to a lifelike scenario, giving workers

the opportunity to contend with workplace dangers without being in any danger themselves. “Through induction and onboarding, we’re able to expose people to those high-risk scenarios in a completely safe environment,” Kemp tells Australian Mining. “It’s hard to explain no-go zones through documents and PowerPoint presentations, but when you feel like you’re actually on the site and immersed in the environment, it’s very easy to get that perception of the environment because people learn by doing.” This method also ensures better memory retention, from being immersed in an actual environment rather than just reading an instruction manual, according to Kemp. “Rather than needing eight people to go and sit on that equipment at different occasions, we can get all of AUSTRALIANMINING

them in the same room at the same time and train them together in the lunch room in one day.” This is also advantageous when training for a position like a train driver, which requires hours of repetition at travelling one route before accreditation. While VR training for accrediting train drivers isn’t a reality yet, LINX Cargo Care Group can see a future where train drivers will achieve this by using the technology. The company is already rolling this method out for its stevedores, having set up a VR port environment that allows users to set the port up for a safe day of work, collecting mobile plans, equipment and moving trucks and trains to safe areas. This is used for onsite assessments and data is automatically gathered, meaning supervisors can use this to provide feedback and lessons for any

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mistakes made. “If we can use VR to understand equipment before it even comes to our port and how we load it, being able to share this knowledge between the two parties is a huge advantage,” Kemp says. As David adds, VR training provides workers with an enormous safety advantage before getting on a real site. He says the step-by-step machine operation is already a muscle memory reflex by then, giving operators the capacity to focus on what’s going on around them. “Training with VR gives you more time to consider your environment, rather than what gear you’re in because you’re more relaxed about how you’re operating the piece of machinery,” David says. “You’ve got your eyes up and looking around your environment

TECHNOLOGY

much more.” Having awareness of the environment and understanding potential risks is essential when working on mine sites, particularly for new employees. It is well recognised that new employees are at a greater risk of being involved in incidents on site, according to Kemp. Not only does this method prepare workers in a lifelike way, data and footage can be captured for LINX Cargo Care Group’s clients, meaning they are assured that their cargo is being taken care of. “When you’re handling a customer’s cargo, be it mining equipment, steel or cars, to be able to show them how we handle their cargo and that we’re maintaining the quality, is a real advantage,” Kemp says. As a leader in logistics and bringing technology into the sector, David will present on behalf of LINX Cargo Care Group at the 11th annual Western Australian Major Projects Conference this month. David will give delegates insight to how innovation and safety are the keys to unlocking supply chain efficiency and using innovative tools, including VR to provide a safer logistics industry. With more than 30 years in transport and logistics, including

stints at Toll, Bis Industries and Sadleirs before joining LINX Cargo Care Group, David not only has experience across all aspects of business, but also deep knowledge of the industry and safety. Part of the insight David will offer includes how safer logistics has a flow-on to the industries it supplies to, including mining. “VR is a part of our innovation for providing a safer supply chain, but I will also be speaking about what

we are doing with our assets to bring about safe outcomes,” he says. “I’m speaking about sharing data between us, a supplier and our clients, and getting better commission outcomes by having a deep understanding of our clients.” As David will cover in his presentation, VR-based training is only the start for LINX Cargo Care Group. “We’re getting a lot of questions from clients about what we’re

doing with technology for mining equipment in the future,” he concludes. “Machinery such as front-end loaders with adapted technology can detect people moving nearby and will alert the machine before it hits the person, that’s the sort of solution we are looking at.” AM The Western Australian Major Projects Conference will be held at the Perth Convention and Exhibition Centre on March 4–5.

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INDUSTRY OUTLOOK

AUSTRALIA-US ALLIANCE KEY TO CREATING CRITICAL MINERALS HUB HAVING RECENTLY INKED A CRITICAL MINERALS DEVELOPMENT DEAL WITH THE UNITED STATES, AUSTRALIA IS SECURING ITS FUTURE AS A KEY GLOBAL PRODUCER OF CRITICAL MINERALS. SALOMAE HASELGROVE INVESTIGATES WHAT STEPS HAVE BEEN TAKEN SO FAR.

AUSTRALIA IS SETTTING UP FUTURE SUPPLY OF CRITICAL MINERALS WITH THE INITIATIVE.

ombining the United States’ expertise in the field with Australia’s ideal deposits, the two nations are set to become a power alliance in the critical earths sector, shaking up a market historically dominated by China. As long-term trading partners and defensive allies, including a critical minerals partnership that started in 2018, Geoscience Australia and the United States Geological Survey (USGS) signed a formal project agreement in November to further solidify this working relationship. The agreement is a logical step in furthering both countries’ prospects within the industry. Critical minerals, or rare earths, are an essential component for advanced technology manufacturing, in industries including aerospace,

defence, renewable energy, agricultural and telecommunication technologies. These minerals are found in lithium ion batteries, which power everyday items such as smartphones and laptops. Critical mineral types in Australia include cobalt, nickel, magnesium, rare earth vanadium, tungsten, rare earth scandium and molybdenum. While Australia, in particular Queensland and Western Australia have the supply, the US has the demand, with its healthy aerospace industry and ramping up of the renewable energy sector. Queensland Resources Council chief executive Ian Macfarlane says this arrangement will give investors confidence in the sector and help it to remain stable. “To have an avenue where you’ve got a strategic alliance and a stable, working market, that gives confidence AUSTRALIANMINING

to people,” Macfarlane tells Australian Mining. “Not only for people to feel confident to invest, but for governments and other agencies to start putting up dollars for exploration and initial developments of deposits. “As long-term trading partners, I think it’s a very good fit. The US will provide expertise and investment capital with companies and we’ve got good deposits, a workforce and expertise.” One of Australia’s most promising regions for development in this space is north-west Queensland, which is renowned for mineral development, according to Macfarlane. The space has seen solid growth during the past few years, with Queensland minerals industry jobs jumping up by almost 50 per cent in three years. “The minerals industry in Queensland supported just under

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47,000 jobs three years ago and now it’s gone up almost 50 per cent on that,” Macfarlane says. “In terms of jobs, there has been a 30 per cent increase in jobs, the industry has seen almost 60,000 jobs in these mineral regions. “At the same time, there’s been a jump in value from $7.8 billion to $11.7 billion so it’s a massive part of Queensland’s economy, highlighting just how well the industry can react when there’s a solid market.” In addition to the formal partner agreement with the US, Australia has also taken steps in its own backyard to further its commitment to this growing sector, opening a Critical Minerals Facilitation Office in Canberra in late January. The office staff will work with all levels of government, industry and the science and research sectors to develop Australian critical

INDUSTRY OUTLOOK

mineral resources and maximise opportunities within this field. The Export Finance Australia, Defence Export Facility and Northern Australia Infrastructure Facility will offer financial support for upcoming Australian critical minerals projects. Macfarlane also believes that there may be the potential to build more strategic alliances with other countries in addition to the US in the future. “We have real potential to expand alliances to other countries,” he says. “Japan is keen to ensure that it’s not reliant on one source of critical minerals, so they would be an obvious next step. “Also, potentially India in time and Korea as well, depending on where it goes with its renewable energy industry.” While more Australian critical minerals deposits and potential for relationships are strong, Macfarlane says infrastructure development is needed, and urges governments and private enterprises alike to support this opportunity. “One of the challenges going forward in developing Australia’s critical minerals sector is the infrastructure and energy costs,” Macfarlane says. “Resolving issues around infrastructure, energy costs and getting a stable local workforce is going to take a strategic approach and

good cooperation between private enterprise and government.” This includes processing infrastructure, which according to Macfarlane, is something often completed overseas for other commodities such as bauxite. “Australia has tended to drift away from processing, due in part to these energy costs,” he explains. “We’ve got to reverse that trend of exporting things we could process here and we need to continue making the big investments required to support this. “Making sure we process these minerals is providing potential jobs for places like Townsville, Mt Isa and other smaller centres, which are just as important.” With the Australia and US alliance stabilising Australia’s critical minerals market, Macfarlane believes the industry is in a positive position to thrive well into the future. “A critical minerals hub would position Queensland, as well as other states well, with deposits of cobalt, nickel, magnesium, tungsten, molybdenum and rare earth vanadium and scandium,” he concludes. “It’s a good sign to have strong commitment from the Queensland Government and the show of solidarity from Washington as we lay down the foundations to build a strong critical minerals sector.” AM

E Q U I P M E N T

P A R T S

AUSTRALIA IS PRIORITISING RESEARCH AND DEVELOPMENT OF CRITICAL MINERALS.

S E R V I C E

ASTEC AUSTRALIA MINING SOLUTIONS

S U P P O R T

EQUIPMENT TO BUILD AND RESTORE THE WORLD’S INFRASTRUCTURE ASTEC AUSTRALIA.

an Astec Industries Company

PO BOX 142, ACACIA RIDGE, QLD, 4110 • 1300 278 322 • astecaustralia.com.au

AUSTRALIANMINING

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MINING EQUIPMENT

MINE RUNNER RETURNS BETTER THAN EVER ASTEC AUSTRALIA’S MINE RUNNER IS RECOGNISED AS ONE OF THE MOST CONVENIENTLY DESIGNED PIECES OF MACHINERY USED IN UNDERGROUND MINES. THE NEW EWB MODEL TAKES THE DESIGN EVEN FURTHER.

ASTEC AUSTRALIA’S MINE RUNNER EWB MODEL.

he latest Mine Runner extended wheel base (EWB) model builds on the original design loved by underground mining companies across

Australia. More than just a piece of underground machinery, the service vehicle is designed to safely transport people throughout a mine while keeping maintenance costs low. As Astec Australia national product manager John Williams explains, the EWB’s updated features take an already innovative piece of equipment to the next level, ensuring users are al-ways ahead of the grade. “The original Mine Runner vehicle itself is very ground breaking because it uses hydrostatic drive,” Williams tells Australian Mining. “So instead of using mechanical linkage like in a normal car, it uses hydraulics to power and motor the vehicles.” The benefits of hydrostatic drive are more reliability and lower maintenance costs, meaning the equipment can be run for longer at a lower capital for the company. Astec’s main change to the original Mine Runner, which has been on the market since 2015, is the higher carrying capacity that a longer tray at the back of the vehicle offers. This development caters to

feedback from clients and can be used to carry mine workers or equipment, or both at the same time, depending on what the workers require on a certain day at work. “There are two carrying modules,” Williams says. “If you put the people carrying module on the back, each can carry six people, so all up it can

carry 15 people fully laden. “Depending how many modules you want to use at one time, you can carry anywhere from three to 15 people, with two in the front, six in the first module then another six on the back module. “It’s got flexibility, so you can use both modules if you want or

THE MINE RUNNER EWB MODEL CAN TRANSPORT UP TO 15 MINE WORKERS WHEN FULLY LADEN.

AUSTRALIANMINING

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just have one, depending how many people you want to move around at one time, or use the deck space for tools, plants or equipment.” Although this change offers a range of new benefits for Mine Runner users, the exclusively underground design doesn’t differ too much from the original, allowing it to carry heavy loads but in a small format suited to thin underground mine roads. The majority of Australian mines are built to a standard size, with main tunnel roads in and out of the mine five metres wide and high, meaning that vehicles being used underground are ideally less than 2.5 metres in width to allow for safe passing by other vehicles within the mine. “The Mine Runner fits this bill, being closer to two metres wide,” Williams says. “Normally to carry loads you would need to go for a larger truck which is not suitable for an underground mining environment. “The Mine Runner EWB is the same width as the initial Mine Runner, but adding that extra length and

MINING EQUIPMENT

MINEARC COLLABORATED WITH ASTEC AUSTRALIA TO DEVELOP THE MINESAFE RESCUE VEHICLE.

capacity to take extra weight in the back without increasing the width.” The wheel bates have also been extended by 1.5 metres, giving the suspension required to carry loads of up to 3295 kilograms, an increased capacity from the original model’s 2700 kilo-grams, while maintaining the thin design. Mine Runner EWB is also one of

the safest underground vehicles on the market, equipped with roll over protective structures (ROPS) and falling object protective structures (FOPS) to protect occupants from rock fall or other underground accidents. Astec has also partnered with other organisations, including MineARC Systems; combining the

Mine Runner’s safety-based design with MineARC’s MineSAFE Refuge Chamber technology, which is designed to shelter workers in the event of an emergency. “MineARC designs refuge chambers for underground mining and they have developed an Rescue Vehicle chamber that can be installed on the rear of the Mine Runner vehicle to be utilised by emergency services – so that’s one of the really exciting new innovations we have,” Williams says. “MineARC’s MineSAFE Rescue Vehicle model is ROPS and FOPS certified as well, so it’s been a welcome development for the Mine Runner to be able to integrate with some of MineARC’s technology.” As well as safety features for emergency situations, the Mine Runner EWB is equipped with safety features for everyday use, such as electronically limiting the speed. According to Williams, a major problem on mine sites is drivers travelling too fast for the mine’s roads, but the Mine Runner’s electronic management system counters this. “Generally, speeds in underground mines are limited to about 35 kilometres per hour because it’s a combined space with a lot going on,” Williams says.

“One of the nifty features of the Mine Runner EWB is the speed can be electronically limited and the electronic management system allows managers to set a customised speed that employees won’t be able to change.” As mining companies continue to mine deeper in search of different orebodies, the cost of ventilation to remove emissions becomes more expensive. Williams believes electric vehicles like the Mine Runner will be the future of underground mining in Australia to overcome this. This is the direction Astec is moving, looking to power vehicles with electric motors instead of diesel. “We’re currently working on different scenarios for electrification, instead of having a diesel motor powering the hydraulic system, we would put in a battery powered electric motor,” Williams says. “If you’ve got a fleet running electrically, there’s no emissions like there is with diesel. There are still questions to be answered regarding electric vehicles, because mining machinery tends to work 20 hours a day and electric vehicles need time to recharge, but we’ve got that on the drawing board and it looks to be the next step.” AM

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MINING CONTRACTORS

NATIONAL GROUP ROLLS OUT WORLD FIRST NEW GENERATION CAT D11 THE NATIONAL GROUP PRIDES ITSELF ON OFFERING THE AUSTRALIAN MINING INDUSTRY THE BEST AND MOST INNOVATIVE MACHINERY. THE NEW CAT D11 DOZER, ITS LATEST PIECE IN THIS RANGE, IS NO EXCEPTION. SALOMAE HASELGROVE WRITES.

he Cat D11 dozer is an exciting addition to the National Group’s fleet, featuring new technology such as load sensing hydraulics and a fuel remap, while maintaining the classic features customers know and love about this series of machine. Queensland-based Caterpillar dealer Hastings Deering, which has delivered the D11 to Australia alongside National Group, has described the dozers as “keeping everything customers liked about the previous model, but just making it better”. Caterpillar has designed the Cat D11 to move more material efficiently and safely at a faster cycle time to produce more dirt at a lower cost per tonne. The Cat D11 boasts new loadsensing flexible hydraulics and high horsepower reverse to deliver up to 8 per cent fuel efficiency improvement on past models.

HASTINGS DEERING MINING ACCOUNT MANAGER JASON GAREA AND NATIONAL GROUP MANAGING DIRECTOR MARK ACKROYD (MIDDLE, FRONT) WITH THE BLACKWATER TEAM.

Its hydraulic pumps are adjustable, allowing operators to adjust the output to meet demand, which helps mine sites save energy, reduce heat generation and extend machine life. National Group has secured the world’s first model of the innovative new dozers straight off the production line and endorses the dozer’s smart new design. The company has wasted no time putting the Cat D11 dozer to work, with it hitting the dirt at BHP Mitsubishi Alliance’s (BMA) Blackwater mine in Queensland in December last year, and another deployed in January of this year. National Group is so impressed with the latest model of the dozer it has ordered four additional machines, which are set to arrive over the coming months. “Our team prides ourselves on having the best equipment available for our clients,” National Group managing director Mark Ackroyd says. “Securing the first ever Cat AUSTRALIANMINING

HASTINGS DEERING MINING ACCOUNT MANAGER JASON GAREA AND NATIONAL GROUP MANAGING DIRECTOR MARK ACKROYD.

MARCH 2020

MINING CONTRACTORS

D11 dozer in the world is testament to this. “The D11 is the industry’s best large dozer, so it was a logical choice for us to bring in six new dozers to our expansive fleet.” Ackroyd is also making the new dozers unique to the company, with all six of the machines to be fitted with a reclamation blade. This is also known as an XU blade, which extends the dozer from a 34-cubic-metre blade to a 42.2-cubic-metre blade for maximum reach. The reclamation blades are more productive than the U blade on previous models; they reduce cost per tonne, while still handling the harsh conditions of a mine site as its predecessor did. The Cat D11 dozer has a new case and frame design, which improves its bearings. This, plus redesigned pin joints and a 30 per cent larger oil pan, lowers maintenance and repair costs, according to Ackroyd. “We expect a lower maintenance and repair cost of up to 5 per cent thanks to the new case and frame design,” he says. Expanding on Cat’s existing safety features, the D11 boasts improved safety on previous models, with the engine oil sump capacity made 30 per cent larger, which extends the preventative maintenance intervals to 500 hours, giving operators less maintenance downtime. The electrical centre is based on ground-level, which provides convenient and safe access to the lockout control, engine shutdown switch and ladder raise and lower

NATIONAL GROUP WILL HAVE SIX CAT D11 DOZERS IN ITS EXTENSIVE FLEET.

switches. For more efficient and safe maintenance, the Cat D11 dozer hosts an Auto Lube system, which means service technicians can change the coolant, hydraulic, engine and powertrain oil from ground level.

THE D11 IS THE INDUSTRY’S BEST LARGE DOZER, SO IT WAS A LOGICAL CHOICE FOR US TO BRING IN SIX NEW DOZERS TO OUR EXPANSIVE FLEET.” There are also optional add on safety features, including sealed or partial bottom guards, undercarriage idler guards and grill door screens, further guaranteeing operator safety.

Caterpillar has also taken advantage of advancing technology, incorporating automated blade assist into the D11 dozer, which increases efficiency while reducing the workload on operators. This is in addition to AutoCarry, which operators can activate to automatically change blade positions to keep track while pushing a load and avoid accidents caused by operator fatigue. There is also the option to add extras for comfort, such as air conditioning, heated and ventilated seats and window shades, for a comfortable day at work regardless of the outside conditions. National Group’s Blackwater project manager Scott Millane says the dozers are already immensely popular within the sector, due to their improved design for safety purposes. “The other thing that makes them fight over these dozers is the

THE CAT D11 DOZER DELIVERS UP TO 8 PER CENT FUEL EFFICIENCY IMPROVEMENT ON PREVIOUS MODELS.

AUSTRALIANMINING

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increased torque. “If there’s an area that’s had some mud stone ripped up, the operators can put the rippers all the way down and the dozer just pulls through.” Hastings Deering mining account manager Jason Garea says the company’s relationship with National Group has grown from strength to strength over many projects. “We have had a long-standing relationship with National Group and being able to deliver another world first with the D11 is a demonstration of things to come,” Garea says. “Mark is committed to innovation and technology. The D11 Dozer has integrated technologies built into it, including terrain which makes for more accuracy on job sites which will ultimately reduce rework.” The partnership will continue to monitor how the D11s perform in Australia as the remainder of the six machines are rolled across mine sites this year. AM

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REDUCE CONVEYOR MAINTENANCE TIME THROUGH BETTER ACCESS DANIEL MARSHALL OF MARTIN ENGINEERING DISCUSSES WAYS TO LOWER THE POTENTIAL FOR DOWNTIME ON CONVEYOR SYSTEMS BY IMPROVING ACCESS TO THEM. ACCESS CAN MEAN OBSERVATION POINTS, ENTRY DOORS AND WORKSPACE FOR SERVICE.

irtually every vehicle on the road today is designed with a hood that can be easily opened for access to the engine, so mechanics can perform routine service and diagnose / address problems that arise during its lifespan. Conveyor systems should be designed in much the same way, with convenient points along the length of the belt to allow technicians to inspect its condition, perform service as needed and help prevent catastrophic failure. Unfortunately, this type of access is often overlooked when engineering conveyor systems until a pressing need arises, which increases the difficulty of ongoing inspection that could have allowed technicians to observe and service critical components before a crisis develops. As a result, costs go up and productivity goes down. Conveyor manufacturers have

A GATE TO A CONVEYOR WALKWAY, CONTROLLED WITH AN RFID SENSOR.

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responded to the need for increased accessibility to system components by developing components and accessories specially designed to reduce labor time, while improving safety during service. Innovative equipment designs such as slide-out cradle frames, belt cleaner assemblies, idler assemblies, as well as sealed heavyduty inspection doors, offer better access for safer and more efficient maintenance, resulting in fewer injuries, reduced labour time and a lower total cost of operation. “This is a cascading issue,” Martin Engineering product engineer Daniel Marshall said. “Insufficient access leads to poor maintenance practices, resulting in emergency outages and diminishing the operation’s productivity and safety. “From an ownership and management perspective, downtime and injuries affect profitability through loss of production, capital expenditures for new equipment and ongoing insurance implications.” In the past, managers often decided against the expense of adding safer and easier access points to a conveyor system beyond what is required by code. However, over the conveyor’s lifetime, safety professionals estimate that poor access adds as much as 65 per cent to maintenance and cleaning costs. When designing proper access into a bulk materials handling system, there are three easily achieved goals: •E asy to see – If equipment cannot be seen, neither can the problems. •E asy to reach – Equipment maintenance is likely to be postponed if it is awkward or dangerous to access. • Easy to replace – Broken equipment is likely to remain that way if it is complicated and time-consuming to service.

Loading zone innovations

“Many conveyor transfer points still have an antiquated roller system tasked with absorbing impact and centering the cargo,” Marshall continued. “These components often break

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INSUFFICIENT ACCESS LEADS TO POOR MAINTENANCE PRACTICES, RESULTING IN EMERGENCY OUTAGES AND DIMINISHING THE OPERATION’S PRODUCTIVITY AND SAFETY.”

Discharge zone maintenance

INSPECTION DOORS AND TRACK-MOUNTED COMPONENTS FACILITATE MAINTENANCE FOR EXTENDED EQUIPMENT LIFE.

and seize, causing friction and a potential fire hazard. “To replace them, several workers must remove the skirtboard and break the plane of the conveyor to reach across the stringer with heavy tools to assess and repair equipment.” To reduce maintenance time and labor, improve safety and extend equipment life, operators should consider track-mounted impact cradles and belt support cradles. Located under the skirtboard

and mounted with rugged steel assemblies, the cradles feature large impact-absorbing UHMW polymer “box bars” engineered with smooth surfaces that the belt can slide across with little friction or belt wear. These assemblies can be pulled out by a single worker and – working safely from outside the conveyor and using only a single tool – the box bars can be simply removed and flipped in a matter of minutes to double the service life. Along the cargo path in the

settling zone and beyond, retractable idlers support the belt and maintain the trough angle. Exposed to the punishing environment, gritty dust and extreme weather, rollers can seize over time. Often set closely together in the loading zone to avoid belt sag, slideout/slide-in roller frames permit workers to perform idler service outside of the belt plane without the need to raise the belt or remove adjacent idlers.

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“Wear parts such as belt cleaner blades need to be monitored, serviced or changed regularly to prevent carryback from causing dust and spillage along the belt path,” Marshall said. “However, blade adjustments and changes can require several hours of downtime.” Primary cleaners – located on the underside of the head pulley – are mounted on rotating assemblies designed to retain the proper tension between the blade and the belt. Secondary cleaners are located behind the head pulley and raised slightly above the belt line for tension. Specially-designed units can slide in and out by simply pulling a lever and releasing a pin. This allows blade maintenance to be performed outside of the system by a single worker in under an hour.

Inspection doors

A tight seal is the key to preventing fugitive dust from leaving any chute. Many current setups require

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FROM AN OWNERSHIP AND MANAGEMENT PERSPECTIVE, DOWNTIME AND INJURIES AFFECT PROFITABILITY THROUGH LOSS OF PRODUCTION, CAPITAL EXPENDITURES FOR NEW EQUIPMENT AND ONGOING INSURANCE IMPLICATIONS.” TRACK-MOUNTED DESIGNS ALLOW COMPONENTS TO SLIDE IN AND OUT EASILY FOR MAINTENANCE.

TRACK-MOUNTED IDLERS ALLOW EASY ACCESS FOR QUICKLY SWAPPING OUT SEIZED ROLLERS.

workers to crouch or crawl under the system or even enter a confined space to inspect it or perform maintenance, which can result in serious injuries. Inspection of the system needs to be fast, easy and safe. Small inspection doors – either solid or grated – can allow several observation points. Larger doors can offer access points with ample space for service of specific wear parts.

Case study

A coal plant in Eastern China had belt damage, spillage and dust issues at two conveyor transfer points with outdated equipment in the loading zones. Raw coal ore was loaded onto the 1000 millimetres wide belts traveling 500fpm (2.56 mps). The first chute had a five-metre high drop chute that loaded into a 12 metres long loading/stilling zone. The second chute had a similar drop, discharging into a 26m long

loading/stilling zone. Suffering from an old design, the belts were supported by impact idlers and a troughed roller system, neither of which was equipped to cope with new production demands. Equipment failures happened regularly, and without proper accessibility for routine maintenance, long periods of downtime were common. Belt sag created gaps between the belt and rollers, causing fugitive dust emissions throughout the facility. Inadequate impact control led to spillage becoming entrapped between the belt and tail pulley, damaging them both. Excessive downtime, costs for cleanup and equipment replacement seriously impacted profitability. Managers sought a solution that better protected the belt, sealed the chute from dust and spillage, and offered easier inspection and ongoing maintenance. AUSTRALIANMINING

Technicians from Martin Engineering China were invited to perform an on-site assessment and suggest an affordable solution. After offering a detailed proposal, the team installed modern equipment that addressed the issues on both conveyors. The first chute was equipped with a track-mounted impact cradle to improve loading and protect the belt and tail pulley. In addition, slider cradles for smoother centering were installed, along with a full-length apron seal to prevent dust and spillage from escaping. A comparable solution was installed in the longer chute, with added cradle support down the entire length. Both chutes featured nonpowered dust bag systems to collect emissions. Since installation, spillage around the loading zones is under control.

Dust emissions have been drastically reduced. Operators report that a considerable drop in equipment failure rates has resulted in a substantial increase in productivity. Contributing to the success was workers’ ability to easily inspect and service components by sliding them out and servicing them outside of the conveyor. “After more than 75 years of working with bulk handlers all over the world, Martin Engineering has discovered that ‘access’ is a common element for both safety and productivity across all industries,” Marshall concluded. “By adding easy access and monitoring in the design phase, equipment can be better maintained using less labour, leading to reduced downtime. “This is reflected in the cost of operation, offering a better overall return on investment.” AM

A HATCH OVER THE TAIL PULLEY ALLOWS STAFF TO EASILY DETECT ENTRAPPED MATERIAL.

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MINING CONTRACTORS

LORAM ASSISTS IN KEEPING MINING ON TRACK RAIL’S ROLE IN THE AUSTRALIAN MINING INDUSTRY REMAINS CRUCIAL IN CONNECTING THE ORE, COAL AND OTHER MATERIALS MINED IN THE COUNTRY TO THE REST OF THE WORLD. AUSTRALIAN MINING SPEAKS TO LORAM ABOUT ITS GROWING LINK TO THE INDUSTRY IN THE COUNTRY.

oram is three months into the acquisition of Aurizon’s rail grinding business, adding to its existing operation. The Brisbane-based organisation, with a United States parent company, has gained a strong team in Aurizon’s 77 talented staff members through the acquisition. The Loram team has been working to deliver a frictionless transition to and sustain longstanding relationships and contracts with the likes of ARTC, Aurizon, BHP and Fortescue Metals Group, putting the company in the midst of Australian freight and mining railways. Rail is a vital asset investment. With Australian railway lines hauling some of the heaviest loads in the world, frequent and quality maintenance interventions are essential to optimise the life of the rail, according to Loram director of business development Tom Smith. “Rail grinding is the cornerstone of virtually every heavy haul railroad maintenance program,” Smith tells Australian Mining. “Loram uses industry leading technology to help maximise the life and value of rail assets with precision removal of fatigued metal, restoration of the rail head profile and removal of rail defects. “Loram brings in the industry’s highest production equipment with the crews that complete the work efficiently to get the trains back

LORAM’S UNDERCUTTING TAKES INSPIRATION FROM THE MINING INDUSTRY.

running as soon as possible - because minutes of track time matter.” While best known for rail grinding, Loram offers far more, bringing a portfolio of proven equipment and services to Australia. Another product line Loram is promoting for its Australian operations is its friction management systems, Top of Rail and Gauge Face, to counter the major expense of fuel locomotives. “By strategically applying friction modifiers to the top of the rail, our customers are able to reduce the resistance to help pull the load more efficiently and saving fuel,” Smith explains. Wheel and rail interaction is directly addressed by the grinding for the rail profile, supplementing the proper profile to optimise rail and wheel life is gauge face lubrication in curves. Another product that offers efficiency is the Loram WagonVac.

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The mines have a cost to ship its product to the port, there is no benefit to ship any part of the payload back to the mine. Often in the dumping process there is a residual amount of product left in the wagons, one to two tonnes per wagon is not unusual. The WagonVac vacuum system sucks out that residual material in the wagons to leave at the port and put it on a ship. “While one to two tonnes may not sound like a lot, when you have 200plus wagons in a unit and potentially 30-plus trains per 24-hours, the tonnes quickly add up,” Smith says. Loram also has a range of ballast equipment but will highlight the full section ballast cleaner, designed with patented, state-of-the-art undercutting digging wheels that provide self-supporting cut-in capabilities. “Ballast degrades over time, becomes fouled, reducing drainage,”

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Smith explains. “Undercutting is continuous excavation of the material below the sleepers to either fully waste, or to screen returning the desired ballast and removing the fines. “Loram looked to the mining industry to learn about digging more efficiently when it created its undercutter design – again track time for machines is taking away from trains, productivity is key.” Loram is bringing a solutions mindset to Australia, with a focus on forming partnership-like relationships with the rail divisions of the mining customers to make them successful in their maintenance investments. The company is optimistic about the opportunities ahead as its Australian market position expands. “It’s an exciting time for Loram to be here, the future is bright, and we are here in Australia for the longterm,” Smith concludes. AM

MINING CONTRACTORS

ERIZON STORMS PAST DUST SUPPRESSION CHALLENGES

ERIZON’S HYDROTRUCKS CAN HYDRAULICALLY SPRAY AT A DISTANCE OF 100 METRES.

CHALLENGES POSED BY AUSTRALIA’S UNPREDICTABLE WEATHER HAVE NOT STOPPED ENVIRONMENTAL SOLUTIONS PROVIDER ERIZON FROM ACHIEVING THE BEST ECO-FRIENDLY OUTCOME.

ust issues caused by wind and rain can not only be damaging to a mine site and its ability to operate efficiently, but can also pose potential health and safety risks to employees and the local community. Environmental solutions company Erizon understands these concerns by operating under a framework that considers the client’s requirements along with those of the site, enabling it to guarantee results. “There’s definitely no one size fits all,” Erizon environmental consultant Glenn Sullivan says. “Our scientific approach allows us to take the time to understand the site conditions, the variable and what solution is going to be most suitable for the substrate material. “Our background investigation allows us to deliver a viable and costeffective solution that can be backed with a guarantee of up to 24 months.” Erizon offers solutions and compliant equipment to carry out environmental issues on all mining areas, including ash and tailings dams, haul roads, stockpiles and sites requiring mine rehabilitation. A recent working example of Erizon’s adaptability to environmental conditions was prompted by damaging southerly winds in the Port Augusta region of South Australia. The winds had picked up dust from the Flinders Power Station ash dams causing abrasive dust storms. Unfortunately, the local community potentially faced serious health and environmental problems

as a result of the dust. Previous revegetation attempts on the site led to poor vegetation growth and limited soil stability on majority of the ash dam surfaces. Erizon was approached by Flinders Power to investigate the problem in high detail. State-ofthe-art technology revealed that the substrate profile was not suitable to support productive plant life. “We find that all successful projects start with a thorough understanding of the soil and substrate where requiring a solution,” Erizon soil scientist Phil Barnett tells Australian Mining. “The first step is to get to the site for an inspection to inspect the environmental and physical characteristics of the location which gives us a real feel of the conditions we’re dealing with.” The Erizon team collected substrate samples from varied locations of the site for a comprehensive soil analysis. Reports indicated that the salinity levels detected in the soil were high to very high, affecting the soil’s ability to germinate and establish vegetation in the host environment. Erizon was confident that vegetation cover would be the only long-term sustainable solution for the ash dam. A non-toxic and environmentally-friendly dust suppressant, in contrast, would only be a short-term option. The company began working towards achieving this goal with HydroBond, a suitable dust suppression product for revegetation that is formulated to effectively suppress dust while promoting faster germination and added seed protection. This was delivered in conjunction AUSTRALIANMINING

with AgCalcium Boost to correct the salinity levels by displacing salt and sodium away from the seed zone. The combined tailored solution was tested on a 2500-square-metre area of the ash dam, which was representative of the various conditions onsite. After a nine-month trial, Erizon was confident it could move forward with the tailored HydroBond solution on the remainder of the high-risk areas spanning across 180 hectares of the property. Erizon made use of its fully mine compliant HydroTrucks, which eliminated the need for working on steep slopes and provided fast and effective coverage thanks to its design, speed and power. The trucks were purposely built to feature agitators within the holding tanks, enabling a consistent solution mix over the surface area. They can also hydraulically spray at a distance of 100 metres, while offering over 50,000 square metres of product coverage a day. The Flinders Power project recommendation provided HydroTrucks technicians with the duty of dispersing product at a rate of 1.5 litres per square metre and consisted of 350 litres per hectare. The selected application method successfully worked in conjunction with the challenging climate conditions, allowing for project completion within 10 days of site mobilisation. The Erizon team continually monitored and inspected the site over an eight-month period to test the dust resistance, surface crust integrity and weather conditions of

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the Flinders Power ash dams. What was achieved was a significantly greater outcome than anticipated; Flinders Power was pleased with the efficiency of the dust control solution and vegetation growth on-site. As this project proves, Erizon’s unique approach not only guarantees success but also saves the client money. Below is an example of how using the correctly product and application methods saves the client money while also providing proven results. AM

Service Comparison: Erizon vs Company X “The client is a miner who requires an effective dust-suppression solution applied across a 20 hectare tailings dam facility” Erizon

Company X

18 months

None

Product

Carefully selected post consultation

One size fits all

Application Method

Carefully selected post consultation

One size fits all

Cost per sqm

$1.10

$1.00

Initial Cost

$220,000

$200,000

Additional applications over 18 months

TOTAL COST OVER 18 MONTH LIFETIME

$220,000

$600,000

COST SAVING

$380,000

Site-Specific Warranty Initial Consultation/ Testing

Monitor / Follow up

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UP DOG DIESEL GOES BACK TO TYRE FITTING BASICS UP DOG DIESEL MAY BE A NEW KID ON THE BLOCK, BUT OWNER DWANE JOHNSON BRINGS TWO DECADES OF HEAVY TYRE FITTING EXPERIENCE AND PLANS TO MENTOR THE NEXT GENERATION OF FITTERS.

wane Johnson launched Up Dog Diesel in October 2018, drawing on 20 years of working around tyres, including 16 in the mining industry, dating back to his late teens. With his wealth of experience, Sunshine Coast-based Johnson’s approach is that of a small, local company with the skills and workers to provide a nation-wide service. Having worked all over Australia and learned from some of the best in the field, Johnson wants to pass this knowledge on to the next generation of heavy tyre fitters. The company’s first move in this direction has been to take on two trainees, Jacob Farlow and Curtis Lake, to complete their Certificate III in Heavy Tyre Fitting under Johnson’s watchful eye. “I’ve worked in the industry all across Australia and really taken the best of what each place was doing,” Johnson tells Australian Mining. “Some places will have excellent maintenance strategies in place to optimise tyre life, but some fall down on the way they instruct people to go about performing maintenance duties.” Johnson’s biggest focus throughout his career has been on safely performing tasks, as reflected by Up Dog Diesel’s Zero Harm Complaint status, having not had a single reportable incident since being founded. However, Johnson feels some modern training doesn’t cover all of the elementary but essential lessons he has learned. “I draw on a lot of the ways I was trained, so what we’re offering is a more back to basics style of training,” he explains. “It seems like the way people train these days they are missing some of the bigger hazards because they’re too focussed looking for the little ones, which you absolutely have to, but in the light of incidents recently, a lot of these issues are caused by big, obvious, major hazards. “Basically, everyone should be able to come home safely from work no matter what you do for a job.”

With Up Dog Diesel based in a strategic position to service the Bowen Basin coal region, Johnson knows firsthand how dangerous the job can be and the need for rigorous training. In the past year alone, two tyre fitters have been fatally injured on the job in Queensland and New South Wales. While Johnson helped trainees in one of his previous mining jobs, this will be his first time overseeing the Certificate III in Heavy Tyre Fitting from start to finish. In addition to training Up Dog Diesel’s trainees to complete the job to the company’s high standards, Johnson also plans to offer them the job prospects he enjoyed for a rewarding career in an industry he loves. “To be able to give people an opportunity in the industry and to give them quality training, knowing they or

JACOB FARLOW IS ONE OF TWO TRAINEES JOINING THE TEAM.

someone else is not going to get hurt, is one of the reasons I love my job,” Johnson says. “I love the challenges in this industry and seeing the results of our work, I don’t get up in the morning and go ‘ugh, I have to go to work’, I definitely love it.” Some of Johnson’s favourite work

A SAFE TYRE BAY IS UP DOG DIESEL’S TOP PRIORITY AS DEMONSTRATED BY TRAINEE CURTIS LAKE.

AUSTRALIANMINING

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UP DOG DIESEL OWNER DWANE JOHNSON.

experiences include developing maintenance schedules for trucks for pressure maintenance and providing trucking clients with schedule management advice. Johnson started his career with tyre giant Bob Jane after he completed high school. He then worked his way up through the automotive industry, with stops at a busy tyre shop in bustling Brisbane, through South Australia and back to Queensland, albeit this time in regional Mt Isa. Johnson moved into the mining industry when his wife noticed an advertisement for a tyre fitter in Western Australia and he hasn’t looked back since. “When I started out and for many years of my career, I was just changing tyres,” he says. “These days, I look after every aspect there is to running a tyre bay and managing tyres on a mine site.” Looking ahead, Johnson is focussed on Up Dog Diesel winning more contracts, in anything from basic mining vehicle tyre services and advice to ending the timing of the tyre bay. Johnson’s plan for his team, which includes tyre fitter Michael Huet and the two new trainees Farlow and Lake, is to prioritise quality over quantity and provide clients with the best service and knowledge at the best prices. Up Dog Diesel may be small, but Johnson has major ambitions for the business. “I can offer the industry a wealth of knowledge from my staff and in the long term I can see this team definitely having the potential and capability to get projects anywhere in Australia,” Johnson concludes. AM

MINING CONTRACTORS

MANUFACT BRIDGES CULTURAL DIFFERENCES WITH LOCAL EXPERTISE MANUFACT HAS RESPONDED TO THE DEMANDS OF AUSTRALIAN MINING COMPANIES BY NAVIGATING CULTURAL DIFFICULTIES AND ACHIEVING TIMELY OUTCOMES NEEDED FOR AN OFFSHORE MANUFACTURING PROJECT.

ewcastle-born mechanical engineer Jonathan Lee has looked to Hong Kong to develop a business opportunity he was convinced would benefit the Australian mining industry. Lee has become a Hong Kong resident after being inspired by the stark difference in manufacturing compliance standards from Chinese manufacturers when supplying heavy engineered products to Australian mines. A former Caterpillar senior design engineer and project manager, Lee has developed expertise with equipment and parts that are designed, assembled and manufactured in China. With Lee’s know-how, he has helped prevent Australian mining companies from suffering from the cost of equipment failure by ensuring operational efficiency and safety from the point of procurement. Lee’s expertise has led him to co-found a procurement and quality manufacturing company called manuFACT after being based in Hong Kong since 2013. The Hong Kong-headquartered company comprises a team of seven mainland China engineers who serve Australian companies in their procurement dealings with Chinese

manufacturers. Every manuFACT engineer has bilingual Mandarin-English capability to act as a strategic intermediary that can execute the manufacturing requirements of Australian companies. Their role is to identify, correct and prevent quality issues during manufacture, as well as overcome any cultural differences that may arise during a procurement project. This expertise comes on the back of in-depth manufacturing, maintenance and operations knowledge in the mining, rail and infrastructure industries. “Our project team understands both sides of the table,” Lee, the now managing director of manuFACT, says. “They understand the Australian client and Chinese manufacturer.” Indeed, manuFACT is backed by a management team that has a combined experience of more than 20 years. Their past projects range from crushing or milling equipment, underground and surface mining vehicles, longwall systems, rollingstock, processing equipment to conveyor belt systems. manuFACT services clients including Australian Government departments, Australian and global mining companies, rail operators and engineering contractors.

MANUFACT HELPS AUSTRALIAN MINING COMPANIES SMOOTH OUT THEIR PROCUREMENT PROCESS FOR MINING EQUIPMENT.

AUSTRALIANMINING

“One of the big problems in a multi-country dealing is that an (Australian) client will go to China expecting its procurement process is going to be similar with any other country, so they don’t put as much planning in place,” Lee says. “Sometimes this lack of planning requires senior company leaders to be involved in meetings to iron out the issues, or even cause companies’ fall out from a project.” These issues span from product quality or compliance, delay in delivery, project status transparency to differences in expectations that can result in added delays, mediation, unplanned concessions and lengthy disputes. Not only do they affect the equipment with rework prior to commissioning, but they can also hit the lifecycle and total cost of ownership, resulting in unplanned maintenance, operational downtime and reduced extraction rates. In providing assistance to a global copper-gold mining company that ran into China procurement difficulties, manuFACT carried out a contract and process audit to find that the SAG mill design, material, specifications and standards had not been specified in the contract. In addition, infrastructure material or welding standards had also not been specified. As manufacturing of the SAG mill has already commenced, the mining operator was left to rely on the manufacturer’s experience and “best practice” in this situation. “Our team stated that the manufacturer must meet known standards and the welding be carried out to AS1554.1,” Lee says. “This was unacceptable to the manufacturer as they were not familiar with ISO or AS.” Lee says the key to a successful procurement project involves early stage planning and on-the-ground inspection, including data analysis. “We highly encourage due diligence auditing of the supplier or manufacturer before signing a contract,” Lee explains. “Almost all Chinese manufacturers will welcome this if the chance of

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winning the contract is real, and it can be completed in as little as two days.” “When a contract has been signed and problems start to arise during manufacturing, the implementation of remediation strategies and process improvements can be difficult and time consuming.” Due diligence auditing and early planning will help reduce any potential cost that comes with variation or modifications that are contrary to the manufacturer’s expectations, he adds. But it is an impossible task, according to Lee, to get these activities across the line after a contract is signed. The involvement of manuFACT engineers from early on can help its client identify and iron out such problems on the Chinese manufacturing floor before they arise. “From a client’s perspective, they are able to achieve levels of transparency and visibility on events occurring on the factory floor in China in real-time, without physically having to be there,” Lee says. manuFACT’s engineers will be in the factory during equipment manufacture, capturing all nonconformances and quality issues. This involvement gives manuFACT an enormous amount of data points from which it can identify areas to target and carry out preventative actions to ensure there are no significant delays. “We have a system that photographs and records every non-conformance as well as project progress digitally and they’re all communicated daily to our client companies,” Lee says. “You don’t have to fly senior leaders or engineers from Australia to wade their way through the complexities of cultural and language barriers to fix a problem.” Instead, Australian mining operators can rely on a company like manuFACT, with its team of project managers and in-house inspectors, to mitigate the risk of overseas manufacturing. AM

MINING CONTRACTORS

A CENTURY-LONG TRACK RECORD READY FOR ANOTHER CHALLENGE A LIFE-LONG PIPE SOLUTION COMES EASY THROUGH ENGAGEMENT WITH AN AUSTRALIAN MANUFACTURER SUCH AS STEEL MAINS, WHICH BOASTS EXPERIENCE IN THE WATER AND MINING INDUSTRIES. 600 welds a day, though construction laying rates vary by terrain profile. “Most watermains in Australia are designed to a maximum of a PN35 rated pipe limit,” Vahdani says. “Steel Mains’ unique Sintajoint RRJ technology offers up to 4.25 megapascal rated pressure.” The company has supplied a 152-kilometre-long DN800 steel pipeline with pressures of up to 4.2 megapascal to a government water authority in the United Arab Emirates, a project commissioned in 2006 with no reported issues ever since.

STEEL MAINS HAS INSTALLED A 120KM RUBBER RING JOINT PIPE FOR A COAL SEAM GAS PIPELINE IN QLD.

teel Mains has supported companies across Asia Pacific and the Middle East with unique engineering solutions for more

than 100 years. In the Pilbara region of Western Australia alone, Steel Mains has supplied more than 100 kilometres of large diameter watermains since 2003. Steel Mains’ expertise has been gained from experiences working with water authorities, complying with the strictest acceptance criteria for water assets. This combines with Steel Mains’ capacity to meet the demands of mining companies for a leakfree, low-maintenance operation, placing the company’s products in a favourable position with water authorities and resources companies. There are four principles which have sustained Steel Mains’ long and successful track record globally.

Minimising total cost of ownership

Steel is synonymous with strength, but corrosion remains a challenge. Steel Mains proprietary Sintakote coating technology is a mediumdensity fusion bonded polyethylene that is bonded to the steel substrate. “Water asset owners have benefitted from using this longlasting quality corrosion protection

coating for many decades,” Steel Mains national business development manager – mining Amir Vahdani tells Australian Mining. “Sintakote offers a design life of over 100 years for buried pipelines and over 50 years for above-ground installations. “Steel Mains also offers a wide range of lining solutions to suit applications, including potable water through to hyper saline, seawater, acidic water, wastewater and sewerage mains.”

Non-welded high-pressure jointing

Steel Mains uses a unique Sintajoint Rubber Ring pipe jointing (RRJ) technology to allow project owners to complete their projects within a shorter construction schedule. With welded joints eliminated, pipe installation can be simpler and involves less construction plant and equipment. It also removes costly nondestructing testing and associated quality control checks, generating material savings in both direct and indirect costs. In fact, Steel Mains’ construction partners have achieved a record maximum pipe laying rate of 7.3 kilometres in a single day (or 58 seconds for a 12.2-metre pipe) during a 9.5-hour construction shift. This non-welded jointing technology has eliminated almost AUSTRALIANMINING

Local manufacturing

Steel Mains has more than 70,000 tonnes of yearly capacity to support project owners and contractors across Australia through three worldclass pipe production mills in two locations: Somerton, Victoria and Kwinana, Western Australia. The company’s products are made from Australian steel and custombuilt to specific project requirements. Unlike most suppliers, Steel Mains products are not off-the-shelf, allowing the company to embrace and tackle bespoke project challenges. “We offer supply of pipe and fittings, pipe design review, value engineering, manufacturability review and pipeline installation training,” Vahdani says. “Steel Mains manufactures steel water pipes from DN100 to DN2500 with pressures up to 6.8 megapascal (68 Bar) depending on diameter.

“Our products are manufactured to Australian Standards under a StandardsMark Licence, and we hold a Water Services Association of Australia (WSAA) product appraisal.” They are also third party audited to the relevant quality, and environmental health safety management systems, according to Vahdani.

An answer to every challenge

From a potable watermain in a regional area through to the hottest and most acidic bore water, Steel Mains has risen to the challenge by delivering a custom-built solution to suit specific project requirements. Whether a solution requires Steel Mains to manage up to a 60 degrees Celsius temperature change in the Pilbara or a river crossing in a rocky mountain, the company prides itself in providing a unique solution. When a 264-kilometre pipeline was required to resolve the issues of continuous water supply to the remote city of Broken Hill in less than 12 months, Steel Mains was able to mobilise both its manufacturing plants to provide the necessary supply to this timesensitive delivery period. The company is also experienced in supplying bespoke solutions for pipelines installed in parallel with a high voltage powerline, fuel line, road and rail line on mine sites, where minimum impact to cultural heritage sensitive areas and national parks are of key importance. AM

STEEL MAINS’ SUPPLIED PIPELINE FOR BROKEN HILL MEASURES 264KM BY 762MM IN DIAMETER.

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SUSTAINABILITY

MINING UNITES IN QUEST FOR WATER IN DROUGHT-STRICKEN LAND MINING COMPANIES SUCH AS WHITEHAVEN COAL, BHP AND NEWCREST MINING ARE FINDING WAYS TO ENSURE MINES AREN’T DRY IN PRODUCTION AS MUCH AS THE LAND HAS BEEN.

ll hands are on deck across Australia when it comes to the threats posed by drought – it is unfortunately an enduring feature of the country’s landscape. Mining operations have to compete with other users such as agriculture and towns for water. Without it, materials such as coal, gold and copper cannot be extracted out of the ground. Water is also core to the transport of ore and waste, separation of minerals, cooling systems around power generation, suppression of dust and washing equipment, according to CSIRO. While the impact on farmers is well-understood, water supply is also crucial for mining operations, according to New South Wales Minerals Council chief executive Stephen Galilee. “Mines support thousands of jobs in regional areas and the security of water supply for mining operations can have major implications for regional economies,” Galilee says. Whitehaven Coal’s Maules Creek mine in the Gunnedah Basin is one mining operation that has been hit by

drought conditions persisting in north west New South Wales. “I am only too aware of the fact this is truly a land of droughts and flooding rains, but the drought conditions we have observed across much of New South Wales have been especially challenging and are arguably the worst since the Federation Drought at the turn of the last century,” Whitehaven chairman Mark Vaile, speaking at the company’s 2019 annual general meeting, says. The company’s Maules Creek mine relies on a high security water licence that draws upon the Namoi River, a primary water source that has been severely impacted by the drought. Whitehaven chief executive Paul Flynn Whitehaven says the company has secured additional long-term groundwater sources for Maules Creek in response to the conditions. Maules Creek has gained access to some of these sources, with work to access the remaining sources still under way. While the impact on production is unclear (at time of writing), Whitehaven is working with New South Wales authorities to mitigate the drought impacts.

Elsewhere in the Hunter Valley region of New South Wales, BHP has been forced to put up additional measures against the dry conditions facing its Mt Arthur Coal operations. BHP is closely monitoring its water take, and has put measures in place to reduce water usage while maintaining operations. “For example, we have installed density gauges to improve water control and reduce un-needed water in the operation,” a BHP spokesperson explains. Joining BHP and Whitehaven in the fight against the drought is Newcrest Mining, this time it’s motivated by community betterment. Newcrest is reducing the amount of water it uses from Orange, close to where its Cadia mine is located. The gold miner has turned to treated effluent to meet its water needs at the Cadia mine, according to the Orange City Council. Under this initiative, Newcrest is pumping an average of eight megalitres a day from Orange’s sewerage water plant, while drawing on groundwater and other sources to sustain its operational needs at Cadia. The combined effect is a reduction

of two megalitres of water drawn from Orange a day. “This arrangement will be in place for the next few months until this requirement is no longer required,” according to Newcrest Cadia Valley operations general manager Peter Sharpe. “This will satisfy the council’s environmental flow obligations and replace the release of surface water from the Suma Park Dam. “Currently average net daily draw of water into the Cadia operations is 30 millilitres a day. This return of water will not impact production in the current year.” Galilee welcomes Newcrest’s initiative, stating that the New South Wales Minerals Council has seen the industry doing its bit to help out local councils and landholders. “Cadia’s reduction in use of treated effluent from Orange (allows) the council (to) continue to provide environmental flows,” Galilee says. “Mines in drought-affected areas are doing all they can to reduce their water use, increase water recycling and look for alternative sources of water such as saline groundwater, which will help conserve higher quality water for other water users.” AM

BHP MT ARTHUR COAL OPERATIONS IN THE HUNTER VALLEY REGION OF NEW SOUTH WALES.

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MINERALS PROCESSING

A VIABLE PATH TO SUSTAINABLE MINERALS PROCESSING WHAT IS THE POTENTIAL FOR REPROCESSED TAILINGS WASTE AND WATER? IN A CHANGING RESOURCES INDUSTRY, CDE EXPLAINS THAT A MINING OPERATION DOESN’T HAVE TO STICK WITH TRADITION.

DE has reinvented ways for mining companies to extract the maximum value out of resources, while reducing their footprint in the environment. This is what CDE calls the “new world of resources”, where companies are finding mine sustainability through ore upgrade, tailings diversion and waste dump reprocessing. Not afraid to walk the talk, CDE partners with Canada-based AuVert Mining Group to pioneer a reclamation solution at a new gold mining operation in Colombia. As the mine sits in a land rich in precious metals, CDE’s experience in dewatering and tailings management complements AuVert’s modern technology. Together, they extract the remaining precious metals in the ground while removing up to 93 per cent of residual mercury. “At the end of mine life, this land will be completely restored, securing agricultural revenue for the community for years to come,” CDE head of mining Adam Holland explains at the opening of the ecofriendly land reclamation site. The AquaCycle thickener and water recycling plant recovers up to 90 per cent of the water for immediate reuse within the system and thickens tailings sludge. This achievement stands on the

shoulder of CDE’s past successes. In 2017, the company delivered two turnkey wet processing plants that upgrade overburden waste at the then Arrium-owned Iron Knob and Iron Baron mines in South Australia. The two wash plants have the capacity to convert 17 million tonnes of low-grade iron ore that has been stockpiled as tailings in waste dumps, into a saleable product. “The low-grade iron ore to be processed has been accumulated over the life of mining of the Iron Monarch and Iron Princess deposits, which first began in 1899, and the Iron Baron deposit in 1930,” CDE’s regional manager for Australasia Daniel Webber says. “These beneficiation plants take low-grade iron ore and convert it to a 63 per cent grade.” The low-grade iron ore waste is ejected based on a feed grade or size before it is turned into high-grade iron ore via gravity separation. Webber believes the high interest in tailings retreatment is due to the economic viability of tailings recovery and a mine’s limited resource life. The potential to reprocess tailings is also attractive to tin miners, given how scarce the metal is, the availability of tin tailings and the volume of high-grade tin contained in tailings compared with the virgin deposits. “Mining companies have invested in mining those materials, so

reprocessing them reduces their mining cost,” Webber says. “Likewise, if a processing plant is getting to the end of its life or its feed grade is starting to degrade, you can boost your mine production by addressing those tailings and extracting valuable minerals out of them.” More and more companies are also recovering and dewatering fine sands, sending -150-micron materials to tailings thanks to the increasing capacity for tailings management in Australia. “At CDE, we can recover and stack some of the material as inert sand, rather than having it go to the tailings dam. This takes the load off the tailings system,” Webber says. To back this up, CDE uses a highly efficient Infinity dewatering screen that maximises water recovery and minimises the amount of solid that passes through the system. CDE’s commitment to providing mining companies with a total packaged solution that facilitates a seamless integration in minerals processing is clearly evident. “The scarcity of water is particularly apparent in remote mining areas,” Webber says. “CDE is increasingly being challenged to recover more water. Our turnkey package means we can offer a dry tailings solution, and we can recover up to 98 per cent of process water using our centrifuge

technology.” CDE uses an industry-leading technology for water processing and integrates the system into the processing plant, all while keeping to a single source of water. The recovered water is immediately recirculated into the system, reducing pre-production capital costs by as much as 13 per cent through design changes and equipment selection, as a CDE project in Mt Isa, Queensland has demonstrated. Mechanically assembled in 31 days by a single crew, franna and crane, the wet processing plant has delivered a sustainable outcome for Centrex Metals. CDE can also create a virtual reality of a mine operation using its in-house technology, testament to a company that goes above and beyond to help junior miners gain the capital required to get their projects off the ground. “This can be a powerful tool for junior companies to engage with the community and lets them see what they can invest in,” Webber says. In addition to a 12-person team in Australia, Northern Irelandbased CDE is active in eight regions globally, supplying local expertise and spare parts to mining companies more quickly than ever before. AM For more information about modular mine solutions, visit CDE at PDAC 2020 Convention, Canada where the team will be part of the Geoscience Ireland / Ireland Pavilion Booth #7115N.

CDE HAS REDUCED A QUEENSLAND MINE’S PRE-PRODUCTION CAPITAL COSTS WITH ITS WET PROCESSING PLANT.

AUSTRALIANMINING

MARCH 2020

PROSPECT AWARDS

WHAT’S IN A CELEBRATION? THE AUSTRALIAN MINING PROSPECT AWARDS ENTERS ITS 17TH YEAR DOING WHAT IT DOES BEST: GIVING CREDIT WHERE CREDIT IS DUE.

ome things do get better with age. For the Australian Mining Prospect Awards, mining professionals and companies have taken the event to another level thanks to the rapid industry ascension and growth they’ve fuelled. Entering a 17th year, the national awards program doesn’t miss the abundance of facets that Australia’s mining industry features. Each winner and nominee of the broad range of Prospect Awards categories highlights just how far the Australian mining sector has progressed in a multitude of disciplines. Despite last decade’s commodity downturn, uncertainty around foreign government strategies and unique challenges faced by companies, Australia’s mining sector continues to overcome its challenges with safer, more advanced mining operations and equipment. The Australian Mining Prospect Awards has recognised Kirkland Lake Gold’s Fosterville mine as the 2018 Hard Rock Mine of the Year and the Myuna Herringbone System as the 2017 Innovative Mining Solution for helping rescue Centennial Coal’s New South Wales colliery from the brink of closure, to name a couple. Every year the award finalists and winners go on to inspire the rest of the industry with their achievements. “Mining services companies see the value of and support the Australian Mining Prospect Awards by being involved in the event year after year,” event manager Lauren Winterbottom says. “It has grown into a muchcelebrated awards program since it was launched in 2004, hitting a record attendance of over 300 in Brisbane last year.” Schenck Process managing director Max Wijasuriya believes that any opportunity for the mining industry to celebrate what individuals have achieved is a good thing. “Our industry needs more knowledge out there,” Wijasuriya tells Australian Mining. “People need to know the good things that we do. There are a

THE AWARDS NIGHT HAS BUILT A REPUTATION FOR RECOGNISING THE BEST IN THE INDUSTRY.

lot of smart people out there that accomplish a lot of good things and work very hard.” His confidence for initiatives such as the Australian Mining Prospect Awards has led Schenck Process to be a sponsor for the Excellence in Mine Safety OH&S category this year. “The awareness around safety in mining is continually improving but it’s something you can never lose vigilance on. Everyone is going through a safety journey. It’s about letting people go home safe,” Wijasuriya says. “At the Australian Mining Prospect Awards, I find so many people get recognised for what they’ve achieved. It’s a great way to celebrate what we do well and recognise those who work behind the scenes to make our industry what it is today.” At Schenck Process, excellence in safety is “part and parcel” for the company, according to Wijasuriya. Safety underpins the company culture and is a critical part of the company’s journey forward. Schenck Process’ ProLift Train Load Out Chute changeout system AUSTRALIANMINING

is testament of this: it takes workers out of harm’s way while improving efficiency for mining operators. “At the core of many innovation and development of mining technology is the goal to improve safety: to improve what we do and how we do things to take people out of harm’s way as much as possible,” Wijasuriya says. The ProLift system is also part of the Schenck Process journey towards automation across the business. Wijasuriya believes this will bring improvement to mining companies in terms of productivity and efficiency. “Mining is critical and important to the Australian economy,” Wijasuriya, who has followed the Australian Mining Prospect Awards for at least a decade, says. “We’re sponsoring the Prospect Awards to recognise the people and companies that work in the mining industry to make this sector a better place. “It’s a great opportunity for us to showcase the credentials of the Australian industry.” AM For more information, visit www.prospectawards.com.au/home/

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THE 2020 AUSTRALIAN MINING PROSPECT AWARDS: 1. Ifm Excellence in IIoT Application 2. Epiroc Contract Miner of the Year 3. Epiroc Hard Rock Mine of the Year 4. SEW-Eurodrive Coal Mine of the Year 5. Metso Excellence in Environmental Management 6. Schenck Process Excellence in Mine Safety, OH&S 7. CDE Minerals Processing of the Year 8. Austmine Innovative Mining Solution 9. Indigenous Engagement 10. C RC Mine Manager of the Year 11. Flexco Safety Advocate Award 12. L iebherr Lifetime Achievement Award 13. N ational Group Mine of the Year

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UNDERGROUND MINING

MINNOVARE SETS STAGE FOR NEXT TECHNOLOGY LAUNCH THE MINING TECHNOLOGY COMPANY IS SET TO SHOWCASE ITS PRODUCTION OPTIMISER TECHNOLOGY ALONGSIDE A NEW RELEASE AT THIS MONTH’S UNDERGROUND OPERATORS CONFERENCE.

irst launched in 2018, the Production Optimiser system has been proven to significantly reduce blast hole drilling deviation and rig set-up times in underground mines, resulting in numerous flow-on benefits, including reduced re-drills, reduced dilution, reduced bridging (improved recovery), and greater all-round visibility and accountability across drill and blast performance. Since its release, the technology has enjoyed strong uptake within the Australian market and further uptake overseas, aided by Australian mining companies acquiring assets in North America and Africa. The Production Optimiser works hand in hand with the company’s Minnovare CORE software (Client Online Reporting Engine). Minnovare CORE gives users an online platform and more streamlined workload, making it easier for engineers and drillers to communicate across sites and shifts. For example, engineers can load drill plans into Minnovare CORE and allocate it to their site’s drill rigs. The data is then reported back to the engineer at the end of the shift. This makes the process smoother for engineers, allowing them to wirelessly upload actual drill-data directly from the rig, rather than waiting until the end of a driller’s shift to undertake a traditional manual transfer. Minnovare managing director and co-founder Callum McCracken says implementing the Production Optimiser will significantly improve the productivity and profitability of an underground mine. “We’ve been continuing to improve and develop our technology, including the Production Optimiser’s mobile (tablet) interface,” McCracken tells Australian Mining. “As soon as the driller comes within Wi-Fi connectivity, new drill plans are pushed wirelessly to the tablet and importantly, any information captured during the previous shift’s drilling is pushed instantaneously back to the Minnovare CORE platform. “That not only becomes a platform for the engineer to allocate the

MINNOVARE CORE HELPS ENGINEERS AND DRILLERS TO COMMUNICATE PLANS ACROSS SHIFTS.

plans wirelessly to the rig, but it also becomes a platform for the engineer to assess drilling performance and productivity during the shift.” Minnovare CORE can be customised to specific sites, allowing miners and engineers to allocate drill plans to specific rigs. The data collected in Minnovare CORE goes beyond just allocating and recording drill plans, with the company now building in-depth analytics programs into the platform. “Currently, you have the ability to run what you could call ‘straightforward’ analytics (such as holes and metres drilled),” McCracken says. “What we’re developing for the future is additional modules that will make Minnovare CORE a valuable performance analytics tool, as we continue to capture more data from the drilling process. “If we can create and capture valuable drill-data whilst ensuring data integrity, that data can be used to analyse and improve the entire long hole drilling process and can also be used by other software programs within the mine to make other operations more efficient.” CORE’s promising future isn’t the only exciting prospect at Minnovare. The company will also release a new

AUSTRALIANMINING

product at the upcoming Australasian Institute of Mining and Metallurgy (AusIMM) Underground Operators Conference in Perth this month. McCracken’s lips remain sealed for the big reveal at the event, but he says the company has teamed up with clients ahead of launching the new technology. “From day one, we’ve partnered and collaborated with our clients and this gives us a really great insight into the problems we are solving for them,” McCracken says. “It gave our clients the ability to have the technology built and designed in a way that’s giving them maximum value and solves their problem.” Using this philosophy, Minnovare collaborated with clients to test the technology, including at Northern Star Resources’ Western Australian gold operations. “The results we’ve achieved through that on-site testing have been really exciting for us,” McCracken says. “It is an enabling technology aimed at underground mining, so we focus on being able to use the same people on the mine site but improve the process and as a result, the performance.” McCracken says engaging with

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clients and giving them the tools to improve their work process is one of the most important parts of Minnovare’s approach when developing new technology. “We can develop the most sophisticated, valuable technology in the world, but if we don’t bring people on that journey, it’s not going to be successful,” McCracken says. Minnovare’s latest technology will be one of many attractions at Underground Operators, which will feature keynote speakers like BHP Olympic Dam asset president Laura Tyler, AusIMM executive chairman Gary Zamel, Swedish rock engineering consultant Knut Garschol and Canadian Institute of Mining, Metallurgy and Petroleum’s Roy Slack. “Underground Operators is arguably the premiere event for the underground mining industry here in Australia,” McCracken concludes. “It creates a great platform for us to display the work we’re doing in underground operations and obviously a great opportunity for us to launch a new product, we’re very much looking forward to it.” AM AusIMM’s Underground Operators Conference will be held March 25–27 at the Perth Convention and Exhibition Centre. Visit Minnovare at Stand 20.

PRODUCTIVITY & EFFICIENCY

OPTIMISING UNDERGROUND METALLIFEROUS MINE ORE RECOVERY MINOVA, IN PARTNERSHIP WITH ROUND OAK MINERALS, HAS LIFTED ORE RECOVERIES IN AN UNMINED AREA OF THE BENTLEY MINE IN WESTERN AUSTRALIA BY 20 PER CENT. HOW DID MINOVA DO IT?

here are many projects that a mining or METS (mining equipment, technology and services) company will say yes to. For Minova, it said yes to going underground into areas that have not been mined for many years. This happened at the Bentley copper-zinc underground mine, which is part of the Jaguar operations north of Kalgoorlie in Western Australia. Its history dates back to 2011 when Jabiru Metals offloaded the site in a deal with IGO. Seven years later, Round Oak Minerals (formerly known as CopperChem) acquired the Jaguar operation from IGO to reposition itself as a significant base metals producer in Australia. In line with this strategy, Round Oak sought Minova’s trusted assistance in maximising ore recovery and improving extraction outcomes in the unmined areas of the Bentley mine. Minova has used its many years of experience to assess the project and underground conditions to ensure a successful outcome. One of the principal mining methods that was historically used at the Bentley mine was the Avoca method. This required all development in a given area to be complete before stoping began in a bottomup sequence. Stope voids were sequentially back-filled with loose runof-mine waste rockfill. Minova grouted large volumes of rockfill, allowing the redesign of the stopes below the rockfill, which improved the overall recovery. “The Bentley mine had a stope

MINOVA HAS 18 YEARS’ EXPERIENCE TO BACK ITS OPTIMISED ORE RECOVERY PROJECT AT THE JAGUAR OPERATIONS.

design which was limited by having rockfill above the stopes, so grouting the rockfill changes the design options,” Minova product lead Douglas Pateman tells Australian Mining. “In turn, Round Oak implemented another mining system in Bentley to work in conjunction with our grouting program. They used cementedaggregate fill in conjunction with the Minova grout system to improve the total ore recovery.”

MINOVA PAYS CLOSE ATTENTION TO SAFETY WHEN WORKING IN AN UNDERGROUND METALLIFEROUS MINE.

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This strategy allowed the height of the primary stopes to extend to their full height, including the originally-designed ore sill pillars, which translated to an increase in the available ore that can be mined. The result was an average 20 per cent increase in ore tonnes on the initial design for these stopes. “It’s a fantastic success,” Pateman, who provided Round Oak with engineering support during the initial set up of the project on-site, says. “The additional ore that the Round Oak team has been able to recover is quite significant. It’s also highgrade ore, which means the additional value that’s been generated is a good outcome for the mine.” Three contractors have worked day and night shifts for a period of three weeks to bring the project to completion. Minova provided a specialist worker who operated the pump each shift, and trained another contractor to inject grout into the rockfill.

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But one of the biggest challenges in the project was to ensure the quality of the water was compatible with the Minova-chosen grout, FB200. This was selected for its unique rapid gel times, quick strength, low viscosity and high-water content, allowing for controlled placement through borehole patterns to gain maximum penetration of the unconsolidated rockfill. “The grout that we used required a greater volume of water compared with that required by traditional grout,” Pateman says. “We did a lot of testing to ensure the compatibility of the water with our grout, with different formulations for different types of water.” Moving and storing this high volume of grout underground was also another challenge. Scheduling, according to Pateman, was an important part of this project, given the large number of truck and vehicle movement required to get the grout underground. “Safety was an absolute priority in this project,” he says. “We used specially designed equipment that is safe for use in underground coal mines, which have greater legislative requirements.” Minova also aimed to minimise the movement of machinery to reduce worker exposure to mobile equipment. “In this project, our greatest risk was interaction with mobile equipment, so most of the time our work was done in a safe location,” Pateman, who has eight years of practical and theoretical knowledge with Minova, says. Minova also injected the grout into the rockfill at a safe working height instead of working above the head, while implementing appropriate dust control and area ventilation. The company has developed its expertise since undertaking a project of similar nature in an underground gold mine in Western Australia back in 2001. It has been involved in a number of projects across Australia and Indonesia since then, building its capacity in maximising ore recovery despite the unique challenges presented by individual mines. AM

THE MINING INDUSTRY HAS MOVED TO A NEW PHASE FOLLOWING THE MINING BOOM, ONE WHERE PRODUCTIVITY, INNOVATION AND SAFETY HAVE EMERGED AS ITS KEY PRIORITIES TECHNOLOGY MINING CONTRACTORS VOLUME 112/2 | MARCH 2020

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INDUSTRY COMMENT

AUSIMM HIGHLIGHTS AUSTRALIA’S URANIUM & NUCLEAR POTENTIAL WHAT IS THE WORLD’S LEADING CARBON-FREE SOURCE OF ENERGY? THE ANSWER IS ALSO THE ENERGY SOURCE THAT PROVIDES 55 PER CENT OF THE UNITED STATES’ CLEAN CARBON-ELECTRICITY.

t’s not solar power, or even wind power, it’s nuclear power. Leading voices across the world, including formerly anti-nuclear activists, recognise that it is virtually impossible to combat climate change and air pollution without a significant contribution from nuclear energy. The world’s existing fleet of 442 nuclear reactors produce massive quantities of baseload, carbon-free electricity. Due to their attributes and unmatched record of efficiency and safety, nations around the world are extending the lives of their fleets. In addition, there are exciting developments in the next generation of nuclear reactors, including small modular reactors and microreactors, which offer enhanced scalability, productivity and safety. As a result, there are truly exciting opportunities for the nuclear fuel sector, including uranium mining. However, low prices and global oversupply have had a negative impact on the nuclear fuel industry, so much so that western mining companies are struggling to remain competitive. Poor prices have been the result of an excess in inventories and over production, according to International Uranium conference chairperson Mark Chalmers. “The long-term prospects for uranium and nuclear fuel are undeniable,” Chalmers explains.

“Even today, global mine production is not meeting demand. “However, in recent years, excess inventories and secondary oversupply have created today’s low prices. “These low prices are causing destruction of uranium mine supply, where even many low cost, Tier 1 uranium mines cannot compete today. “Adding to the complexity, the global uranium market is increasingly being dominated by a small number of state-owned enterprises in Russia, China and elsewhere. “Despite all of this, Australian uranium production remains highly competitive, and we should be proud of that fact. “In addition, western nations, including in the United States, are coming to the realisation that some level of government support is required to maintain the strength of their domestic industries due to uranium’s close relationship with energy security, non-proliferation and national security.” This will all be covered in key details during the Australasian Institute of Mining and Metallurgy (AusIMM) International Uranium Conference, which is returning for its 15th consecutive year in July 2020. This event will bring some of the world’s most knowledgeable uranium and nuclear experts together in South Australia, which is home to two of Australia’s three producing uranium

mines – Olympic Dam and Beverly. As the delegates gather in Adelaide for the conference, they will be approximately 600 kilometres from some of the country’s most prospective uranium territory, the state’s Far North region. As well as the Olympic Dam and Beverly mines, South Australia also has another fully permitted and constructed uranium project on standby, further solidifying it as a key region for Australian uranium mining. “I applaud South Australia for taking the lead in all things uranium, nuclear, and clean energy,” Chalmers says. “Uranium is accepted and well received by the public in South Australia. There are exciting technological developments in the uranium and nuclear sectors, including the potential commercialisation of the next generation of reactors. “Finally, there has been significant bipartisan support from both the Liberal and Labor parties in the state for nearly 20 years. “This makes South Australia a unique destination for the conference and the sector. “With increasing global demand for nuclear fuel, Australia’s large uranium resource base places us in a fantastic position to scale up production over the next five-plus years and be a sustainable economic driver for many years thereafter.” But it isn’t just South Australia

SPEAKERS KATHY EHRIGI, SCOTT MELBYE AND TONY CAREY WITH AUSIMM PRESIDENT JANINE HERZIG AND INTERNATIONAL URANIUM CONFERENCE CHAIRPERSON MARK CHALMERS.

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that is in a position to capitalise on uranium; Chalmers says Australia as a whole is in one of the best positions in the world to take advantage of the growing market, with a number of fully permitted mines in Western Australia which are just awaiting higher uranium prices. “I believe Australia is in one of the best positions of any country in the world to expand uranium production with improved market conditions, and to even perhaps deploy the next generation of advanced nuclear reactors,” he says. “Australia needs to have both baseload and intermittent energy sources (renewables) with energy storage in the right proportions, while balancing emissions, grid reliability and costs.” The turnaround of the uranium and nuclear market, particularly in Australia is what Chalmers believes will be one of the key discussion points by presenters at the conference. With technology allowing for more cost effective and productive mining for other commodities, such as hard rock and underground mining, it can also give uranium the push it needs to improve its competitiveness. Delegates at the International Uranium Conference will have the opportunity to get a sneak peek into what the latest technology offers the sector. Chalmers says the benefits of a healthy uranium industry, supported by modern technology, carries over into other sectors, for example with nuclear medicine saving many lives around the world every year. “Technology is improving very rapidly. There are, and there will continue to be, exciting opportunities to do things better and at lower costs,” he concludes. “The key is to blend this evolution with proper, proven science and the International Uranium Conference is an event that fully recognises and promotes these dynamics.” AM The International Uranium Conference will be held at the Adelaide Convention Centre on July 1–2. For more information, visit www. uranium.ausimm.com.

PRODUCTS

ALL ABOARD MOBILARIS ONBOARD TECHNOLOGY Described as “google for your mine”, Mobilaris Onboard is giving underground mine workers more situational awareness for safer operations. Collecting real-time information about personnel, equipment and vehicles, Mobilaris Onboard provides workers with 3D maps, allowing them to see what is around them. Using an algorithm called Mobilaris Hybrid Positioning, Mobilaris Onboard allows for self-sustained positioning of a vehicle with five to 10 metres accuracy, without needing infrastructure for positioning. This is all displayed on a modern tablet computer mounted inside a machine’s cabin. The information gathered is all stored locally so it can still be used when workers are travelling out of network coverage.

• mobilaris.se

WEIR HYDROCYCLONES REDUCE GRINDING MILL RECIRCULATION Weir Minerals Cavex 400CVX10 hydrocyclones improve separation efficiency within grinding mills, providing strength and corrosion resistance. The Cavex hydrocyclones feature a 360-degree laminar spiral inlet geometry design, which gives a natural flow path into the hydrocyclone. This design allows feed to blend smoothly inside the chamber with rotating slurry, reducing turbulence. Minimum turbulence creates a more natural wear pattern that can outlast traditional hydrocyclones by three times as much and reduces the number needed within a cluster. It also guarantees a greatly reduced amount of misplaced coarse particles compared with conventional models. The design helps mines to save a significant amount in cyclone and pump maintenance costs as well as power and ball consumption.

• global.weir

HEXAGON COUNTERS DROWSY DRIVERS

KOMATSU JOY STAMLER RF5 RECLAIM FEEDER

Hexagon’s HxGN MineProtect Operator Alertness System Light Vehicle detects driver fatigue and distraction on mine sites. The system provides real-time alerts in the event of driver distraction, drowsiness or microsleeps, allowing them to act and prevent accidents. HXGN MineProtect communicates with the OAS-HV Analytics server, which enables full vehicle fleet monitoring. The in-cab unit can be fitted in medium-sized mobile equipment, light vehicles and semi-trucks. It works in light and dark conditions, making it ideal for open cut and underground mine operations and also through prescription glasses or lenses.

Efficient and cost effective, Komatsu’s JOY Stamler RF5 reclaim feeder gives a versatile crushing experience. The RF5 is ideal for both coal and industrial mineral applications, with a capacity of up to 3650 tonnes per hour. The need for in-ground hoppers, grids, tunnels and underground belt conveyor systems are eliminated with the RF5, with the feeder only requiring solid, level ground conditions for installation. This makes it easy to load and material can be directly moved from the feeder onto the drag-chain conveyor. The RF5 has an average machine life of more than 20 years.

• hexagon.com

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• mining.komatsu

MARCH 2020

PRODUCTS

DINGO’S TRAKKA SOFTWARE PREDICTS EQUIPMENT FAILURES

BOLLE GOGGLES GIVE 180-DEGREE VISION

The Trakka Anomaly Detection and Remaining Useful Life software by Dingo is allowing mining companies to predict impending equipment failures with a high degree of accuracy. This allows engineering teams to address maintenance issues earlier and restore equipment quicker. Anomaly Detection detects anomalies well before traditional engineering limits are reached while Remaining Useful Life predicts how long mining assets are going to remain in operation through its probability of failure and degradation guides. With Trakka, mining companies will be able to forsee and proactively manage maintenance shutdowns for the best possible safety and productivity while equipment is down.

Bolle’s 180 goggles provide workers with 180-degree vision with style, comfort and of course safety, with a flexible bi-material ventilated frame. The 180 is compatible with respirator masks, making it ideal for underground mining operations, and fits over prescription glasses. This model is coated with permanent platinum coating, giving it a high resistance to scratching and delaying the onset of fogging for the best possible vision. The Bolle 180 has been approved for both indoor and outdoor usage by Australian Standards, meaning it can be used in both underground and open cut operations. It is also tested and approved for use against splashes and chemical handling and provides appropriate dust protection.

• dingo.com

• bollesafety.com.au

STRATACONNECT MC2 KEEPS MINERS CONNECTED The StrataConnect MC2 communication and tracking device uses Strata’s wireless mesh network to provide two-way text communication for underground mine workers. MC2 also provides personnel location tracking, critical alert and response functions in case of an emergency, allowing workers to account for one another’s whereabouts in remote workspaces with the Find Miner function. Emergency messages are clearly distinguishable from regular ones, which allows miners to respond quickly and easily to the situation. The rechargeable battery lasts through multiple shifts and the device automatically updates contact lists, firmware and timestamps when put into the charging dock.

• strataworldwide.com

SANDVIK IMPROVES TRUCK PERFORMANCE WITH NEW TRANSMISSION Sandvik has brought in new transmission for its flagship trucks, Sandvik TH663i and Sandvik TH551i. The new transmission boasts eight gears compared with the previous six, which allows for maximum speed and efficiency. This is expected to increase the trucks’ productivity and enable shorter cycle times. The fully proportional and more powerful hydraulic retarder operates with the engine brake for easier downhill control and higher speeds. Further lock-up gear shifting enables quick and smooth shifting and keeps speed better while driving uphill. The new transmission control system has been improved and fully integrated into the Sandvik Intelligent Control System, enabling easy and fast troubleshooting without the need for external diagnostics tools.

• rocktechnology.sandvik

AUSTRALIANMINING

MARCH 2020

EVENTS

CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@AUSTRALIANMINING.COM.AU Australasian Oil & Gas Exhibition & Conference, Perth, March 11-13 The Australasian Oil & Gas Exhibition & Conference (AOG), a showcase of the latest products and services, will be held at the Perth Convention and Exhibition Centre from March 11-13. AOG attracts over 8000 global visitors providing opportunities to network and learn about the latest technological and innovative breakthroughs which will drive the industry into the future. The conference is a chance to explore specialised industry zones showcasing the latest in instrumentation control and automation, asset integrity, subsea, health, safety and environment, drilling and completion. It also provides the opportunity to earn from internationally renowned speakers and technical specialists at free-to-attend conference sessions held in theatres on the exhibition floor, featuring three forums dedicated to collaboration, subsea and knowledge. • aogexpo.com.au Global Iron Ore and Steel Forecast Conference, Perth, March 18-19 The 23rd annual Global Iron Ore and Steel Forecast Conference will flesh out the latest outlook for iron ore and steel demand and supply. Learn from industry leaders as they discuss future plans, and the opportunities and challenges ahead. The conference will focus on exploring the iron ore boom 2.0, with numerous new mine and expansion projects injecting hundreds of millions of dollars into the Pilbara region. Key topics for discussion include

creating value in a changing market, China’s changing iron ore demands, project updates and expansion plans, innovation and automation, reducing energy costs and managing the second iron ore boom. • informa.com.au Perth Mining Innovation Roadshow, Perth, March 19 Austmine is bringing its mining innovation roadshow back to Perth to drive key discussions and outcomes around future challenges, digital transformation priorities, sustainability focus areas and emerging smart solutions. Themes of the roadshow include the automated future, cyber security and zero harm, the energy future, inclusion and diversity as well as collaborative exchanges and partnerships. Delegates can expect to discover the latest mining innovation in action through insightful presentations and case studies, and hear about current and future innovation projects from major and mid-tier mining companies. The roadshow is sponsored by Rockwell Automation. • austmine.com.au MEGATRANS, Melbourne, April 1-3 MEGATRANS returns in 2020 to facilitate cross-industry collaboration in a multidimensional and integrated conference and exhibition for the freight and logistics industry. For the first time, MEGATRANS2020 will take place in conjunction with the specialised bulk handling expo, Australian Bulk Handling Expo 2020. The two

AUSTRALIANMINING

events will be held side-by-side, with one ticket entry into both exhibitions. MEGATRANS2020 will showcase the latest in artificial intelligence, robotics, automated racking, telematics and route optimisation, warehouse automation, intelligent fleet systems, blockchain, Internet of Things, big data and advanced analytics. • megatrans.com.au Mine Waste and Tailings Conference, Brisbane, July 29-30 The Mine Waste and Tailings Conference aims to set the benchmark for sharing knowledge and insights on mine waste and tailings management, sustainable practice and facility closures. Jointly hosted by the Australasian Institute of Mining and Metallurgy (AusIMM) and the University of Queensland, the conference will address all aspects of the life-cycle, from site selection and design to post-closure care. Over two days, the conference will feature selected technical papers with a strong operational focus, an exhibition showcasing the latest innovations and networking functions. In addition, there will be a pre-conference workshop providing additional professional development opportunities. • tailings.ausimm.com Diggers and Dealers Mining Forum, Kalgoorlie, August 3-5 This annual conference brings together mining and exploration companies, brokers, bankers, investors, financiers and mining service industries into Australia’s unofficial gold mining

MARCH 2020

capital, Kalgoorlie in Western Australia. The event combines presentations by listed mining and exploration companies with a large display area, housing a range of exhibitors from within the sector. Diggers and Dealers also features a world-class entertainment program, including a keynote address from a world-class speaker, who is yet to be announced. Previous keynote speakers include former Prime Minister John Howard and British economist and public servant Mervyn King. It is also possible to visit sites in the Goldfields region during the conference, by contacting companies directly. • diggersndealers.com.au GMG Mining Forum, Brisbane, Aug 18-19 Global Mining Guidelines Group and Austmine are set to address the burning issues impacting the mining industry in their 2020 forum series. This forum features experts from inside and outside mining to allow learning from each other’s successes and failures. Delegates will have the opportunity to tap into their diverse pool of knowledge and experience. The forum will address key aspects in mining such as automation, interoperability, artificial intelligence, data, cybersecurity, electrification and blockchain. • austmine.com.au MINExpo International, Las Vegas, September 28-30 MINExpo International is the world’s largest and most comprehensive global mining event. Held every four years, MINExpo brings together worldwide industry leaders who are ready to purchase the latest equipment and services, see innovative new technologies, meet face-to-face with vendors and make valuable new connections. The expo showcases all of the latest cutting-edge equipment, innovations, services and technologies to take your operations to a new level and fuel long term growth. MINExpo attendees have the buying power and influence to purchase the equipment, products and services that are brought to the show. In just three days, meet thousands of mine operators from all over the world – all in one place. • minexpo.com

DONâ&#x20AC;&#x2122;T MISS THE BIGGEST AUSTMINE YET! JOIN US IN PERTH FOR AUSTMINE 2021

Austmine 2019 exceeded all expectations and was a landmark conference for the Australian METS sector and mining industry. In addition to a soldout exhibition floor and record delegate numbers, Austmine 2019 provided more interactive, educational and networking opportunities than ever before. Austmine 2021 will build upon this success and continue to drive the mining innovation conversation forward, fostering connections and business opportunities with leading mining companies across the world.

AUSTMINE 2019: THE LANDMARK EVENT

1200+

75+

CONFERENCE DELEGATES

UNIQUE MINING COMPANIES IN ATTENDANCE

80+

20+

EXHIBITING COMPANIES

750

INDUSTRY LEADERS AND AWARDS DINNER ATTENDEES

COUNTRIES REPRESENTED

SPEAKERS

AUSTMINECONFERENCE.COM.AU

SECURE YOUR STAND

TODAY! Karlena James

Manager - Conference & Events 02 8310 0602 Karlena.james @austmine.com.au

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