AM Apr 2020 by Prime Creative Media

MAINTENANCE NICKEL SPOTLIGHT VOLUME 112/3 | APRIL 2020

MATERIALS HANDLING

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MAINTENANCE NICKEL SPOTLIGHT VOLUME 112/3 | APRIL 2020

MATERIALS HANDLING

PROCESSING OPPORTUNITIES

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COMMENT

AUSTRALIA’S ATTRACTIVENESS UNDER THE MICROSCOPE BEN CREAGH

Ben.Creagh@primecreative.com.au

AUSTRALIA REMAINS ONE OF THE WORLD’S TOP MINING REGIONS TO INVEST IN, BUT INDIVIDUALLY THE FORTUNES OF OUR STATES AND TERRITORIES ARE FLUCTUATING.

anada’s Fraser Institute has a unique ability of reminding the Australian mining industry of where it sits against the rest of the world. The latest high rankings in Fraser’s annual mining investment survey have again showed why Australia is considered a world leader in the industry. They did, however, also return mixed results for Australia’s states and territories as they encounter unique challenges. As perennial high achievers, any signs of slippage inevitably lead to calls that Australia cannot afford to become complacent. The report surveys global executives to rank 76 jurisdictions around the world based on the geological attractiveness and government policies that encourage or deter exploration and investment. In 2019, Western Australia and South Australia were the only Australian jurisdictions to figure in the top 10. Australia was the second most attractive region behind Europe. Western Australia moved back into the top spot overall for the first time since 2015, while South Australia jumped from 24th to sixth – its first top 10 finish since 2015. South Australia’s industry must be delighted with its turnaround, which reflects a renewed focus on increasing exploration activity, project development, future job creation and exports. The state’s rise highlights concepts such as the Accelerated Discovery Initiative, an exploration incentive that has been reintroduced by the South Australian Government. Despite two top 10 finishes, if there is cause for alarm it would be due to the decline in policy scores for all of Australia’s jurisdictions in comparison with the previous survey.

Tasmania, Queensland and New South Wales were particularly hit in this area. The Queensland Resources Council (QRC) went as far as calling the state’s two spot drop to 16th as a “wake-up call,” saying abundant resources are not enough for the sector to thrive. Queensland’s policy environment has been criticised for reasons such as uncertainty concerning disputed land claims, socioeconomic agreements and community development conditions, and security. While Queensland finished well ahead of Victoria or New South Wales, the QRC believes the state should be on equal footing with Western Australia given its resources and skills. And perhaps the council is right, especially when the gap between Queensland’s policy rating (31st) and where it placed for mineral potential (11th) is considered. But Queensland wasn’t alone when it comes to the policy evaluation; New South Wales’ permitting processes were described as onerous and unpredictable, while Victoria’s introduction of a 2.75 per cent gold royalty was questioned. Even Western Australia was criticised for the uncertainty around its uranium policies. With continued strong performance across Australia, it can be easy to overreact to negative criticism that surfaces in a respected survey such as this. On the flipside, the feedback does provide a guide for how Australia can continue to improve against the rest of the world.

TARA HAMID Email: tara.hamid@primecreative.com.au

GRAPHIC DESIGNERS Kerry Pert, Madeline McCarty

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In this issue, we highlight the important role of the minerals processing sector with a special feature on the companies that are shaping the future in this area. This edition puts the spotlight on Australia’s evolving nickel market and how mining companies are building for emerging demand from battery manufacturers. Australian Mining also explores the increasing focus on hydrogen, both as an option for the coal industry and as an energy source for mining more broadly. We also look at Flexco’s commitment to manufacturing in Australia since launching operations here 26 years ago.

Cover image: Western Areas.

Ben Creagh Managing Editor

CHIEF EXECUTIVE OFFICER JOHN MURPHY

MANAGING EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au

FRONT COVER

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APRIL 2020

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CONTENTS MINING SERVICES

COMMODITY SPOTLIGHT NICKEL TO DRIVE GREENER FUTURE Western Australian companies lay out growth plans

POWER TO THE WELDER Welding Industries bypasses obstacles

16-17 FUTURE OF MINING

49 MATERIALS HANDLING

50-53

HYDROGEN’S EVOLVING OPPORTUNITY Renewables, coal and hydrogen: A triple treat

DIACON AND FLEXCO LEAVE THEIR MARK Conveyor safety and an Aussie commitment

19-20 MARKET OUTLOOK

22-23

INDUSTRY COMMENT

IRON ORE: NOW AND THE FUTURE May the prices be in Australia’s favour

THIRTY YEARS OF METS TRANSFORMATION Minerals processing through Austmine’s eyes

RESEARCH & DEVELOPMENT

24 54-55

ROY HILL CONVEYOR INNOVATION Bridgestone’s observations from a visit to the site

MEASUREMENT & MONITORING

COMMUNITY INTERACTION

VEGA MOVES INTO NEW TERRITORY Mining challenges turned into opportunities

A PLACE FOR WESTERN AUSTRALIA’S NEXT GEN BHP, West Coast Eagles form social connection

ENGINEERING

CARTLEDGE MINING THINKS AHEAD Geotechnical backing for the Middlemount mine

MINERALS PROCESSING DIVIDING VALUE FROM WASTE Separation solutions for prized minerals

57 29-42 TECHNOLOGY

PROSPECT AWARDS

58 IFM PUSHES TECH BOUNDARIES The combined power of sensors and the Internet of Things

A SHOWCASE OF LASE AND C-TRACK Bringing technology innovation to market

42-44 MAINTENANCE

EVENT SPOTLIGHT

MINEXPO INTERNATIONAL RETURNS IN 2020 A display of equipment, technologies and services

OVERCOMING UNPLANNED SHUTDOWNS Inenco Group pinpoints the roots of past problems

46-47 REGULARS NEWS 9-14

PRODUCTS 60-61 AUSTRALIANMINING

APRIL 2020

EVENTS 62

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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. ROY HILL CHOOSES EPIROC, ASI TO AUTOMATE HAUL TRUCKS

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

ROY HILL, EPIROC AND ASI MINING CELEBRATE THE AGREEMENT.

Roy Hill has signed a contract with Epiroc to automate the Western Australian iron ore miner’s mixed fleet of 77 Hitachi and Cat haul trucks. Epiroc, in partnership with automation specialist ASI Mining, will deliver an interoperable solution with the ability to expand to other mining vehicle types and manufacturers. The solution will also have the capability to integrate with existing and future Roy Hill systems. Epiroc will work with Hitachi/ Wencomine on truck conversion and integration of Roy Hill’s existing Wenco fleet management system. The project will involve an initial

phase of testing and production verification of up to eight trucks, before the full fleet of Roy Hill machines is converted from mid 2021. Roy Hill chief executive officer Barry Fitzgerald said the Pilbara iron ore site was well positioned to transition to automation. “Our teams on site and in our remote operations centre in Perth have demonstrated a clear capacity to deliver complex projects, sustainable change and operational excellence with the recent success of the autonomous drill program and fleet optimisation initiatives,” Fitzgerald said. “Now is the right time to bring

the combined expertise of Roy Hill, Epiroc, ASI Mining and Wenco together to convert our haul truck fleet.” Epiroc and ASI Mining plan to establish a highly-credentialed team in Western Australia to deliver the project. ASI CEO Mel Torrie said the companies would also partner with key suppliers, including mining technology integrator Sedna, to deliver the automation haulage system (AHS) at Roy Hill. “As a manufacturer-agnostic solutions provider ASI Mining looks forward to highlighting the opportunities presented by an interoperable approach to

autonomous mining,” Torrie said. Fitzgerald reinforced the role of Roy Hill’s people in this project, saying they were at the forefront of the decision to undertake truck automation. He said Roy Hill had established reskilling and redeployment plans to assist the transition of operators to new roles within the business. “We are committed to an automation journey that creates an environment in which our people can develop new skills critical to the workforce of the future. Our focus is on setting people up to succeed and further contribute to the Roy Hill community,” Fitzgerald said.

WA TOPS WORLD AS MINING JURISDICTION FOR INVESTMENT Western Australia is once again the leading mining jurisdiction in the world for attracting investment, according to Fraser Institute’s annual survey of mining company rankings. The state leads the way for the first time since 2015 after being rated the second most attractive jurisdiction in the world by the Canadian think-tank last year. A total of 76 jurisdictions across the globe were assessed,

with South Australia one of the big movers in 2020, climbing from 24th last year to sixth. “The mining survey is the most comprehensive report on government policies that either attract or discourage mining investors,” Fraser Institute senior policy analyst Ashley Stedman said. “A sound regulatory regime coupled with competitive taxes are key to making a jurisdiction AUSTRALIANMINING

attractive to investors.” Meanwhile, Queensland (15th) has lost its previous spot to the Northern Territory (13th), which has entered the top 20 this year. Tasmania (22nd) and Victoria (43rd) sit outside the top 20 – but have jumped significantly from their previous rankings. However, New South Wales (47th) has dropped down from 42nd place in the last survey. Despite Western Australia topping

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the charts for mining jurisdictions, the country as a whole saw declines across the board for policy production index scores. “The Policy Perception Index, or PPI provides a comprehensive assessment of the attractiveness of mining policies in a jurisdiction, and can serve as a report card to governments on how attractive their policies are from the point of view of an exploration manager,” the report read.

NEWS

AUSTRALIAN GOLD PRODUCTION ACHIEVES ALL-TIME HIGH Australian gold production reached an all-time record of 325 tonnes last year, with a particularly outstanding December quarter, according to Surbiton Associates. Gold production during the December period hit a record quarterly output of 87 tonnes, exceeding the previous record of 82 tonnes in the June quarter last year. The record quarters were responsible for the yearly all-time high, with eight tonnes more than the previous record of 317 tonnes in 2018. Surbiton Associates director Sandra Close said this was due in part to new projects coming online and a steady increase in output. “In addition to 2019 having the

highest ever gold production in Australia, the December 2019 quarter was really outstanding,” she said. “The record output was due to new projects coming on stream and ramping up production, other operations recovering from poor performances in the September quarter and some increases in throughput and grade.” This includes Newcrest Mining’s Cadia East mine in New South Wales, which produced 68,000 ounces more gold than in the previous quarter. In the same period, Gold Fields lifted its production at the St Ives operation in Western Australia by 32,600 ounces. “Kirkland Lake Gold’s Fosterville

mine in Victoria continues to shine,” Close said. “It reported an average of an extraordinary 49.3 grams per tonne gold for the quarter, resulting in an increase in production of 33,600 ounces, making it now Australia’s third largest operation on a quarterly and annual basis.” The Gruyere joint venture in Western Australia also ramped up rapidly to reach its full rated capacity, with an output of 70,000 ounces in the December quarter, an increase of 41,000 ounces on the September quarter. Surbiton noted that the local gold producers had been making the most of rising Australian and US dollar gold

prices in 2019. “The Australian dollar gold price averaged a record $2168 per ounce in the last three months of 2019, due to a higher US dollar gold price and a weaker Australian dollar exchange rate,” Close said. “Since then the Australian dollar gold price has continued to rise, hitting a record high of $2529 per ounce on 24 February 2020.” Close added that at a gold price of $2400 an ounce, gold became a major export earner in Australia, with the value of the 2019 output exceeding $25 billion. “Gold retains a certain safe-haven status and its price often rises with uncertainty,” Close said. KALGOORLIE’S SUPER PIT GOLD MINE CHANGED HANDS IN 2019.

ADANI TO TRANSITION TO PRODUCER IN 2021 Adani Mining chief executive Lucas Dow has stressed that the Carmichael mine and rail project in Queensland is “well and truly under way” to delivering first coal next year. Dow, speaking at the first Bowen Basin Mining Club luncheon of 2020, said business opportunities for contractors would flow in the coming months. The company expects to announce primary civil contractors

shortly, on top of more than $750 million in signed contracts that were already announced. Dow also said that Adani was the sixth largest solar producer in the world. “Coal-fired generation capacity in the Asia Pacific region is set to grow by more than 80 per cent by 2040,” Dow said. “Coal and renewables are both important in the energy mix – India can’t grow and bring people out of AUSTRALIANMINING

poverty without coal. “There’s an opportunity here for us, our kids and our grandkids, to keep jobs here in Queensland producing high-quality, low-emission coal. “We’re all for democracy and people airing their opinions – but I’m committed to making sure the debate is based on facts, not on lies and mythology.” Adani has 200 workers on the Carmichael site, 22 per cent of

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which are Indigenous, according to Dow. “While Rockhampton and Townsville are benefitting as our regional project hubs, the project’s benefits are also flowing here in Mackay, with 40 locals building our first 25 trucks,” he said. Bowen Basin Mining Club director Jodie Currie said the progress Adani had made showed the impact the resources industry could have when presenting a united front.

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NEWS

NEWMONT TO AUTOMATE BODDINGTON TRUCKS IN WORLD FIRST A CAT 793F AUTONOMOUS MINING TRUCK.

Newmont has approved a $US150 million ($227 million) investment in a Caterpillar autonomous haulage system (AHS) at the Boddington gold mine in Western Australia. Boddington will become the world’s first open pit gold mine with an autonomous haul truck fleet when the MineStar Command for hauling system is operational in 2021. Newmont expects the project will extend Boddington’s mine life by at least two years through the improved efficiencies provided by the AHS. Boddington is already Western Australia’s largest producer of gold, with

709,000 ounces delivered in 2018. The fleet of autonomous Caterpillar 793F haul trucks will feature rigorous safety controls that reduce worker exposure to potential vehicle interactions, according to the United States-based company. Newmont is executing a people strategy at Boddington that will provide opportunities for reskilling and redeployment of haul truck drivers to other roles supporting the AHS. “Not only does Boddington continue to deliver strong performance, our investment in autonomous haul trucks will generate an internal rate of

return greater than 35 per cent with a more controlled and efficient haulage operation,” Newmont president and chief executive officer Tom Palmer said. “We are also uniquely positioned in the gold sector to support effective implementation and operation of the fleet thanks to the technical capabilities and previous experience of leaders in our business. “Simply put, Boddington will be a safer, more productive world-class gold mine in a top-tier jurisdiction.” Caterpillar will work with Perth-based Cat dealer WesTrac to manage logistics of the autonomous haul truck delivery

and commissioning. WesTrac will play a key role in implementing the technology solutions at Boddington and plans to leverage the autonomous technology training facility that it is constructing in Collie in the state’s South West region. Caterpillar group president resource industries Denise Johnson said Command for hauling had shown its ability to enhance safety, optimise production and lower costs at sites around the world. “The Caterpillar team is eager to demonstrate these positive results in gold mining,” Johnson said.

NQ MINERALS INKS DEAL TO BUY BEACONSFIELD NQ Minerals plans to restart the Beaconsfield gold mine after signing a $2 million deal for the Tasmanian site. The new agreement is just one of many recent additions to Australia’s thriving gold mining sector. NQ chairman David Lenigas said the company and its engineering consultant teams would commence an extensive due diligence program on Beaconsfield as part of the acquisition agreement after

securing the deal. “NQ will be working with its consultants and relevant government departments in Tasmania to assess and ascertain what is required to re-open Beaconsfield as soon as possible,” he said. Beaconsfield gold mine was decommissioned in 2012. Prior to its closure, the mine produced nearly two million ounces of gold between 1887 and 2012. AUSTRALIANMINING

The mine’s previous operator BCD Resources had reported that the mine underground reserves and resources totalled 336,514 ounces of gold. There are large areas of the mine’s gold deposits that remain unexplored, according to NQ. “Acquiring an established gold processing plant for a fraction of the cost to build and permit a new one, not to mention the typical lead time associated with permitting a new

APRIL 2020

facility in Tasmania is an exciting opportunity,” Lenigas said. “Recent notable successes in re-assessing new potential around historic high-grade gold mining centres has seen significant value add for investors at projects like Fosterville in Victoria and Bellevue in Western Australia. “In this regard, we believe that Beaconsfield offers a genuine opportunity for the company to develop a high-quality gold asset.”

NEWS

TERMITE MOUNDS SEND CLUES ON UNKNOWN DEPOSITS RED TERMITE MOUNDS IN THE PILBARA.

Metallic blue crusts within soil and termite mounds could be a signpost for hidden metal deposits in the southern Pilbara region of Western Australia. A CSIRO study from the region shows how metallic blue crusts, known as manganese crusts, display unique zinc characteristics that indicate the presence of other base

metals in the area. These include nickel and cobalt, elements that are essential in the global transition towards a low emissions future. The manganese crusts are also found in rock and cave varnishes, making them an easily accessible exploration tool for base metals. “As the world transitions to a

low emission future, there’s a need for more nickel and cobalt to build electric vehicles and batteries to store renewable energy,” CSIRO senior research geoscientist and lead scientist on the research, Sam Spinks said. “We’ve shown that analysing zinc isotopes found in manganese crusts have huge potential to be used to

explore for these metal deposits, and others.” The CSIRO has proven the connection by comparing its analysis of termite mounds and soils located close to a zinc-lead-silver deposit to other samples. Spinks said zinc was commonly found in most base metal deposits, and over time ended up in a range of natural materials including soils, termite mounds and vegetation. “The zinc is altered as it moves from the metal deposit to the surface, which has traditionally made it unreliable as an exploration tool, but we’ve been able to apply recent advances in data analysis to understand it in more detail,” he said. “This new research shows we can now measure zinc variations, or isotopes, so accurately that we can identify what metal deposit lies deep underground.” Termite mounds are already being used in Australian exploration, following earlier CSIRO research that found termites extract small particles from ore deposits to store in their mounds. “Australian exploration companies have been analysing samples from termite mounds in gold exploration in recent years, now zinc offers another technique for use in broader environments and to find a range of metals,” CSIRO research group leader Yulia Uvarova concluded.

RIO TINTO SLASHES PILBARA SHIPMENTS OUTLOOK Rio Tinto has revealed the impact that Tropical Cyclone Damien had at its Pilbara iron ore operations in Western Australia during February. The category 3 cyclone wreaked havoc across the Pilbara region, causing damage to roads, buildings and electrical infrastructure. The Pilbara region was

hammered with 162 millimetres of rainfall at Karratha Airport, which services Rio Tinto’s operations. All of Rio Tinto’s Pilbara mines were impacted by the cyclone, with the company conceding it would take time for normal operations to resume.

The company’s Pilbara shipments have been forecast to decrease from between 330 million tonnes and 343 million tones, to 324 million and 334 million tonnes. Rio Tinto insisted the company was focussed on keeping disruption to a minimum despite the downgrade.

The company continued to take safety measures at its extensive network of mines while fixing any damage left by the cyclones. Rio Tinto will also continue to develop mining infrastructure in the Pilbara, with completion of the Koodaideri iron ore project slated for the end of 2021.

NEWCREST BROADENS SEARCH FOR PATERSON GOLD Newcrest Mining has inked a $60 million agreement with Antipa Minerals to explore the southern portion of the junior’s ground in the Paterson Province, Western Australia. The project, called Wilki, comprises 1700 square kilometres of ground, which includes existing gold-copper resources at Minyari-WACA. It also

hosts the newly discovered ReaperPoblano-Serrano gold-copper trend. Wilki is in proximity to the Winu (Rio Tinto), Citadel (Antipa-Rio Tinto), Havieron (Greatland Gold-Newcrest) and Telfer (Newcrest) projects. “This transaction demonstrates Newcrest’s commitment to the region and its strong belief in the AUSTRALIANMINING

prospectivity of the Wilki project, which is strategically located surrounding its long-running Telfer gold-copper operation and ore processing facility,” Antipa chairman Stephen Power said. “The agreement with Newcrest is designed to ensure a robust exploration program will be undertaken across the Wilki project over the

APRIL 2020

coming years, including the drill testing of a number of highly prospective targets. Newcrest could earn up to a 75 per cent interest in the Wilki joint venture in a staged process. The company has committed to sole fund at least $6 million expenditure within two years of executing the agreement.

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COMMODITY SPOTLIGHT

NICKEL BACK ON TRACK FOR A GREEN MINING FUTURE AS SOCIAL CONVERSATIONS SURROUND THE FUTURE OF MINING, WITH FOCUS ON CLIMATE CHANGE, GREEN BATTERIES, ELECTRIC VEHICLES AND DECARBONISING OPERATIONS, NICKEL IS MAKING A COMEBACK.

hina is a world leader in adopting electric vehicles (EVs) powered by lithium ion batteries, with the government’s subsidies a massive incentive for people looking to purchase an EV. Although Australia is lagging behind nations such as China when it comes to adopting EVs, the move towards greener cars and power is in motion. As IGO chief executive officer Peter Bradford highlights in a Melbourne Mining Club speech, the decision to prioritise greener everyday solutions is something the company wants to “practice what it preaches”, including Bradford himself being a leader. “We want to be a smarter, kinder and more innovative company,” Bradford explains. “We want to be globally relevant and make quality products that our customers desire. We want to be vertically integrated and proactively green. “We believe in a green energy future and by delivering the metals for new age batteries, we are making it happen.” Bradford has started his own personal journey to contribute to a greener future by adding a Tesla S to his beloved car collection, which he fuels from the solar panels on his roof. “That’s me making a difference, but it’s not me alone; there’s millions of people across the globe that want to make a difference to clean up the oceans and clean up the air,” he says. “This makes for a perfect storm for nickel.” Bradford believes there is going to be an explosion in EV demand brought about by consumer choices, with governments also helping to drive this evolving market through incentives such as those in China and the promotion of clean energy solutions. He also notes the difference in performance of EVs by using better quality batteries, further drawing people to nickel-powered batteries. With the Nova nickel-copper-cobalt mine in Western Australia’s Fraser Range, IGO is equipped to capitalise on this growing demand. IGO has doubled its exploration

WESTERN AREAS CHIEF EXECUTIVE OFFICER budget over the past three to four years, with 60 per cent of the AND MANAGING DIRECTOR DANIEL LOUGHER. funding focussed on greenfield sites, identifying hundreds of targets within the region. “We have a high conviction that there’s more Novas to be found,” Bradford says. “There is a belt that we think is prospective for Nova style discoveries that extends over a strike of some 420 kilometres. “That’s a huge distance and if you’ve been out there and seen the gold mine after gold mine and nickel mine after nickel mine, you’ll realise the sort of concentration that could be achieved.” It isn’t just what IGO is mining that is pushing the company towards a greener future, it is also the way it powers the Nova operation with a solar farm, which provides 15 per cent of overall power requirements to the site. This reduces Nova’s carbon footprint by 6500 tonnes annually and has inspired IGO to turn to other means of lowering its impact. “IGO is looking at the potential to change our diesel fire power station to natural gas, which would result in a further carbon footprint reduction of about 15,000 tonnes per year,” Bradford says. “We have also started to look at EVs underground and we will do our first trials with electric light vehicles this year.” Western Areas joins IGO as a Western Australian producer supplying nickel to support renewed global demand. The Perth-based company signed an agreement in January with China’s largest nickel matte and cathode producer, Jinchuan, to supply the mineral from the Forrestania mine. Western Areas chief executive officer and managing director Daniel Lougher is confident Australian nickel has a promising future, not just in batteries but also in other areas. “In terms of volumes, batteries

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APRIL 2020

COMMODITY SPOTLIGHT

WESTERN AREAS’ FORRESTANIA NICKEL OPERATIONS IN WESTERN AUSTRALIA.

make up about 6 per cent of the world’s nickel production,” Lougher tells Australian Mining. “The other side of nickel is its usage in stainless steel, which makes up about 70 per cent.” According to Lougher, stainless steel will continue to be the main product that Australian nickel is an ingredient for because of its noncorrosive properties. As well as being used in conventional areas such as construction, there is further growth on the horizon for stainless steel within the renewables sector – to build the structures required for alternative energy sources such as wind power. “When you start thinking about marine usage, such as for tidal energy or wind energy, all of these require big turbines,” Lougher explains. “These have to be made out of anticorrosive material, because seawater is extremely corrosive.” Although stainless steel remains the key market for Australian nickel, companies such as Western Areas are still keeping a close eye on EV demand and keenly anticipating its ramp up. Like IGO, Western Areas believes the ramp up of nickel mining in Australia will result in cleaner mining, which in the long run will also be more economic, despite the upfront costs. “We’ll have significantly less diesel trucks underground, which will obviously improve ventilation and require less cleaning,” Lougher says. “That will reduce the power that’s needed and provide cleaner air for mine workers.”

Western Areas is also upping its exploration expenditure, spending around $15 million on greenfield and brownfield exploration annually. “We are already picking up quite a lot of nickel,” Lougher says. “It may be in the lower grade, but the world grade is only slightly below 1 per cent. “We’ve got two of the best belts in Australia at Cosmos and Forrestania in terms of grades and past production, and one of the reasons that attracted us to buying Cosmos (in 2015) was the large underexplored areas of belt.” One of Western Areas’ exciting nickel assets is the Mt Alexander joint venture with junior company St George Mining, in which Western Areas holds a 25 per cent non-contributing interest. St George not only has highly prospective nickel, copper and platinum group metals opportunities within its portfolio, but also the advantage of shallow deposits, which are cheaper and easier to mine, according to company chairman John Prineas. He says the inevitable boom in demand for EV battery metals will change the structure of the normal commodity cycle. “There’s all new demand coming through for new, higher grade battery grade nickel,” Prineas says. “This is just the normal cycle of the commodity (but) the EV revolution is having a structural change to the whole nickel market and will change the cycle.” Prineas compares nickel’s resurgence to that of iron ore, which in the past AUSTRALIANMINING

was not an attractive investment proposal due to low prices until the Chinese construction boom emerged and prices shot up. He also recognises nickel’s role in stainless steel, noting the 5 per cent increase in demand for the metal from manufacturers of steel during the past 20 years. “That is still progressively going up but the real exponential growth will be from the electric vehicle and new energy storage demand,” Prineas says.

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APRIL 2020

With governments worldwide following China’s lead and bringing in laws mandating the use of EVs, such as the United Kingdom passing a motion that all vehicles must be electric or hybrid by 2045, Prineas is also confident about nickel’s future. “There is no substitute for nickel in these batteries,” he concludes. “It takes a while for new technologies to gain market share momentum, but we think the tipping point is coming close.” AM

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FUTURE OF MINING

HYDROGEN TO DELIVER TRUCKLOAD OF MINING BENEFITS THE MINING INDUSTRY IS SEEKING WAYS TO CAPITALISE ON THE POSSIBILITIES THAT HYDROGEN OFFERS. VANESSA ZHOU LOOKS AT WHAT COMPANIES ARE DOING TO UNLOCK THE POTENTIAL OF THE FUEL. REFUELLING OF A HYDROGEN FUEL CELL ELECTRIC VEHICLE WITH HIGH PURITY HYDROGEN. IMAGE: CSIRO.

ining is a challenging sector to decarbonise, but hydrogen shapes as a formidable part of the strategy to do so. McKinsey states that the sector alone produces between 1.9 and 5.1 gigatonnes of carbon dioxide equivalent of greenhouse gas emissions (GHG) each year. As a major contributor to Australia’s gross domestic product (GDP), technology and mining companies are racing to develop methods that decarbonise operations and maintain the industry’s modern integrity. An obvious method in this pursuit is to tap into renewable energy as a power source. Renewable energy is being adopted by mine sites around the world. In

Western Australia, Gold Fields (at the Agnew mine) and Fortescue Metals Group (at the Chichester Hub) are two leading companies moving towards a lower carbon future. As awareness of climate change grows ominously, McKinsey predicts that coal could be under the biggest threat of shifting mineral demand. But this may not be the case if the mining sector is quick to embrace coal as a vital element in carbon capture, utilisation and storage (CCUS). The Council of Australian Governments (COAG) Energy Council highlights that coal resources underpin the production of clean and affordable hydrogen at scale. Coal21 chief executive Mark McCallum reinforces the importance of coal, adding that all forms of hydrogen production will be needed as global demand for this “incredible AUSTRALIANMINING

energy source” increases. “Technology already in use around the world today can support the use of Australia’s significant coal resources to produce clean and affordable hydrogen at scale after gasification,” McCallum says. Large-scale production of hydrogen from coal will also be possible within the next few years in an Australian first. This will take place at the Coal21-backed CCUS Hub in Queensland, which is a $550 million low emission technology fund established by the Australian black coal industry. McCallum believes coal’s role in Australia’s affordable, reliable and clean hydrogen economy will be central to the country moving to a lower emission future and meeting the Paris Agreement emissions reduction goals.

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“Current cost estimates indicate that using coal with the carbon dioxide removed via carbon capture produces hydrogen up to 13 times cheaper than hydrogen produced by curtailed renewable energy sources, and up to three times cheaper than grid electricity,” McCallum says. The CSIRO roadmap from 2018 also highlights that hydrogen is one of those more likely to become economically viable in the short term compared with diesel. Coal21 chief scientist Alan Finkel, in a National Press Club address, adds, “By producing hydrogen from natural gas or coal, using carbon capture and permanent storage, we can add back two more lanes to our energy highway, ensuring we have four primary energy sources to meet the needs of the future – solar, wind, hydrogen from natural gas,

FUTURE OF MINING

and hydrogen from coal.” Kawasaki Heavy Industries’ construction of facilities in Victoria to liquefy and ship hydrogen to Japan is a leading example of how an economy for the fuel is forming and the role Australia has to play. The Japanese company plans to start exporting hydrogen from Australia in a trial by the second half of this year. Backed by the Australian, Victorian and Japanese governments, the project will produce hydrogen from brown coal mined from AGL Energy’s Loy Yang operation. Australian Gas Networks, as another example, plans to erect a $4.2 million hydrogen plant in Gladstone, Queensland this November. The plant will deliver up to 10 per cent blended hydrogen across the city’s 770 residential, small commercial and industrial customer base. Using hydrogen as a medium for renewable energy storage offers the potential to significantly reduce carbon emissions associated with power generation, CSIRO Energy’s leader, Hydrogen Energy Systems Future Science Platform, Daniel Roberts says. “The mining industry is wellsuited to using hydrogen as an energy source due largely to its reliance on large amounts of trucked-in diesel and the location of many mining operations in areas of high renewable energy availability,” Roberts says. CSIRO formed a partnership with iron ore major Fortescue in November 2018 that aims to capitalise on the economic opportunities associated with hydrogen and support the development of a competitive hydrogen industry in Australia. The partnership is part of a range of energy initiatives at Fortescue, including the $US700 million ($1.07 billion) Pilbara Energy Connect project which plans to enable

uptake of renewable power into the company’s network of iron ore operations. Fortescue chief executive Elizabeth Gaines says a portfolio of projects around hydrogen production, storage and use are also in development. They include generating and using renewable hydrogen at a large scale, as the company expects hydrogen to play a key role in its decarbonisation journey. “Fortescue believes hydrogen has the potential to play a key role in the future energy mix and we want to ensure that we capitalise on the economic opportunities associated with hydrogen and support the development of a competitive domestic and global hydrogen industry,” Gaines tells Australian Mining. “Fortescue’s development and adoption of innovation and technology has helped the company become one of the lowest cost producers of iron ore, and we are carrying this technology-first strategy into our hydrogen activities. “Our mobile fleet also presents an opportunity for hydrogen to have an impact on our emissions intensity and we are working closely with vehicle manufacturers to guide the development of zero-emission vehicles for the mining sector.” Fellow miner Anglo American is also leveraging hydrogen to power its mining equipment. The company has partnered with Williams Advanced Engineering to develop a hydrogen-powered ultra-class electric mining haul truck. “First motion” of the vehicle will be retrofitted with a total of eight FCveloCity-HD modules this year to replace the existing diesel engine. Anglo American will test the hydrogen-powered vehicle at the Mogalakwena platinum mine in South Africa during the second half of this year, after which the trucks

ANGLO AMERICAN HAS DEVELOPED A HYDROGEN-POWERED ELECTRIC TRUCK.

AUSTRALIANMINING

CSIRO’S METAL MEMBRANES ARE USED TO EXTRACT ULTRA-HIGH PURITY HYDROGEN. IMAGE: CSIRO.

are expected to be deployed at other operations. “Due to the large scale of mines, we are able to justify the investment in green hydrogen infrastructure and provide a better solution for the entire mine site power system to enable a move to net zero carbon emissions,” an Anglo American spokesperson says. “In the mobile application, hydrogen is well suited to the 24/7 activities at the site where production is paramount and asset utilisation needs to be very high. “We can now generate our own fuel on site, eliminating out reliance on importing fuels and decoupling ourselves from the oil price as we transition.” Across multiple industries, the move to hydrogen as a power source has been flagged as part of the strategy for decarbonisation. CSIRO Mineral Resources, Carbon Steel Materials, group leader Keith Vining says the organisation has set its short-term goal on hydrogen-based transport, thanks to hydrogen vehicle prototypes that

APRIL 2020

have been developed. Hydrogen is applicable to powering large passenger vehicles, medium-duty trucks for regional haul, passenger trains for regional transport and metals processing, as shown in the report, ‘Path to Hydrogen Competitiveness, 2020’ by the Hydrogen Council and McKinsey. “The availability of renewably produced hydrogen also has significant potential to reduce the carbon footprint of energy-intensive aspects of mineral processing, such as comminution,” Vining says. “Furthermore, it’s often overlooked that hydrogen is an excellent reductant for metallurgical processes, which could reduce the overall lifecycle of commodities beyond the mining process.” Technologies that are required to generate hydrogen on site, from solar or wind energy to replace diesel are already at a ready state, and in some cases, commercially available. The potential abounds for hydrogen as this environment emerges. AM

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MARKET OUTLOOK

WHY IRON ORE IS TIPPED FOR A BIG YEAR AMID AGGRESSIVE CHINESE STIMULUS AND VALE’S PLANNED RAMP UP IN BRAZIL, THE IRON ORE SECTOR IS SET TO ENJOY A FAVOURABLE LANDSCAPE IN THE FORESEEABLE FUTURE. VANESSA ZHOU WRITES.

alks of the coronavirus outbreak have permeated across international and domestic markets, not the least the iron ore industry in Australia. Globally, the mining sector has started the year positively, with the United States and China solidifying a trade deal that has boosted metal prices. Mining has enjoyed greater risk sentiment and general interest in commodities. That was, until coronavirus fears started infiltrating markets, according to Fitch Solutions senior commodities analyst Sabrin Chowdhury. Commodity prices, including that of iron ore fell as a result. But the iron ore sector has proven resilient with prices largely stabilising in February. This was in part driven by Brazilian major, Vale, which released its first quarter production guidance. “Vale is aiming to return to its previous production levels by the

end of this year,” Chowdhury tells Australian Mining. “During the first quarter, Vale announced it would not be able to meet the (quarterly) guidance, but it would still stick to the full-year guidance by picking up production in a faster rate in the coming years. “They also have an expansion going on, which will boost their production level for the coming year as well, pending regulatory issues.” The move has driven optimism into the market, allowing iron ore prices to bounce back from a short-lived slump, according to Chowdhury. Singapore-based Chowdhury also expects the Chinese Government to embark on a stimulus campaign in the infrastructure sector following the impacts of the coronavirus outbreak on the economy. This could act as indirect support for short-term steel demand. “Whenever there is an economic headwind such as the US-China trade war, it will leave a huge impact on the Chinese economy. The coronavirus

WHENEVER THERE IS AN ECONOMIC HEADWIND SUCH AS THE US-CHINA TRADE WAR, IT WILL LEAVE A HUGE IMPACT ON THE CHINESE ECONOMY. THE CORONAVIRUS DISEASE 2019 (COVID-19) IS SET TO HAVE A REALLY BIG IMPACT ON THE CHINESE ECONOMY AS WELL.”

disease 2019 (COVID-19) is set to have a really big impact on the Chinese economy as well,” Chowdhury says. “The Chinese Government has growth targets to meet – they’re already in a structural slowdown, and external forces impacting the country’s growth like the COVID-19 does require the government to implement strong, aggressive stimulus and (prevent) domestic industry from (curling under) further external pressure. “This is why Chinese production of steel was really high last year in order

FORTESCUE METALS GROUP’S CLOUDBREAK ORE PROCESSING FACILITY. IMAGE CREDIT: FORTESCUE METALS GROUP. AUSTRALIANMINING

APRIL 2020

to support domestic growth and boost the national gross domestic product (GDP).” China aims to double its GDP from 2010 by this year. This is good news for the Australian iron ore sector as greater steel production could fuel demand through the second half of 2020 if the coronavirus outbreak eases. The forecast growth could also last until next year given the flowon effects of this year’s performance, Chowdhury adds. Australia’s major iron ore producers could enjoy this market development,

MARKET OUTLOOK

with Tier 1 projects set to begin production over the next two years. They include Rio Tinto’s Koodaideri project, BHP’s South Flank project, and Fortescue Metals Group’s Eliwana project, all in the Pilbara, Western Australia. Both Rio Tinto and BHP expect to start production at their mega projects next year. The advanced technology that the global mining industry is set to witness at a mine such as Koodaideri will also determine who remains in the market and who loses out, according to Chowdhury. With the highest quality iron ore mines in Australia mostly owned by major miners, they are set to benefit from greater economies of scale. BHP, for example, boasts $US14 ($21.38) a tonne production costs compared with the average of $US30 a tonne among junior miners, according to Chowdhury. Many juniors could be forced to exit the sector in the coming decade, driving the “minimal” iron ore production growth that Fitch Solutions has forecast for 2020–2029 in Australia. The predicted average of 0.7 per cent growth a year pales in comparison to the 8.7 per cent growth over the previous 10-year period. Global iron ore production, too, is predicted to grow “modestly” from 2.896 billion tonnes to 3.147 million tonnes by 2029.

One thing’s for sure, with a spike in iron ore prices, new mines will come online and companies will lift their production to leverage a price rally, Chowdhury concludes. With iron ore demand set to remain buoyant in the near term, the global sector is in a position to watch another era of growth unfold as supply remains strong. But the relationship with China will remain critical. Fortescue chief executive Elizabeth Gaines reinforced the importance of the strong, long-term relationship with China in a February speech, saying it has undoubtedly underpinned the success and longevity of the trading partnership with Western Australia. “China has been Western Australia’s largest market for exports since 2006 and last year this was valued at $81.4 billion,” Gaines says. “Western Australia is the largest source of iron ore for China, which in 2019, produced a record 996 million tonnes of crude steel as it continues on its path of urbanisation and development. “It is critical that we all have a strong narrative about Australia’s relationship with China, which reflects the experience of the resources sector specifically, and (Western Australia) more broadly.” With Fortescue on track to launch its Eliwana project this year, the Perth-based company, for one, looks sets to strengthen this relationship over the coming decade. AM

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RESEARCH & DEVELOPMENT

PARTNERS IN PRODUCTS, SERVICE AND TECHNOLOGY A VISIT BY BRIDGESTONE’S VICE PRESIDENT FROM JAPAN TO ROY HILL’S IRON ORE PROJECT HAS HIGHLIGHTED THE COMPANY’S INTENTION TO ASPIRE TO OFFER THE BEST FOR ITS CUSTOMERS BY LISTENING AND WORKING DIRECTLY ALONGSIDE THEM. THE CONVEYORS PLAY A KEY ROLE IN THE ROY HILL MINE HITTING ITS PRODUCTION TARGETS.

he Roy Hill iron ore project in the Pilbara might seem like a strange place to see Hiroshi Harashima, vice president of Bridgestone’s diversified products development and production technology. However, a visit to the Roy Hill Pilbara iron ore site has given Harashima-san an indepth understanding of whether conveyors are operating at optimum efficiency in Pilbara conditions and how Bridgestone’s research and development (R&D) department can contribute to continual improvement. “Part of Bridgestone’s foundation is to practice ‘Genbutsu-Genba’ decision-making based on verified onsite observations,” Bridgestone conveyor belt senior specialist Brian Farwell says. “We then use these observations to make informed decisions. It’s about not being satisfied with the current situation and making informed decisions that will lead us ever closer to ideal products and solutions. “We also practice ‘Kaizen’. This refers to activities that continuously improve all functions of our business and involves everyone.” Harashima-san’s trip down under exemplifies the personal commitment to product development, creative pioneering, improving processes, integrity and teamwork. It forms part of the company’s strategy to work literally alongside customers to ramp up innovation and boost the productivity of conveyors by providing strong service and support.

The development of a closed loop communication cycle is allowing information onsite to be fed directly back to the global R&D and product development teams, allowing Bridgestone to tailor continual improvement. “We have major contracts with our customers, so our focus is to actively engage with them to understand their pain points and work together to produce positive outcomes in all operational aspects of conveying,” Farwell says. Bridgestone’s ultimate aim at Roy Hill is to increase the life and reliability of the conveyor belts, which are imperative in delivering a site that produces 55 million tonnes per annum, and beyond to 60 million tonnes. “The success of our business is directly proportional to how consistently we are able to improve our products. There are some conveyor belts that require frequent changes, so if we can extend the life of our belts there are huge operational benefits to our customers,” Farwell says. While Bridgestone products have been used on the Roy Hill sites since inception in 2014, a recent contract has solidified the relationship, with Bridgestone to supply products and services to the ports and mines. Bridgestone’s manager of its Pilbara Mining Solution Centre in Port Hedland (PMSC), Michael Guilfoyle, says the close relationship with Roy Hill has benefited both parties. The PMSC that opened in 2017 is in convenient proximity to the Roy Hill site, again emphasising the company’s increased focus on working AUSTRALIANMINING

with its customers. “We are able to help Roy Hill’s strategic supply and growth over the next few years so that they can not only secure a supply of equipment, but also have the knowledge and safety of a factory facility like we have in Port Hedland,” Guilfoyle says. Guilfoyle emphasises that this sentiment is captured by a visit that the company’s Japanese executives made to the Roy Hill site. “The objective was to figure out how we can align factory services to suit the site,” he says. “The secondary goal was to take recommendations back to the factory to enhance our tailor-made solutions on offer specifically for Roy Hill.” The ultimate goal is what Guilfoyle describes as a “direct line” to Japan, ridding Bridgestone of any miscommunication that can occur in the process. This provides Bridgestone’s engineers with a direct line of communication with its customers, therefore feeding the company’s factories with principal information. “Our engineers have a total

understanding of any issue and can review their model to suit where possible, so the customer receives an outcome that meets expectations – this process eliminates any possibility of issues lost in translation and misconceptions,” Guilfoyle says. Bridgestone is proactively being challenged within the company to drive innovation through its R&D to achieve peak efficiency for Roy Hill’s conveyors. As Guilfoyle points out, conveyors specifically require improvements to be tailored towards a customer’s individual preference. “Our R&D team is constantly working to improve our products. Our aim is to increase the operational productivity at Roy Hill,” he says. “Unlike other products that are made to suit a vast number of machines, conveyor belts are made specifically for customers, therefore, customer’s input is vital.” The logic is emblematic of Bridgestone’s approach to forming close relationships with its customers and partnering with them to innovate and optimise products onsite. AM BRIDGESTONE CHALLENGES ITS R&D DEPARTMENT TO OFFER INNOVATIVE PRODUCTS TO ROY HILL.

APRIL 2020

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COMMUNITY INTERACTION

BHP, WEST COAST TAKE NEXT GENERATION UNDER THEIR WINGS THE MINING INDUSTRY HAS LONG BEEN A CONTRIBUTOR TO THE LIFEBLOOD OF WESTERN AUSTRALIA. FOR BHP, THAT COMMITMENT GOES BEYOND THE SECTOR WITH ITS WEST COAST EAGLES PARTNERSHIP.

he powerful combination of a major mining company and an AFL club has proven to be a vehicle for social connection in Western Australia. Dotted throughout the state’s landscape are countless young people living in remote areas who do not have access to the same benefits of children living in metropolitan Perth. The West Coast Eagles endeavour to bridge that gap by visiting more than 150,000 youths located in regional Western Australia every year. BHP has been working with the West Coast Eagles for over 15 years to help deliver free community engagement programs for boys and girls of all ages. With Australian Rules as its backbone, these programs help multicultural and Indigenous teenagers meet new people, make friends and stay active. On any afternoon, West Coast Eagles coaches could be taking more than 50 Indigenous and multicultural youths through the steps of how to play football. The majority of them may have never crossed paths before the program started, but they now share a newfound bond by learning about one another. Many of the boys and girls are so isolated that they rarely get a chance to make contact with wider social networks. This football program is an

example of the opportunities made possible for young people who are just trying to find their place in the world. West Coast Eagles general manager of community and game development Richard O’Connell is the person responsible for the West Coast Eagles community engagement program, which helps young people connect and engage at a level not possible where many of them come from. “The programs we run across Western Australia are all team based, promoting the importance of working together towards a shared goal. They may come from different walks of life but once the jumper is on we are all members of the same team – fostering a sense of belonging,” he says. “At many of the sessions or the games we include organisations such as Mission Australia whose youth workers are available to the youth to strike up a conversation. “We recognise that many of the issues these young people face are complex and thus it takes a team approach to make real change.”

Generosity from the club’s elite

West Coast aims to ensure young people in rural areas have the same access to the programs as those living in metropolitan areas, with the team behind the program travelling more than 110,000 kilometres each year. “BHP and the West Coast

EAGLES AFLW PLAYER, TARNEE TESTER. AUSTRALIANMINING

WEST COAST EAGLES STAR, NIC NAITANUI.

Eagles commenced an innovative partnership in 2004 which focussed on incentivising students in the Pilbara to attend school,” BHP corporate affairs state manager Meath Hammond says. “Since then we have worked closely to accelerate inclusion and diversity related social outcomes, by underwriting the cost of attending the Naitanui (and Female Academy) programs to ensure access is available to all walks of life, no matter what economic situation the family faces.” Eagles star Nic Naitanui is one of the figureheads for the club’s community programs. With the help of West Coast life member Kim Hannah, the 2012 All Australian ruckman founded the Naitanui Academy, which aims to engage aspiring multicultural footballers. What started as an idea soon turned into a reality when Hannah – who is a former teacher that has worked in schools and football for over 40 years – supported Naitanui’s vision to develop community programs for youths. Naitanui was once one of the many kids who experienced the challenges of feeling like an outsider in a

APRIL 2020

football-crazy state. The proud Fijian moved from New South Wales to Bassendean, Western Australia, where he met and became friends with many Indigenous people. “I recognise that I am able to leave a lifelong legacy by supporting young people to make good choices. It’s easier if you are surrounded by good people. They feel supported and there are people to turn to for advice – a team mate, a coach or a friend,” Naitanui says. “It sounds pretty simple but sadly too many young men and women don’t have this support. I’m grateful that BHP shares my passion for helping do good. Without their support we couldn’t make this a truly inclusive program.”

Eagles stories

The club is set to continue telling the unique individual stories that have impacted its community programs over the past year in a special content series called Eagles Stories. It will also feature inspiring tales from several AFL players, AFLW athletes and dedicated West Coast Eagles fans. AM

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MINERALS PROCESSING

MINPROVISE PROCESSES A TOTAL PACKAGE FUTURE WITH MINPROVISE’S ALL-ENCOMPASSING SKILLS IN MINERALS PROCESSING, IT IS NO SURPRISE THAT THE COMPANY IS CHASING A BIGGER GOAL: TO BE AN END-TO-END SOLUTION PROVIDER.

inprovise is on track to make project execution easier and smoother for its clients in the mining, oil and gas, and infrastructure industries. The specialist equipment and services provider is in the process of consolidating its expertise through the establishment of its new Project Services division. Minprovise has built a solid pipeline of on-site maintenance, shutdown work and fabrication jobs since founder Graham Townsend established the company in 2004. The company initially focussed on the installation, maintenance and shutdown services of crushers, before expanding its expertise into other areas of fixed plant including apron feeders, screens and belt filters. Minprovise further increased its product and services offering by partnering with original equipment manufacturers (OEMs) to supply equipment, parts and products that were complimentary to the current suite of services. “Our skills grew as the number of people in the business grew,” Minprovise’s executive general manager, projects and valueadded services, Nino Fasolo tells Australian Mining. It is now within the company’s capacity to integrate these strengths into a broader solution offering for its existing clients, enabling increased efficiency and productivity for projects. The company has enjoyed rapid expansion over the past 12 months and Minprovise’s long-term strategy of providing an end-to-end solution for clients has led to the creation of the Project Services division to further support this growth. “We decided to go top-down: What do we need to do to set up a new business division?” Fasolo explains. “We appointed an accomplished projects director and went on to create an organisation structure that encompassed the skills and expertise required to deliver an end-to-end solution to our clients.

IRON ORE MINE EXPANSIONS HAVE GUIDED AN OVERWHELMING NUMBER OF REQUESTS FOR QUOTES FROM MINPROVISE.

“This has included the appointment of an engineering manager and execution managers, and we are employing mechanical, structural and electrical experts to sit within these sub-divisions who will be responsible for launching the projects won by the company, on time and within budget. “Minprovise has such a nimble management team. We have an entrepreneurial way of thinking that feeds off how our owner Graham Townsend has conducted the business since 2004. “We tend to think and act pretty quickly, including the way we’re setting this division up for success. We have all the resources to back what we promise to deliver.” Minprovise’s new division complements and builds on its core capabilities and services. “With the number of projects coming online and various expansions being considered in the Pilbara, the demand in the market to provide project services, equipment and products has increased,” Fasolo says. “This (high demand for quotes) is actually the biggest challenge we’re facing right now, where we are AUSTRALIANMINING

responding to quotes on a daily basis.” Even taking into account the high demand, there is no doubt that Minprovise is fully equipped with skilled employees and the appropriate tools to meet clients’ needs. Minprovise has an edge over competition with its ability to offer design, engineering, supply, fabrication, installation and commissioning services and on-site maintenance all in-house. This also enables Minprovise to offer build, own and operate plants on the basis of a cost per tonne arrangement. The Project Services division will oversee and execute these projects. With any growth within an organisation comes an ongoing need for diligence in health and safety practices and procedures, which Fasolo says Minprovise is prepared to stay on top of. “We’re proactive in all levels of the business, to the extent of our executive team dedicating a lot of their time in the field to ensure that people stay safe and are compliant with health and safety regulations,” Fasolo says. Minprovise is not only capable

APRIL 2020

of winning bigger projects that require a safe delivery of end-to-end solutions, but is also geographically advantaged with branches throughout Western Australia. The organisation now boasts four major locations across the state, with three business divisions and workshops in Perth’s industrial hub of Welshpool and a fourth in Karratha for Pilbarabased projects and time efficiencies. These locations each consolidate and expand on Minprovise’s continually growing list of capabilities, with corrosion control, abrasive paint and blasting and scaffolding hire services as new additions in the last six months. Fasolo is optimistic about Minprovise’s prospects for the rest of 2020. He foresees “a lot of growth” ahead for the company as the concept of the new division gains traction. “There are a lot of projects that we’re working on at the moment – a lot of industry expansion in the infrastructure side of things – positioning Minprovise as part of that growth,” Fasolo says. “I’m confident we’ll pick up our fair share of those projects going forward.” AM

MINERALS PROCESSING

THE COAL INDUSTRY’S PATH TO A LOW CARBON ECONOMY THE DISTANCE BETWEEN AUSTRALIA AND SWITZERLAND HASN’T STOPPED SEFAR FROM TAKING ITS MANUFACTURING TECHNOLOGY UP A NOTCH WITH FILTER MEDIA SOLUTIONS THAT ADDRESS TODAY’S CHALLENGES.

hen it comes to climate change, coal miners are pushed into a state of kaizen, a Japanese term that creates a culture where companies benefit from continuous improvement of all functions. Kaizen is not purely about a switch to electric equipment or renewable energy, but also sustainable practices in minerals processing. After all, the environmental friendliness of every process counts towards a company’s low carbon economy, an idea that is still farfetched to some. A coal producer in New South Wales managed to achieve this improvement while experiencing a lift in production. The company made use of ready-touse filter belts that were developed by Switzerland-headquartered Sefar for tailings dewatering applications. This move eliminated the company’s downtime as the belts lasted longer than the previously-used products, while allowing the coal miner to achieve its target levels of cake moisture content and increase capacity. “We often talk about total cost of ownership, taking into consideration the initial cost of the product, plus factors such as a reduction in downtime due to an increase in service life and efficiency improvements in the overall filtration process,” Sefar Oceania minerals market manager Max Riboni says.

SEFAR CONTINUES TO INVEST IN THE BEST TECHNOLOGY AVAILABLE.

“In this case, the coal producer was able to reduce the number of belts due to an increase in service life and throughput. This also helped to reduce the downtime and service costs significantly.” Sefar provides customised filtration solutions for all main types of filtration equipment used in the coal industry, and it is able to do so due to its ownership of technologies that play a vital part in the product manufacturing process. In fact, technology development has been the biggest driver at Sefar throughout its 190-year history, according to Riboni.

SEFAR’S FILTRATION MEDIA SOLUTION FOR ROTARY DRUM FILTERS.

AUSTRALIANMINING

“Sefar continuously invests in innovation and research and development (R&D) to be able to offer competitive, tailor-made solutions based on the customer’s requirements,” he says. “Sefar produces technical fabrics from start to finish. Only Sefar controls the entire process, vertically integrated, from polymer to yarn, to weaving, finishing and fabricating the final filter product.” This allows Sefar to be fully in control of the product quality and being able to offer a consistent product quality. With fabrication plants and a fully integrated supply chain across 26 countries, Sefar is now the leader in monofilament filter media manufacturing. Its cloths are a top performer in the areas of separation efficiency, residual cake moisture and abrasion resistance. “We help our customers to be successful and competitive in their market, leveraging on our strong technical knowledge. The members of the global minerals core team meet on a regular basis and exchange experience and knowledge amongst the team,” Riboni says. Sefar’s filter media solutions are today used in coal, alumina, copper, gold and lithium mineral processing plants, to name a few.

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Companies can use Sefar fabrics in both fine and tailings dewatering, whether it be applied to a rotary disc filter, filter press, belt press filter, rotary drum filter or horizontal vacuum belt filter. “With the atmosphere surrounding the coal industry right now, coal producers are required to meet certain emissions standards,” Riboni says. “We’re working in conjunction with our customers to try and achieve their key performance indicators with materials and product designs that are more durable, increase efficiency levels and lower the overall footprint.” Sefar Oceania was established in 1968. Its six sales regions cover Australia, New Zealand and the Pacific Rim. Sefar locally stocks an extensive range of products in its Sydney, Perth and Auckland warehouses to service its customers and reduce their needs and costs of on-site inventory. “Coal, as far as the environment is concerned, is still going to play a big part in energy supply for many years to come,” Riboni concludes. “We are determined to do our part to make coal production as efficient and clean as possible and to help our customers and the world to reduce the carbon footprint.” AM

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MINERALS PROCESSING

MINERALS PROCESSING IN THE DIGITAL AGE BRADKEN IS WORKING ON A DIGITAL SIMULATION MODEL THAT HAS POTENTIAL TO REVOLUTIONISE THE WAY GRINDING MILLS ARE DESIGNED AND OPERATED. TARA HAMID WRITES.

perational efficiency and sustainability are prime focus areas for the mineral processing industry. Comminution, the process whereby rocks are crushed or ground into smaller fragments, is one of the most energy intensive processes on a mine site and poses a risk to achieving peak performance in these areas. Bradken, a global provider of wear solutions, is working on a digital solution that will facilitate better liner designs for grinding mills, in addition to a myriad of other benefits for operators. As part of a research collective led by the University of Newcastle, the company has been awarded a research grant worth over half a million dollars by the Australian Government to create a digital twin of the grinding mill. Bradken’s global research and development manager Reece Attwood says the potentially game-changing project will give global mining and resources operators the ability to precisely target grinding efficiency, mill liner service life, power consumption and carbon emissions, to optimise their operations. “In the past few years our investment into simulation technology and the opportunity to refine and trial designs in that environment has helped improve efficiencies, but also demonstrated the importance of validation of such models,” he tells Australian Mining. “With good inputs for simulation

we can short cut the design cycle and optimise the customer’s operations more effectively and sustainably. This search by our engineers for accurate and measurable data is what has driven the initiation of this research project.” The project will be hosted by the University of Newcastle’s Institute for Energy and Resources (NIER), in collaboration with the University of New South Wales and the Commonwealth Scientific and Industrial Research Organisation (CSIRO), as well as international involvement from Delft University of Technology in the Netherlands. It will combine a number of technologies, such as Internet of Things (IoT) instrumentation, enhanced simulation techniques and deep learning. Attwood says good quality simulations can allow Bradken’s design engineers to trial solutions and optimisation options, to refine the final design and best understand the advantage each change has on the total mill operation before being sent to manufacturing facilities.

Maintenance benefits

The simulation tool will benefit machine maintenance and upkeep, in addition to enabling the engineers to improve the design of existing and new grinding mills, according to Attwood. “A simulation is only as good as the quality of the outputs, and any small modelling error can have a significant

BRADKEN RESEARCH AND DEVELOPMENT MANAGER REECE ATTWOOD.

AUSTRALIANMINING

BRADKEN IS WORKING ON A DIGITAL SOLUTION THAT WILL FACILITATE BETTER LINER DESIGNS FOR GRINDING MILLS.

impact on the quality of predictions,” Attwood says. “One of the key focus areas for this project is to reduce those errors as much as possible, meaning higher confidence process control and maintenance planning.” Bradken’s existing preventive maintenance service to customers, known as ‘Vision Insight’, provides predictions on the remaining useful life of liners. While accurate by today’s standards, Attwood says these predictions are based on empirical data and subject to confidence error that needs to be managed. “Precise simulations will help us to pinpoint remaining useful life and assist the customer to optimise shut scheduling – to get more from their liners,” Attwood continues. Bradken has already used this simulation technology to understand where opportunities for improvements are found. The company has created products in collaboration with its customers using this simulation technology to help them hit their targets. Attwood says Bradken recently demonstrated the improvements on a 40-foot semi-autogenous grinding (SAG) mill for one of its customers. “Through design optimisation and validation with simulation technology, Bradken proposed a new mill layout and bullnose products that brought about a 25 per cent reduction in the number of bolts to secure the liners, as well as a 33 per cent reduction in the total number of liners,” Attwood says.

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BRADKEN SENIOR RESEARCH SCIENTIST – PROCESS CONTROL DR WEI CHEN.

“The improvements increased the mill availability and provided an additional 15 hours of grinding.” Attwood says the scope of the simulation project is broad and can, in the future, be developed to feed data into advanced process controls. “There is always room for improvement in the minerals processing sector. For example, IoT and artificial intelligence (AI) are not new concepts. They are now buzz words because our ability to capture and process data has improved, and they will continue to improve into the future,” he concludes. “It is the application of those technologies in new and innovative ways that will yield ongoing significant impacts, and that is what we are doing with this project – the application of machine learning as we are proposing to do has not been done before. We are excited to see the result.” AM

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MINERALS PROCESSING

THE PURSUIT OF HIGH TONNAGE PRODUCTION RATES HAVER & BOECKER NIAGARA HAS DEMONSTRATED THAT WHEN IT COMES TO VIBRATING SCREENS, SIZE IS KING. THE CAPACITY OF THE COMPANY’S SCREENS IS BACKED BY ITS MULTI-CENTURY HISTORY.

ustralia’s mining industry continues to attract the attention of equipment providers from across the world. The potential in Australia is enough that mining suppliers have gone on to establish a local presence in the country. A family-led and mid-size company like Haver & Boecker Niagara has joined this movement. The manufacturer of screening machines boasts manufacturing facilities in Germany, Brazil and Canada. To grow even further, the company chose the mining mecca of Perth in Western Australia as its next international base last year. Australia offers the company “huge potential” for its massive mining sectors, including coal and iron ore sectors, according to Haver & Boecker Niagara marketing manager for North American and Australian operations, Kristen Randall. “We looked at the huge potential and knew we had to have a base in Western Australia. We need to service our Australian clients with a team directly located in the country,” Randall tells Australian Mining. “The need in Australia fits with our capabilities very well, given that mining companies in the

country face greater production demand that requires high capacity screening technology.” With almost 150 years’ experience, Haver & Boecker Niagara has grown its people, operations and capacity. A company that started by producing woven wire products in the late 1800s diversified into producing vibrating screens in the 1930s. Nearly a century later, Haver & Boecker Niagara’s vibrating screens are designed to fulfil and exceed customers’ requirements. The Niagara XL-Class vibrating screen is able to handle up to 15,000 tonnes an hour on a screen surface of 4000 by 11,000 millimetres within an extreme temperature range of -45 to 85 degrees Celsius. “One successful case is the development of an asymmetrical exciter-driven vibrating screen dedicated for high natural moisture iron ore,” Haver & Boecker Niagara vice president, engineering and technology for North American and Australian operations, Dieter Takev says. “This equipment uses dry screening and an elliptical motion at high acceleration instead of common use of wash water to remove the fines, eliminating the needs of tailing dams.” To date, Haver & Boecker Niagara has supplied more than 390

THE NIAGARA XL-CLASS VIBRATING SCREEN BOASTS LARGE DECK SIZES TO MAXIMISE FEED RATES.

AUSTRALIANMINING

THE NIAGARA XL-CLASS VIBRATING SCREEN IS SUITABLE FOR CLASSIFYING, SAG MILL SCREENING AND DEWATERING APPLICATIONS.

specialised high capacity vibrating screens to the global mining market. Haver & Boecker Niagara provides an option for the Australian mining sector to increase production rates at lower cost per tonne using larger equipment. The company has also advanced equipment performance and improved uptime by developing its own screen media to meet unique screening demands. This detailed consideration starts from the design phase, which is initiated by a thorough analysis of the screening task at hand. “Computer simulation of the process with Haver & Boecker Niagara’s NIAFlow software helps us determine the size and type of equipment, as well as features required to perform optimal screening,” Takev says. “In many cases that leads to a unique configuration and a tailormade design process starts. Finite Element Analysis (FEA) is one of the essential tools we employ for all high capacity vibrating screens. “Screens are tested with strain gauge measurements and experimental modal analysis is used

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to validate the dynamic stress and natural frequencies of the FEA.” Still, Haver & Boecker Niagara doesn’t stop with developing equipment that boasts a distinct high capacity for screening mining materials. The company complements the equipment by analysing data from the vibrating screens. The Pulse Vibration Analysis system uses unique hardware and software, as well as advanced signal processing algorithms to detect abnormal behaviour. “Our extensive knowledge and experience with vibrating screen equipment have led to the development of an online accessible database for vibration data that also provides the function to generate a comprehensive vibration analysis report,” Takev says. The system is designed to provide results fast and the measurement and evaluation of data is drastically simplified. No special knowledge is required to perform a measurement, and the report is generated in under 15 minutes. Haver & Boecker Niagara has arrived in Australia with a full package to offer. And the industry’s pursuit of increased tonnes and efficiency may just be closer to the mine gate than ever. AM

MINERALS PROCESSING

RAISING THE BAR FOR RUBBER LINING WEIR MINERALS HAS LAUNCHED A NATIONALLY ACCREDITED VOCATIONAL RUBBER LINING TRAINING COURSE TO MAKE SURE THE QUALITY OF WORKMANSHIP REMAINS ON PAR WITH THE QUALITY OF ITS PREMIUM RUBBER PRODUCTS.

ining and aggregate operators rely on quality rubber lining to protect their equipment from abrasive materials. While a properly lined steel pipe can easily pump highly abrasive slurry for 12 months or more, the same pipe is likely to wear out in less than a week without rubber lining. Rubber lining is a highly specialised task that requires experience and proper training. Even when the best rubber compounds are used, poor quality workmanship can compromise the overall quality, risking damage to the equipment. In Australia, there hasn’t been any systemic program for training rubber liners available to date. Most of the people currently performing rubber lining were trained by their respective employers, some of which do not always follow rubber-lining best practices and industry standards. This results in poor surface preparation and premature failure of the equipment. As a manufacturer of rubber compounds (including industry leading Linatex rubber) for nearly a century, Weir Minerals wanted to make sure that well-trained rubber liners were readily available to handle their projects. To this end, Weir Minerals has introduced the first governmentcertified program for rubber liners in Australia. The course will provide trainees with an informed and structured program under the

FOR THE FIRST TIME IN AUSTRALIA, WEIR MINERALS IS PUTTING RUBBER LINERS THROUGH A STRUCTURED TRAINING COURSE.

guidance of an experienced rubber lining instructor. To create the program, Weir Minerals worked together with a registered training organisation to develop a national certification program for rubber lining, officially called Certificate III in Surface Preparation and Coating Application. Over 90 per cent of the course is focussed on rubber lining, to ensure the trainees graduate with a specialised rubber liner skill set. Weir Minerals quality assurance &

RUBBER LINING IS A HIGHLY SPECIALISED TASK THAT REQUIRES EXPERIENCE AND PROPER TRAINING.

AUSTRALIANMINING

training officer Darryl Crawford, who contributed to the program, says it is based on the company’s standards for rubber lining, which take into account all relevant international standards. “I have been rubber lining for 16 years. From my very first day in the workshop, I knew that to find knowledgeable and efficient rubber liners was an issue. As time has passed, many of the old rubber lining experts have retired; there has been no transfer of knowledge, and the issue is slowly getting worse,” he tells Australian Mining. “The skill level shortfalls were evident: quite often rubber liners were only taught to cut, buff and stick the lining material without any training on surface preparation and other critical techniques and procedures.” According to Crawford, the training will provide trainees with an informed and structured program under the guidance of an experienced rubber liner, who teaches every aspect of quality rubber lining as per the required standards, methodologies, techniques and procedures. “It will ensure that Weir Minerals rubber liners will have the best knowledge and skill set within Australia, and over time internationally as our training program is being rolled out globally within

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Weir Minerals,” he says. While Weir Minerals already has a fleet of well-trained rubber lining experts, the company is putting the existing team through the same training program, along with the newly enrolled employees to ensure a unified skillset is available. By the start of 2021, Weir Minerals will have over 34 trainees at different stages of certification in Australia. Weir Minerals global product manager – rubber, Mark Doyle, is confident that the initiative will benefit the end customer. “The Weir Minerals rubber liners often get asked to strip and reapply rubber lining after someone else’s incorrect application and poor workmanship,” he says. “Such shortcuts to get the equipment up and running end up costing the customer double. “We want to ensure that our customers get the best value for the money they pay for premium products such as Linatex Premium Rubber and that we offer them services of over 30 Weir Minerals rubber liners throughout Australia. “Weir Minerals wanted to create a minimum standard of quality of rubber lining in Australia, so that our customers get a known outcome, every time.” AM

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MINERALS PROCESSING

ALFA LAVAL SOLID BOWL CENTRIFUGE TECHNOLOGY MAKES TAILINGS DAMS REDUNDANT AS AUSTRALIA’S WATER SUPPLIES CONTINUE TO PLUMMET, MINING COMPANIES ARE SEARCHING FOR NEW WAYS TO PROCESS MINERALS WITHOUT USING A TAILINGS DAM. ALFA LAVAL OFFERS AN ANSWER TO THIS NEED WITH ADVANCED DEWATERING SOLUTIONS.

ALFA LAVAL’S SKID MOUNTED SOLID BOWL CENTRIFUGE.

amid Foroush is a technical support engineer at Alfa Laval and is one of the many brains behind the company’s solid bowl centrifuge technology. The machines provide a new way to dewater tailings, allowing mineral processing plants to reuse tailings water. Solid bowl centrifuges provide an economically and environmentally friendly solution to dewatering tailings dams. Alfa Laval has a significant installed base for its solid bowl centrifuges with large machines currently being used by mining companies across Australia and in other large mining regions around the world. “We’ve got several machines installed and commissioned in Queensland and New South Wales, for coal tailings application as well as a number of units in WA for

mineral processing,” says Foroush, who has just finished trialling the technology’s next generation. “A solid bowl centrifuge is a type of equipment used for dewatering tailings. We normally get the slurry from one point of the machine. The slurry contains suspended solids with water. Alfa Laval’s unique technology separates the solids from water using centrifugal force. As a result, the solids come out from solid discharge and the liquid from liquid discharge.” Larger solid bowl centrifuge machines can spin slurry at up to 1600 revolutions per minute (RPM) when processing coal tailings. The speed allows the solids to separate from water – removing the need to wait for water to evaporate in a tailings dam. “The water which is recovered could be used for processing – it can just be pumped back to the plant for reuse,” Foroush says. Not only is the technology effective in reducing how much water is AUSTRALIANMINING

wasted, but it also has the potential to save costs during the rehabilitation process of a mine. “With the current practice of pumping slurries into a tailings storage facility (TSF), the rehabilitation costs are huge at the end of mine life for mining companies,” Foroush says. “If the customers already have some other technologies for dewatering, it still pays to compare. Our technology usually consumes less polymer, has smaller footprints, and operates with an enclosed process that is fully automatic. Also, solid bowl centrifuge technology works better for finer particles where filters struggle.” Foroush says the speed and efficiency of solid bowl centrifuge technology makes it a better choice for tailings dewatering. “The dewatering stations within solid bowl centrifuges have a very small footprint compared to belt filter press, and belt and frame press, and can make tailings dams completely

APRIL 2020

redundant or add critical capacity as new TSF licences are harder to come by. Normally the life expectancy for our machines is between 25 to 30 years,” Foroush says. “If you use tailings dam you will lose water through evaporation because it might take several weeks for the solids to settle. “But if you use solid bowl centrifuge technology, you will recover the water instantly and you can use it straight away in the plant. We’re seeing customers in Australia that are able to re-use 80–90 percent of their process water in the plant, thanks to Alfa Laval solid bowl centrifuges.” Foroush says Alfa Laval Australia has a design for full scale skid mounted solid bowl centrifuge which could be used for trials as well as an interim solution for sites where tailing dams are reaching its capacity. “Our trial unit allows customers to see the operational benefits and results firsthand before committing to a full-scale deployment,” he says. Safety is another important factor when processing minerals. As pressure to improve safety and operational performance increases, major mining companies are looking to eliminate tailings dams and move towards what they call “dry stacking” or “dry disposal” of tailings. Foroush explains that Alfa Laval’s solid bowl centrifuges discharge solids as a cake with a low moisture content that can be dry-stacked, and used for mine rehabilitation in a similar fashion to overburden and coarse rejects. “Depending on the mineral being processed and other parameters such as solids density and particle size distribution, the cake moisture ranges from 15-40 percent,” he says. With solid bowl centrifuge technology, mining companies have the opportunity to move away from storing slurries in dams and lower the risks associated with TSF. AM

CMY

MINERALS PROCESSING

FENNER DUNLOP ELECTRIFIES AUSTRALIAN MINES FENNER DUNLOP IS A VALUED SUPPLIER OF MATERIALS HANDLING, MECHANICAL AND ELECTRICAL SERVICES FOR MANY AUSTRALIAN MINING COMPANIES. HOWEVER, THE COMPANY CONSIDERS ITSELF TO BE MORE OF A PARTNER THAN SUPPLIER.

ince acquiring Australian Conveyor Engineering (ACE) in 2012, Fenner Dunlop has become recognised for a service portfolio that includes ACE’s 25-plus years of experience in conveyor design, manufacturing and installation abilities. Fenner Dunlop ACE regional manager for New South Wales Shane Wilson says an aspect of the company that sets it apart from competitors is having both the in-house electrical and mechanical engineering teams working collaboratively. “We work together at the same location to ensure a complete customer engineered solution is provided,” Wilson tells Australian Mining. “We don’t look at the problems or projects individually, we work collectively to ensure we produce the best outcome for the customer. “ACE has been manufacturing electrical solutions for the industry over the past 15 years. These solutions include both hardware and control systems to ensure reliability, market advances and user operability are included in the final solution.” The company used this process when working with a New South Wales coal mine, building not only a positive working relationship, but also helping the mine to improve productivity during all phases of the mining process. “In mining when an outbye conveyor

is stopped, all inbye conveyors are also stopped,” Wilson explains. “An outbye conveyor could stop due to belt tracking issues, a belt rip or equipment inspection, which can cost 10 to 20 minutes of productivity each time depending on the site. “While this doesn’t sound like much on its own, it quickly adds up. To combat the loss of production in these times we have implemented systems to ensure we can continue to maintain coal on these belts until it reaches the conveyor that has stopped.

“This provides the longwall development an opportunity to continue to produce, which reduces start up times whilst enabling some production to continue, especially when the stoppage is a short one. “This enables coal processing to continue rather than coming to a standstill.” In addition to increased productivity, Fenner Dunlop has developed solutions to improve both safety and productivity for the industry using its electrical solutions.

FENNER DUNLOP’S ANCILLARY STARTERS CAN BE OPERATED INDEPENDENTLY OR INTEGRATED WITH EXISTING EQUIPMENT.

AUSTRALIANMINING

APRIL 2020

One example that Fenner Dunlop has developed is an online thickness tester, a unit that allows remote monitoring of the cover belt over the entire length and width for the conveyor belt. This means rather than having people manually measure the belt cover thickness, there is a permanent monitoring system that removes workers from the equation. The data is remotely monitored and reports are provided to the customer. Conveyor belts are considered one of the most dangerous areas on a mine site, due to the sheer number of moving parts, and trip and slip hazards, particularly in poor environmental conditions. “We spend a lot of time designing how we assemble our equipment to ensure that maintenance or repairs can be completed practically and safely,” Wilson says. “We have our electricians and engineers on site regularly to provide real-world feedback on our designs and how we can constantly improve to make equipment safer.” Part of the Fenner Dunlop’s manufacturing process is putting all equipment through its in-house high voltage test bay for function testing before putting it out in the field. This ensures that substation starters and associated equipment are tested at their nominal voltage prior to dispatch. The testing isn’t limited to Fenner

MINERALS PROCESSING

FENNER DUNLOP ACTS AS A PARTNER TO ITS CLIENTS, RATHER THAN JUST A SUPPLIER.

Dunlop’s staff though, with customers also involved in the development of their projects once it is deemed safe for them to do so. “Once we’ve completed our safety protocols and concluded our internal testing, we open up that test space for customers to do their own testing,” Wilson explains. “This ensures when it goes in to be commissioned, there’s less time spent in that commissioning process on site, as it’s easier to diagnose and rectify during testing in the workshop.” Projekt2 10.02.20 13:54 Seite 1

FENNER DUNLOP’S CONVEYOR STARTERS.

This is reflective of Fenner Dunlop’s close relationship with its clients – as a partner instead of a regular supplier. Fenner Dunlop’s partnership approach goes as far as the company having ongoing support teams on certain sites, allowing them to be close by to resolve any issues and take on valuable feedback from clients. The company also offers remote support and monitoring, which is ideal for more isolated sites. Fenner Dunlop considers itself only a phone call away and able to assist,

AUSTRALIANMINING

despite the geographical distance that Australia’s remote mining operations pose. “If a client rings us in the middle of the night or during the day for support, instead of having to drive or fly out to a site, which can be five to six hours, you can log in remotely,” Wilson says. “Having an experienced support team, we can have a look at appropriate trends and understand what might be happening to remotely fault find. The systems are designed so that all information is available to you.”

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Even if the Fenner Dunlop team is unable to see what’s physically happening on-site, the remote monitoring system is advanced enough that being connected to the client by phone allows them to troubleshoot most issues. “The motto of Fenner Dunlop is all about being customer centric and ensuring our customers problems can be resolved quickly,” Wilson concludes. “Our brand is on the equipment, so we want to be a partner with our clients the whole way through.” AM

TECHNOLOGY

LASE TECHNOLOGY OPTIMISES STACKER RECLAIMER OPERATIONS WHO KNEW THAT STACKER MEASUREMENT AND COLLISION PREVENTION WERE TWO BIRDS THAT MINING OPERATORS COULD ADDRESS WITH ONE STONE? LASE CERTAINLY DID.

ean efficiencies are something that mining operations have to work towards. For mining companies that rely on the technology and innovation of a mining equipment, technology and services (METS) company, the drive to improve efficiencies needs to begin there. LASE lives up to a 21st century penchant for simplification in this pursuit. The global laser specialist uses only a handful of components to deliver more than 10 different applications in the mining sector. It simply comes down to the key features of software behind the device and where a 2D or 3D scanner is being mounted. Installations on drill rigs, dump trucks, conveyor belts or stacker/ reclaimers are just some of the possible applications. “Nowadays, it’s all about automation,” LASE Australia general manager Lars Mohr, who has relocated from Germany to Perth to launch the company’s first Australian branch, says. “A machine needs to know what

it’s doing and for this it needs a pair of eyes. “But we’re the eyes of the machine. We enable the machine, say a stacker/reclaimer to see what’s going on around it with our laser measurement systems.” Using LASE’s tried and tested scanning technology, a company can obtain data gathered by the company’s scanners, have it processed using LASE’s algorithm software and interpreted to a user or machine programmable logic controller (PLC). This isn’t restricted to data from just one piece of mining equipment. LASE also has the ability to combine data from multiple machines to give a complete picture of a mining operation using multiple scanners in several applications. “This means we generate an interconnected automation that is not only limited to one machine. We’re able to distribute the data on multiple different interfaces. The possibility is limitless,” Mohr says. “We did this in the port business, with multiple Australian container terminals adopting LASE system in

LASE’S 3D LASER SCANNER INSTALLED ON AN INSPECTION PLATFORM.

AUSTRALIANMINING

LASE’S 3D SCANNER LOOKS FROM ABOVE THE MACHINE ON THE RECLAIMED MATERIAL.

its automated operation. “They run machines that don’t have cabins anymore and are all automated with laser-based measurement systems from LASE.” The good news about interconnected automation – across inventory management and volume measurement – is that data helps to support incident prevention. Mine operators can also install one or more of LASE’s 3D laser scanners on a stacker or reclaimer to get a precise measurement of heaps or piles. The LASE scanner looks from above the machine on the heap and scans the heap profile. It focusses on getting a measurement which can then be used to automate machines and monitor processes. The LASE software provides answers to questions such as how much material is on the stockpile, how high the material flow is in exact figures and whether equipment might collide with other objects, machines or the heap. Mohr says that the LASE application is highly versatile and can be applied across several types of heaps and piles, while also being used to prevent collisions between equipment. “We aim to address safety issues and other mining challenges for the benefit of mining companies,” Mohr says. “We know we have a solution, and we can provide that solution with a technical approach while giving a greater picture of processes and generating benefits for operations.

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“If you’re concerned an operation will result in ineffective processes or in a collision of machines, we address this problem in a two-fold manner to ensure you maintain safe operation and reap economic benefits – the two are connected quite closely.” Mining operators can run a fully automated stacker/reclaimer operation, optimising an operating distance of bucket wheel and stockpile, while receiving a real-time scan model of the stockyard. “Automation is a very big topic in the mining industry today, and you always need data of your surroundings and the processes within mining operations to automate your equipment,” Mohr says. A laser scanning application uses fewer sensors than, for example, radar systems. In a bulk volume scanning system, a maximum of only two 3D scanners are required. But achieving the same vision with radar systems would require between 12 and 16 sensors, according to Mohr. Fewer components also mean lower initial and maintenance costs for companies, he continues. Further, laser technology is not affected by daylight or night time as it uses an active light source, unlike a time of flight (TOF) 3D camera technology system. LASE has been operating around the world for 30 years, developing laser technology that helps make automation a smooth affair at industrial sites. AM

Cartledge Mining & Geotechnics delivers practical and innovative geotechnical solutions as consultants specialising in the mining industry.

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TECHNOLOGY

CTRACK BRINGS REAL-TIME EQUIPMENT MONITORING TO MINING CTRACK ALREADY PROVIDES COMPANIES WITH COMPLETE VISIBILITY OF THEIR FLEET, FROM A VEHICLE’S WHEREABOUTS TO DRIVER PERFORMANCE, THROUGH ITS VEHICLE TRACKING SOLUTIONS. NOW THE COMPANY HAS TURNED ITS ATTENTION TO REAL-TIME ASSET VISIBILITY.

o make real-time asset monitoring a reality, Ctrack is unveiling a new product, Ctrack Asset. The product, which just launched this March, will make a variety of different devices available depending on the application. Through Ctrack Asset, companies will be able to monitor both powered and non-powered assets, from mining vehicles to equipment such as ladders and toolboxes. As Ctrack technical and product lead Dale Kingston explains, this can be used in open cut and underground operations, as the Ctrack Asset platform features options for both indoor and outdoor tracking. “There’s a variety of different options in mining,” Kingston tells Australian Mining. “Companies can opt to just locate an asset on a day-byday basis, all the way through to live visibility on the asset as well, if it is hooked up to a powered vehicle. “As well as traditional outdoor tracking options, there are also options for indoor or underground tracking in areas where GPS coverage can be an issue. “There are certain devices that can connect via the site’s WiFi network, and perform an address look-up. “If you’re tracking assets without GPS coverage, then you will still be

able to locate that device or asset.” The Ctrack Asset platform launch is exciting because the product can be used in an underground environment or out of normal GPS coverage. The product’s value from a maintenance perspective only adds to the excitement. Instead of focussing on the traditional bodies tracked, such as monitoring a site’s fleet of machinery and watching for driver performance and vehicle location, Ctrack’s Asset can be used to keep track of maintenance needs. “Through the platform, you are able to keep tabs on maintenance,” Kingston explains. “This includes when the vehicle was last serviced etc, so you’re able to make sure you’ve got a good record of all the maintenance that an asset may need. “Using the maintenance recorders within the system you’re (also) able to keep tabs on what the maintenance costs are against the asset. It’s making sure that an asset has an overhaul or service at the defined interval.” To make monitoring maintenance schedules even easier for site managers, users can set up alerts on Ctrack Asset to give scheduled reminders of timetables, which can be set up on both iOS and Android devices. The alerts are not just assigned for the right piece of equipment, but

CTRACK’S RANGE OF TRACKERS ALLOWS OPERATORS TO MONITOR BOTH POWERED AND NON-POWERED ASSETS.

AUSTRALIANMINING

CTRACK IS LAUNCHING CTRACK ASSET, WHICH ALLOWS OPERATORS TO MONITOR THEIR ASSETS IN AREAS OUT OF REGULAR GPS COVERAGE.

also the right operator for the job, according to Kingston. “Basically, you can create a schedule and then set up an alert, so it comes through as a pop up on your phone or as an email,” Kingston says. “We’ve gone for a very clean and basic approach, so it’s very intuitive for day to day use.” Another solution Ctrack provides is a Bluetooth tag and gateway solution, which is ideal for lower cost assets, according to Kingston. The gateways can be placed at strategic locations around a mine site and are configured to provide a positional update at an interval as defined by the operator, such as every half an hour or hour, depending on the operation. This goes hand in hand with the AT-04 device, which can be fitted to stationary or moving assets. Upon updating, the gateway solution also relays a positional update to all BT-01 BLE tags within range, allowing for further innovative asset tracking. This range of equipment allows Ctrack to offer a versatile solution, from a basic Bluetooth asset tracker that is reliant on the gateway for its position, to standalone devices that can be used for larger machinery, including excavators. “These have their own sim card and communication protocol, whereas the Bluetooth tags are designed more for smaller assets,” Kingston says. Ctrack asset management devices have security in mind, with options to

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locate or recover an asset if it is stolen from a site, as well as getting in-depth updates on battery life and managing expenses on the asset. “You can also set more customised alerts if an asset moves outside of a designated zone or if it’s used after hours,” Kingston explains. Kingston himself is an expert about not only the Asset platform product but across all aspects of Ctrack’s business, with 16 years under his belt in multiple disciplines. During his time with Ctrack, Kingston has worked in installation, customer support, operations and product development. “With the background I’ve had, it gives me that insight into how (clients) are going to install it and how it is actually going to be operated,” Kingston says. “Then from a support perspective, I know how they’re going to use the system as well, so it definitely helps with implementing these kinds of systems and solutions.” Although the Asset platform is Ctrack’s newest release, it is just the start of a big year for the company. Ctrack also plans to release a new fleet tracking software in the coming months, as well as various video solutions, allowing operators to embed video into the tracking platform. “We’re investing quite heavily in development, making sure we’ve got a full spread, not only introducing new products, but enhancing the existing ones we have as well,” Kingston concludes. AM

MAINTENANCE

PREVENTING UNPLANNED SHUTDOWNS: WHAT’S THE REAL FIX? TWO KEY AREAS THAT MINING OPERATIONS COULD IMPROVE UPON TO PREVENT UNPLANNED SHUTDOWNS AND INCREASE THROUGHPUT ARE EQUIPMENT RELIABILITY AND DOCUMENTED PREDICTABILITY, SAYS INDUSTRY EXPERT DAVID GREIG.

s key accounts application manager to the mining, power and oil & gas industries with Henkel Australia, David Greig is more than familiar with the issues that operations within this segment face, including the pressure to remain sustainably profitable in an increasingly competitive market space. “The main ongoing issue that mining operations have is in their equipment failing outside of planned maintenance shutdowns. An unplanned shutdown will have a major impact on the entire mining operation in terms of lost production and profits,” explains Greig. “For example, a coal mine site that is putting 600 tonnes of coal per hour through their wash plant and selling that coal at $100 per tonne, would be losing $60,000 per hour on production in an unplanned shutdown. Calculate that for a day, or a 24-hour period, and that’s over $1.4 million.” Moreover, there are environmental concerns associated with unplanned shutdowns in addition

to workplace safety which need to be taken into account. “Environmental considerations cannot be understated. If you get an uncontrollable release of contamination, that creates a massive problem as it results in an unplanned shutdown and due to this, a loss of production at the site,” Greig stresses. What’s the answer? Greig advocates the need for process change and the adoption of newer technologies. Specifically, he talks about the way maintenance is performed. He has visited numerous mine sites during their maintenance periods and says staff struggle to get all the planed jobs completed during planned shutdowns. This is largely due to the fact that they are repeating the same job, on the same equipment, time after time; which prevents them from improving other areas of the plant. “In some instances – and with the correct product – you can extend the life of a piece of equipment in a maintenance period by up to four times, sometimes more, of what is currently being achieved,” he explains. “This frees up time to do

other jobs, makes the equipment more reliable and improves the safety of your plant.” Importantly, Greig is adamant that operations need documentation. “For every new customer and application that we start working on, documentation is essential. We need to establish a baseline for performance. If you don’t know where you’re at, you won’t know where you’re going to,” Greig says. While the LOCTITE brand has a reputation among customers as “the products that always work when they need to,” Greig asserts that long term goals such as reliability and profitability are only achieved when products are optimised to suit their applications. Additionally, gaining an understanding of how a plant is operating will enable engineers to come up with holistic working solutions. This is where LOCTITE relies on its distribution partners to not only supply products to customers but engage in site surveys to get an insight

UNPLANNED SHUTDOWNS CAN COST A COMPANY UP TO $60,000/HOUR. AUSTRALIANMINING

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into the customer’s needs. One of the major partners is CBC Australia, which has been distributing the LOCTITE product range in Australia for 40 years. “We work very closely with the CBC engineers, often going to mining plants together to identify issues and make recommendations. It’s a critical partnership, as we rely on CBC to make sure everything will work all the way through,” says Greig. In fact, the CBC engineers are trained with exactly the same materials that we are, so they are going out to sites with the same knowledge.” Michael Rowe, who is the CBC product manager for adhesives and sealants, echoes Greig’s comments, adding that the CBC network of branches and staff are an extra

MAINTENANCE

between the outer tracks and the support on the dozer fleet. “This was resulting in the tracks being forced from their bed and the machines suffering premature track failure,” he explains. “The customer trusted our recommendation to use the flange sealant to provide a seal between the track and the bed. This shows their ability to think outside the box and try an untested application solution. It’s provided them with a simple, costeffective solution.” To summarise on his key messages,

LOCTITE’S RANGE OF WEARING COMPOUNDS.

advantage to customers. “We provide national coverage of the LOCTITE product range and our stock holdings allow us to provide customers with speedy deliveries, ensuring downtime is limited on affected equipment,” he explains. “The knowledge of our trained team also ensures reliable assessment of each customers’ situation and the capability to provide swift solutions to the customer requirements.” To illustrate how mining operations can improve their reliability and throughput, Greig references two case studies. One family of products that Greig says is regularly used at mine sites is the LOCTITE PC 9313 High Impact Wearing Compound; a polymer

reinforced matrix that is combined with high-grade ceramics. He cites the example of an Australian coal mine which was having issues with the underflow discharge pan where maintenance teams were applying a generic wearing compound frequently. After they started using the LOCTITE PC 9313 the customer improved the time between applications by at least four times over the other compound and saved an estimated $50,000 each month. Another common product used in heavy industry machinery is the LOCTITE 515 Flange Sealant. Greig gives an example of an Australian coal port where the site was having issues with coal being forced

AUSTRALIANMINING

HENKEL AUSTRALIA KEY ACCOUNTS APPLICATION MANAGER DAVID GREIG.

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Greig reiterates the value of embracing change and innovation. He mentions that his own company, Henkel, continues to focus on highly efficient innovations and steadily reducing resource consumption while maintaining or improving performance. “In order to do better, you need to change the way you do things, or you’ll continue to get the same results,” he points out. “The formula is simple. Improve reliability, reduce maintenance and increase your profits.” AM

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MINING SERVICES

ROBUST AND VERSATILE WELDING FOR THE MINING INDUSTRY WELDING INDUSTRIES OF AUSTRALIA (WIA) HAS A NUMBER OF WELDING SOLUTIONS FOR THE MINING INDUSTRY. FUHAI LIU, PRODUCT & SALES MANAGER – END MARKETS AT WIA TALKS THROUGH THE LATEST OFFERINGS.

ne of the common usages for welding equipment in the mining industry is for gouging, according to Fuhai Liu, product & sales manager – end markets at Welding Industries of Australia. These kinds of repairs often take place on remote sites, where the welder is usually at quite a distance from any kind of power source, presenting a unique number of challenges. “Our Big Blue engine driven welders are typically used on mining sites when they need to carry out repairs on earth moving equipment,” he explains. The engine driven power sources are self-sufficient without the need of onsite power supply and are often used to remove cracks or damaged parts from the equipment via a very efficient process – Air Carbon Gauging (ACG). The Miller engine driven and multi-process invertor welding machines offer an efficient way to remove metal from damaged or breakdown equipment on site and/or at the workshop environment. According to Liu, people’s view of a multi-process inverter welding machine is often that it doesn’t offer the same capabilities and quality as a transformer welding machine. However, with the Dimension 650

THE ARCREACH SYSTEM FROM MILLER GIVES REMOTE CONTROL OF THE WELDING POWER SOURCE WITHOUT ADDITIONAL CORDS.

this is not the case. It boasts a rugged design and proven reliability within the mining MRO segments globally. On the engine driven equipment side, one of the features of the 700X and 800X Big Blue welders is the ArcReach, which allows the remote control of the power source without additional control cord, but via the welding power cable only. “ArcReach technology uses the existing weld cable to communicate

WELDING INDUSTRIES OF AUSTRALIA HAS A NUMBER OF WELDING SOLUTIONS FOR THE MINING INDUSTRY.

AUSTRALIANMINING

welding control information between the power source and wire feeder or stick/TIG pendant. This is particularly beneficial on a mining site as the feeder could be 50 to 100 metres away,” Liu explains. In addition to the convenience of being able to adjust welding voltage and amperage at the weld, this also offers added safety benefits. “There could be all kinds of obstacles and safety risks that would make it difficult for the welder to walk across a mining site. The ArcReach technology eliminates this risk by allowing the welding operator to change settings without having to walk across a potentially hazardous site,” Liu says. There is also the added benefit of productivity gains. If a welder has to walk to the power source every time they need to change the setting, this causes a loss in production time. If an operator walks four times a day to a power source to adjust the settings, and each walk takes an average of 15 minutes, this will waste 250 hours a year per operator. If organisations can gain back this lost welding time, then they can experience increased productivity. Further cost benefits can be realised with regards to energy consumption,

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particularly with reference to the latest offering – the Dimension 650 machine. The Dimension 650 Provides 800 amps of usable power, a full 650 amps of power at 100 per cent duty cycle. “The Miller inverter range doesn’t use as much electricity as a transformer machine. In fact, with the Dimension 650, the energy cost savings mean that the machine has pretty much paid for itself in two years depending on the equipment rate of usage,” Liu says. The Dimension 650 is a new offering in the multi-process equipment range and offers a lighter and easier to handle machine. “The Dimension 650 is relatively new to the market here in Australia, and it offers significant energy savings, as well as a very convenient and easy to move machine,” Liu says. Miller ensures that all of its welding machines are tested extensively before rolling them out internationally, Liu adds. “Before any machine reaches the international market, it will have been trialled locally for an extended time period. The Dimension 650 has been receiving great feedback in the mining market and we’re excited to bring this product to the Australian mining industry.” AM

MATERIALS HANDLING

DIACON GUARDS MINE WORKERS FROM CONVEYOR DANGERS DIACON AUSTRALIA PRIDES ITSELF ON BEING A GENUINE AUSTRALIAN MANUFACTURER OF PLASTIC CONVEYOR GUARDS, WITH A TEAM OF DEDICATED ENGINEERS THAT SET IT APART FROM COMPETITORS. SALOMAE HASELGROVE WRITES.

iacon Australia is a leading innovator of conveyor spillage control and guarding products used to protect mine workers from the safety risks of conveyor systems, considered one of the most dangerous areas of a site. The aim of a conveyor guard is to eliminate the risk for operators to get entangled in nip points on the conveyor belts. The potential injuries range from minor wounds such as a bruised finger, to major injuries like amputations or worse, worker fatalities. Queensland-based Diacon is a connoisseur of using plastics, having been in the industry for over 30 years and engineering and producing guarding systems for over 10 years. While Diacon prides itself on being a completely Australian-owned operator and manufacturer, the inspiration to pursue the innovation for the company’s iconic guards actually comes from Germany’s K-Fair world plastics exhibition. Diacon Australia managing director Brendan Refalo says the company’s directors attended the event with the intention to find a

manufactured then completed test trials within its own facility before customers even saw them. “We needed to make sure what we were offering not only met customer needs, but complied with Australian standards,” Refalo says. The company’s intent to use plastic instead of steel was based on the need for a more adaptable material on mine sites, with steel often being too expensive to customise for individual applications. “When we started, we were having to install steel guards on conveyor belts,” Refalo says. “Once you put a spillage control hungry board on a conveyor belt, the trough idlers become nip points. It wasn’t until probably the second or third project that we decided we needed to use a better material for guarding other than steel.

partner to assist with manufacturing the guards the company had designed. As this was a completely new innovation, and no one had the experience to work alongside Diacon Australia on the project, the company decided to go at it alone. “K-Fair has some 3000 exhibitors in the world plastics industry, everything from drink containers to automotive, aerospace and industrial plastics, we really just verified that our concept was quite unique” Refalo tells Australian Mining. Diacon Australia went on to patent and manufacture its first guards in early 2012, before hitting the market with the product in 2013 after a meticulous trial period. With strict Australian safety standards to adhere to, Diacon spent a year trialling the first guards it

QUEENSLAND-BASED DIACON GUARDS MINE WORKERS WORLDWIDE FROM THE RISKS OF WORKING AROUND CONVEYORS.

AUSTRALIANMINING

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MATERIALS HANDLING

DIACON AUSTRALIA’S CONVEYOR GUARDS ARE MADE OF AUSTRALIAN HDPE.

CAPTION

“That was where the concept of making a plastic mesh guard came about; we felt we could manufacture our own guards that were more suited to what the industry needed.” Plastic materials have the added advantages of being lightweight, corrosion free and never require painting. It can also be more easily processed allowing many variations to be achieved with minimal jigging and set up costs. Part of what sets Diacon Australia apart from its competitors is the experience and diversity of their workers, according to Refalo. “We’re a plastics company but we’re fundamentally an engineering company,” he explains. “We employ six mechanical engineers and a team of draftsmen, and from a plastics point of view, that’s what sets us apart. We proudly offer a complete guarding solution from

concept to installation.” It is a point of difference that allows Diacon to design customised guards that may look identical, but are designed to deliberately fit around different mine site obstacles, such as weigh stations, metal detectors, sampling equipment and belt tracking systems. The company prides itself on designing around these obstructions in a way that still looks uniform by employing modern laser scanning technology. “Sometimes, we make a conveyor that has a total of 300 guards on it, many of which may need to be customised to fit the application. With a job like this, having different sized guards on a single conveyor, keeping them looking uniform is the key,” Refalo says. “We laser scan the conveyors, giving us an accurate model of the

AUSTRALIANMINING

conveyor. We then overlay what the guards need to look like onto the real structure.” With many alternative options on the market being designed and manufactured overseas, this is a unique trait of Diacon, one that gets extremely positive feedback from clients. “When people look at our guards, they always comment on how neat they look,” Refalo says. “The reality of this, is often there are a variety of sizes in both guards and brackets but our attention to detail is what delivers a highly functional yet well presented product.” Diacon still makes the effort to attend sites to ensure the structure is completely accurate with the scanning before manufacture and subsequent installation. This is such an exact design

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process that Diacon modifies less than 1 per cent of its brackets and guards after installation for changes, with a commitment to get it right the first time. “We spend several days on each site making sure what we’ve measured is absolutely correct before we leave the site,” Refalo says. Diacon fits its own guards across sites within central Queensland, where it is based. The company also has a distributor network across Australia, which ensures a hasslefree installation process, with only qualified technicians installing the guards. The company uses quality Australian manufactured highdensity polyethylene (HDPE) material for all of its guards; has exceptional ultra-violet stability to suit Australian conditions, and provides a 15-year material guarantee. Diacon guards can be used at underground and open pit operations, with a specialised fireresistant anti-static (FRAS) design for coal operations available upon special order. “They’re easily adaptable to site conditions and are designed to be hung on the handrail beside the conveyor during maintenance, which removes them from sitting on the catwalk becoming another workplace hazard,” Refalo explains. In addition to being costeffective, versatile and safer than steel counterparts, Refalo says there are three key reasons clients are so impressed by the Diacon Australia plastic conveyor guards. “They are lightweight, corrosion free and don’t need to be painted,” he concludes. “We’ve been consistently developing our guards for over 10 years and we can proudly say that all of our components are designed and manufactured locally to the highest of standards.” AM

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MATERIALS HANDLING

FLEXCO’S JOURNEY INTO THE AUSTRALIAN MARKET FLEXCO HAS MAINTAINED AN UNCOMPROMISING APPROACH TO QUALITY IN AUSTRALIA BY CONTINUING TO MANUFACTURE ITS PRODUCTS IN THE COUNTRY 30 YEARS AFTER DECIDING TO ENTER THE LOCAL MARKET.

hirty years ago, while expanding its product line to incorporate a range of belt conveyor products to support a legendary range of mechanical belt fasteners, the board of directors at Flexco made the decision to break into the Australian market. Flexco Australia took on the mighty task of producing Flex-Lag Pulley Lagging and later, tungsten carbide tips, to support the company’s operations globally. In 2020, Flexco marks 26 years of Australian manufacturing. Flexco pours polyurethane cleaner blades at its Grand Rapids location in Michigan, United States. However, tungsten carbide tips are better suited to the Australian market, where vulcanisation is the favoured method for joining belts. Flexco Australia’s manufacturing facility allows quality to be closely monitored to ensure only the best product is delivered to its customers.

FLEXCO MARKS 26 YEARS OF MANUFACTURING IN AUSTRALIA IN 2020.

For more than 30 years, Flexco has been purchasing the same tungsten carbide. “While there are definitely cheaper alternatives, we won’t ever compromise on the quality of our product,” Flexco Australia managing director Mark Colbourn says. The important thing to look for in a quality tungsten carbide product is the correct composite of carbide granules and binder metals. “Our carbides have the optimum balance of profiling to the belt quickly, without being too aggressive on the belt and damaging the belt cover,” says Flexco Australia quality assurance manager Soroosh Mirzaee when describing the quality of tungsten carbide used. The Flexco team of engineers has conducted numerous, extensive testing – both in the lab and out in the field – to ensure that the carbide used is the best available. Mirzaee also conducts batch spectrometric and dimensional testing AUSTRALIANMINING

of all carbides that Flexco receives into its Sydney manufacturing facility to ensure the company acquires the exact same quality of carbide every time. He also regularly conducts comparative tests with other similar products in the market to ensure the carbide is consistently the best available. The manufacturing process at the Sydney facility is also closely monitored to ensure consistency and maximum efficiency. Flexco has developed an optimum brazing process over the years that ensures a high-quality bond between the carbide and the body, while achieving the required manufacturing tolerances. Local manufacturing also allows Flexco to keep up with market demands and develops new products quite easily. Over the past few years, the Flexco team has researched, engineered, and manufactured a complete range of extra-life tips (15 millimetres) and extra-extra life tips (25 millimetres), as well as a corrosion-resistant variety for abrasive applications such as iron ore or gold. The extra life tips were made so that Flexco could continue using the same quality grade of tungsten, which quickly profiles to the belt, but also has a product that kept up with the faster belts and increased time between shutdowns, an aspect that is now becoming integral to mine productivity. “That’s why we have continued to manufacture in Australia; there are obviously cheaper options to outsource, but we believe that having the flexibility to manufacture exactly what our customer’s need for their specific environment is integral to our success as a company,” Colbourn notes. “While we know that our product is by far the best quality available in the market, we know that constant research and development is the key to staying relevant in an ever-changing mining industry.” Colbourn says other value adding resources, such as quick lead times for urgent orders to address breakdowns or emergencies are integral to the company’s success. In addition to reacting quickly

APRIL 2020

to market needs and providing an unwavering quality policy backed by local manufacturing, Flexco has also built a reputation for its expertise and extensive field support. Flexco has been the originator of many innovations, such as extra-extra life 25 millimetres tips. Before the launch of the tungsten tip innovation – a large iron ore conglomerate was purchasing 15 millimetres tips every 12 weeks, equating to about five sets per year, per conveyor. With the integration of the new 25 millimetres tips, the site only needs to purchase two sets of 25 millimetres tips per year. That’s a 20 per cent cost reduction on just one conveyor. The site also saved the time it took to replace existing tips during shutdowns. This saves about an hour for each cleaner on the belt. With some conveyors having in excess of four cleaners, this amounts to approximately eight hours per conveyor, per year – time that can be better allocated to other productivity-boosting projects on site. Due to the outstanding trial results, the iron ore site has specified the 25 millimetres tungsten tips for all cleaners on conveyors as part of 10/20 week shutdown strategies. AM

TEDDY TEWDROS IN A FLEXCO AUSTRALIA MANUFACTURING FACILITY.

INDUSTRY COMMENT

MINERALS PROCESSING: 30 YEARS OF METS SECTOR TRANSFORMATION

CONVEYOR BELTS AT A PROCESSING SITE.

THERE HAVE BEEN SIGNIFICANT CHANGES IN MINERAL PROCESSING OVER THE LAST THREE DECADES. AUSTMINE DISCUSSES HOW THE SECTOR HAS EVOLVED WITH A TRIO OF ITS KEY PLAYERS.

s higher grade and easier to extract deposits have been mined, the mining industry faces the challenge of processing lower grade and more complex deposits. Australian mining equipment, technology and services (METS) companies have responded to this challenge with new innovations and technologies that have increased efficiency and productivity. In order to properly see how far we have progressed in minerals processing, Austmine gathered insights from industry leaders Mipac, Eriez and Ausenco.

Progressing through the decades Challenges associated with cost, energy, water supplies and deposit

complexity have caused the industry to look for more innovative technologies and solutions. Matt Pyle, director technical solutions at Ausenco provides his view on the need for change. Pyle notes that global demand for most base and precious metals has increased by approximately 30 per cent each decade over the last 50 years and evidence suggests demand will continue to grow. “In concert, processing costs in real terms per tonne of ore have more than halved, enabled by the advent of heap leaching, improved work practices, computer controls and economies of scale, helping offset declining grades over this period,” Pyle says. “However, as new discovered deposits become less frequent, smaller, of lower grades, deeper and more

complex, we may be approaching limits within our current technologies and approaches. “Furthermore, as we increase equipment sizes, we may observe a diseconomy of scale as we push beyond manufacturing and transport constraints. We need to develop more selective processes, tailored to suit each operation with a focus on improving energy and water efficiency. “There are significant opportunities to improve performance of existing assets. Mine-to-mill continues to

A GOLD PROCESSING PLANT IN AUSTRALIA.

drive large amounts of value simply by optimising the total operation rather than the performance within individual silos or cost centres.” Pyles says more recently we have seen a range of new step-change technologies cross the “innovation valley of death” – many adapted from other industries – making real improvements to efficiency and productivity. While reflecting on the past three decades, Mipac digital solutions manager Dominic Stoll points out positive industry changes, including around automation and better work practices across the board. “Advancements in instrumentation and control systems has allowed a vastly more sophisticated level of automation,” Stoll says. “Automation allows variability to be reduced to achieve stability and make a step change in performance to the upper operating limit of a process or system.”

Partnerships, innovation and technology

Staying ahead of the curve can be a challenge in Australia’s competitive and world-leading METS sector and there is no one-size-fits-all technique. Stoll highlights Mipac’s successful long-term partnerships with clients and vendor peers as key to remaining a leader in the industry, as well as integrating digital and AUSTRALIANMINING

APRIL 2020

INDUSTRY COMMENT

Greg Lane says the company’s ability to quickly adopt and adapt new technology in a cost-effective manner has been a focus for clients. The Cadia Hydrofloat circuit, designed and built by Ausenco, is a case in point. “We have also taken cost effective principles used in small plant design and adapted that thinking to deliver large copper concentrators,” Lane says. “This has allowed Ausenco to provide more cost-effective designs for larger projects than those typically offered by the larger engineering and project delivery businesses.”

Our biggest challenges

automation portfolios for a more comprehensive solution. “We can provide technology agnostic solutions to problems that had previously been thought impossible,” Stoll says. “The secret to our success has been seamlessly integrating our evolving digital solutions portfolio with our industrial automation portfolio to offer our clients an end-to-end solution, from enabling infrastructure through monitoring and intervention systems and to recommendation deployment.” Developing, testing and commercialising minerals processing equipment that improves on conventional equipment in radical, non-incremental ways has helped Eriez stay at the top of the game, according to Eric Wasmund, Eriez Flotation Division. “Our HydroFloat, commissioned at Newcrest’s Cadia for copper/gold recently, allows mining companies to significantly reduce the requirement for fine tails impoundments, energy, and water consumption,” Wasmund says. “Since Cadia, we have seen uptake of this concept with many other mining and engineering companies.” From the outset, Ausenco has been an early adopter of new technology, enabling the company to remain at the forefront in process development and smart engineering design. Ausenco chief technical officer

As we step into 2020, some of the biggest challenges facing minerals processing are personnel shortages, unlocking value from digital technology and processing more complex deposits. Stoll from Mipac notes, “Changing societal expectations and a recurring commodity cycle means that experienced personnel are harder to attract and retain at remote mining operations. “Furthermore, the supply of mining professionals from Australian mining universities are at their lowest levels in decades just as we head towards the peak of the current commodity cycle.” However, human resourcing challenges are likely symptomatic of a single greater challenge – improving the social perception of mining and minerals processing. Ausenco director of technical solutions Grant Ballantyne points out, “As an industry we need to continue to innovate, work collaboratively and broadcast our successes to the world. “We have a unique opportunity to find a better way to mine and process the raw ingredients that support the growth of our society whilst providing positive outcomes for our environment and communities. “This is a good news story that can help us attract the brightest minds for tomorrow’s biggest challenges.”

Future of minerals processing

A plethora of innovations have helped shape the industry in the past 30 years and the METS leaders agree that fast computing power, smart instrumentation and specialised equipment have all played their part. Ausenco’s Greg Lane sees innovations which increase production rates, reduce capital and unit operating costs, and minimise energy, water and environmental impact as the next big disruptors. Lane offered pre-concentration technologies, more energy efficient comminution technologies and circuits, coarse particle recovery, and

A BALL MILL INSIDE OF A COPPER PROCESSING PLANT.

storage of drier tailings as examples. “In the face of lower grade deposits, which require mining and processing of much larger tonnages, pre-concentration offers hope,” Lane says. “There are several technologies that can be used for pre-concentration including pre-screening, sorting, gravity and coarse particle flotation. However, the economic viability of pre-concentration and sorting is very case specific, depending on the

value of the ore, ore heterogeneity, mineralogical response and mining and processing cost structures.” Eriez is focussing on products that assist in reducing energy and improving the efficiency of the extractive processes. Wasmund concludes, “As we go forward, it is our mission to work with our partners at mining companies and engineering houses to make the mining enterprise more sustainable for the future.” AM

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2/25/20 2:12 PM

MEASUREMENT & MONITORING

VEGA TAPS INTO NEW OPPORTUNITIES VEGA AUSTRALIA HAS EXPANDED ITS PRODUCT RANGE TO CATER TO ALL FACETS OF THE MINING INDUSTRY, ENSURING COMPANIES HAVE ACCESS TO QUALITY LEVEL MEASUREMENT FOR GASES, LIQUIDS AND SOLIDS.

or more than 30 years, Vega Australia has provided highend solutions for problems within the mining industry, including heavy dust, vibration and foaming to name a few. The company took a step back four years ago to look at areas it was overlooking in the marketplace and expanded its range accordingly. Vega Australia managing director John Leadbetter says the company has started to focus on a more simplistic part of the market – clients looking for the same quality, without all the bells and whistles. “Where we’ve got simple applications, such as water tanks or pressure and hydraulic lines, which are relatively straightforward applications, all of our equipment was way over specified,” Leadbetter tells Australian Mining. “The development on this expanded range of products is still giving the customers the quality, it’s still giving them the performance and the accuracy, but it’s without all the fruit.” From extensive customer feedback, Vega Australia realised the cost constraints operators within the mining industry need to consider when operating, meaning that purchasing equipment can add pressure on capital expenditure. “At the end of the day, as much as people look at the mining industry as big and powerful, it still has cost constraints so operators look at how they can improve their

bottom line,” Leadbetter says. As Leadbetter explains, this isn’t just limited to the cost of the equipment itself, but the mine as a whole. “By all means, the equipment and parts are a cost, but what is the cost of that mine not running because something breaks down?” Leadbetter asks. “You could be talking a million dollars an hour.” The company identified three key areas to simplify based on surveys conducted on its clients around the world. Vega Australia decided to focus its simplistic range expansion on its radio level transmitters, which are used for non-contact level measurements of liquids and bulk solids; its level switches, used for level measurement of liquids and solids; and pressure transmitters, which measure and process differential pressure, volume, density and mass flow of gases, vapours and liquids. “We have a full range of radar level transmitters,” he says. “What we’ve looked at there is the simple end of the market and expanded the range of radar transmitters. “Keeping in mind the market’s shift towards Internet of Things (IoT) 4.0, we’ve given these products Bluetooth communication but simplistic programming.” For the switches, Vega Australia adapted the product to cover the simple plug-in level switches used in water tanks or sumps, to give the basic indication of if a tank is empty or full.

VEGA AUSTRALIA’S EXPANDED RANGE OFFERS THE SAME QUALITY WITHOUT ALL THE BELLS AND WHISTLES.

AUSTRALIANMINING

VEGA AUSTRALIA’S PRODUCT RANGE NOW INCLUDES SIMPLIFIED VERSIONS OF ITS POPULAR PRODUCTS.

In developing hydraulic and water pressure transmitters, the company also implemented Bluetooth connectivity, for ease of communication and monitoring. It’s not just the products themselves that are more simplistic, but also the maintenance and installation process, saving mining companies time and capital when installing new equipment or maintaining existing equipment. “Generally, with instruments like these, there’s a safety requirement to bring a technician out to wire and power it up,” Leadbetter explains. “With these new products, they’re a M12 plug arrangement, so the operators can change them. “This is an area where the operators become the maintainers, so we’re adapting to the market, we’re not asking the market to adapt to us.” Vega Australia also uses the

APRIL 2020

feedback from its customers to ensure its products are ready for realistic operations. This testing period allows Vega to ensure its products are safe and efficient for mining operations, while clients have firsthand insight into how the products are changing. “We have good relationships with a number of customers around the world,” Leadbetter says. “We offer them what we call zero devices, which in other words is test devices, we’ll give them those to test in real life situations for us. “Our customers are more than happy to do this because it’s helping them to understand how the products are going to fit in with particular systems or future plans.” Vega Australia manufactures its expanded range in the same German factory as all of its products, proving it does not cut corners or compromise quality for lower capital expenditure. The expanded range provides the same formal guarantees, safety ratings and efficiency as its other products, while catering for a new part of the market previously overlooked. “We haven’t come out with a cheap range of products, we’ve come out with the same quality and the same performance,” Leadbetter says. “All we’ve done is incorporated less features, so it’s a simplistic version of our traditional advanced systems, made in the same factory, all we’ve done is given them a simpler and more adaptable product to suit that particular part of the market.” AM

ENGINEERING

PROACTIVE GEOTECHNICAL ADVICE TO SAVE MINE OPERATORS MILLIONS CARTLEDGE MINING AND GEOTECHNICS PRINCIPAL CONSULTANT TIM CARTLEDGE EXPLAINS WHY FORWARD-THINKING GEOTECHNICAL DESIGN CAN LEAD TO CONSIDERABLE COST SAVINGS FOR MINING COMPANIES.

any Australian mining companies still consider geotechnical inspections as an obstruction to production because they are often onerous and potentially lead to shutdown of active circuits, impacting their production targets. In reality, expert geotechnical inspections are essential to ensuring mining operations are safe and have the potential to save operators millions of dollars in the long run. Early identification of geotechnical hazards and development of mitigatory designs during the planning process leads to better financial risk management. Geological problems are the principal cause of pit wall failures in most mines. The average cost of a geotechnical failure is about $5 million in coal mines and can range up to $40 million. Total losses can be in the hundreds of millions of dollars if a mine is forced to shut. Appropriate geotechnical site investigations and robust geotechnical designs increase geotechnical confidence, reduce the risk of costly wall failures and subsequent delays in the mine schedule, and improve safety for personnel. Product sales are often locked into the mining schedule 12 months in advance, meaning any delays in the mine schedule can result in significant financial impairments. Therefore, good mine designs should identify latent geotechnical hazards and provide mitigating designs at least 12 months in advance. To do this, proactive geotechnical

design must be integrated into the mine design process through the mine design lifecycle, from long term, through to short-term and review and reconciliation. This can be broken down into design phases that are commensurate with product sales, such as those shown in Table 1 (see below, right). Each design phase is intended to increase the level-of-detail: • L ong term – High level review of geological structure and potential hazards for input to life-of-mine exploration programs. • M id-term period – Identify potential significant geotechnical hazards and define scope of work to de-risk (e.g. additional studies for alternative designs, exploration to improve fault interpretation) prior to locking in product sales in short-range forecast (SRF) window. • S RF – Develop detailed geotechnical designs and hazard plans to provide to mid- and shortterm planning engineers. • S hort term – Validate SRF design, and geology and geotechnical models against observed pit conditions to produce pit shell / highwall plans. • R eview and reconciliation – Review pit performance against expected ground conditions and provide feedback to technical services team and input to SRF design process. The establishment of a staged, robust geotechnical design process can significantly reduce the risk of financial shocks due to unexpected delays caused by geotechnical hazards. Smart mine operators who weigh up the cost of good geotechnical design

against the potential losses of a failure soon decide what is the smart choice. This is particularly the case when an expert analysis of the vulnerability of a mine could cost as little as a few thousand dollars. A good example of what can be achieved is the case of Middlemount coal mine, which engaged Cartledge Mining and Geotechnics to provide geotechnical support after experiencing several significant highwall failures in areas where they were not historically a problem. The mine was approaching the regional scale Jellinbah fault and expecting that geological structures would become more prevalent during subsequent strips. After meeting with company officials and discussing their needs, it was decided we would supply mid-term design, pitwall mapping, regular site inspections and ad-hoc geotechnical support. We presented Middlemount with the abovementioned proposed timeline for a staged approach to geotechnical mine design. We used software that utilises photogrammetry techniques to capture orientation data for linear geological

structures and geotechnical data for use in geological modelling and geotechnical assessments. This proactive approach paid dividends with a reduction in pit wall failures and the number of mininginduced hazards steadily declining. The future looks bright for Middlemount because they were willing to bring in experts to not only solve existing problems, but also ensure future problems could be avoided. Based on what I’m seeing in the sector, this proactive approach is going to become more of a common concept as more and more mine operators see the value in expert geotechnical inspections as a way to ensure mining operations are safe, while potentially staving off millions in losses in the long run. AM Tim Cartledge has multi-disciplinary experience in civil and mining geotechnics, and mine engineering throughout Eastern Australia and Southeast Asia. He has provided operational mine planning and geotechnical advice for world class deposits including Mount Isa and McArthur River mines, as well as small scale, selective mining operations.

TABLE 1: NOMINAL TIMELINE OF GEOTECHNICAL DESIGN PHASES DESIGN PERIOD

TIME FRAME

LONG-TERM

5 YEARS TO LOM

MID-TERM

2 – 5 YEARS

SRF

4 MONTHS – 2 YEARS

SHORT-TERM

0 – 4 MONTHS

REVIEW AND RECONCILIATION

0 MONTHS – -4 WEEKS

PEABODY ENERGY AND YANCOAL ARE JOINT VENTURE PARTNERS IN THE MIDDLEMOUNT MINE IN QUEENSLAND. AUSTRALIANMINING

APRIL 2020

PROSPECT AWARDS

RECOGNISING THE FUTURE OF MINING TECHNOLOGY WITH A GOAL TO PUSH INDUSTRY FORWARD, IFM IS ONE OF MANY INNOVATIVE COMPANIES PROVIDING AUTOMATION TECHNOLOGY TO THE MINING SECTOR. THIS YEAR, THE COMPANY WILL PRESENT THE FIRST EXCELLENCE IN INDUSTRIAL INTERNET OF THINGS APPLICATION AWARD AT THE 2020 PROSPECT AWARDS.

ociety’s pursuit to evolve has pushed the boundaries of digital technology. The mining industry is in the midst of revolutionising how day-to-day tasks are handled through new technology such as sensors and machine-learning. This is referred to as the industrial internet of things (IIoT). ifm has helped push the envelope of industrial technology for over 50 years. The company provides a wide range of automation technologies that mining companies can use for driverless trucks and other autonomous machines. The company’s national product and brand manager, Glenn Thornton, is one of the many people from ifm helping to improve the mining industry through the power of IIoT. “An increasing number of mining companies are seeking higher level efficiencies, improving production throughput and staff safety and gaining an edge over competition,” Thornton tells Australian Mining. “Collecting, monitoring and analysing information from mining equipment, mining operators can take action in real-time. To have these critical points occur, practical solutions for the digital connection of machinery is required for the collection and use of relevant and important data. “The basis is to increase efficiency, avoid downtime, optimise processes and increase profitability.” But how does it work? For ifm it’s

IFM’S SENSOR TECHNOLOGY IS USED AT MINE SITES ACROSS THE GLOBE.

simple: Collate the data from sensors located on mining equipment and use it to derive facts and figures that help with machine maintenance, repair and production levels. Thornton says the information starts with advanced sensor technology that generates large amounts of data that is transferred through all levels. “This is generated from the machine as fixed plant or a mobile machine that is then sent to the control system in production and also to company administration infrastructure such as ERP,” Thornton says.

IFM’S SENSORS HELP ENHANCE SAFETY AT MINE SITES.

AUSTRALIANMINING

“In other words, solutions allow continuous flow of information from the shop floor (machine infrastructure) to the top floor (IT infrastructure).” ifm sees the mining industry is reasonably confident with the adoption of new data centric technology that uses the industrial internet. “The industrial internet was born more or less out of commercial systems some 20-plus years ago,” Thornton says.” With the evolution of technology, industrial Ethernet has proven to be extremely robust in this environment. “It’s the biggest thing that’s going in industry. It’s the ability for companies to advance into a technologically competitive environment and be able to improve efficiencies. “Some amazing application within this would be something that’s going to be starting with the information that’s been gathered to create a smarter machine – a more productive machine.” And while a large number of mining companies are making the switch to digital technology, Thornton encourages more companies to align their operations with the future. “For many industries, the view is about not only being efficient and competitive, it’s also about future proofing their business which entails

APRIL 2020

a mind shift in the practices being utilised today,” he says. “The requirement of a more visionary outlook to take the first step towards change is imperative but may seem daunting to many business owners, plant supervisors, engineers and so on. “However, it isn’t such a big step to begin with and can be quite low cost to have a simple dabble with the technology.” ifm will present the inaugural Excellence in IIoT Application Award at this year’s Australian Mining Prospect Awards to express this commitment to driving mining forward with technology. The Prospect Awards have covered a wide range of disciplines in the Australian mining and minerals industry since 2004. For Thornton, the ifm sponsored award provides an opportunity to showcase companies which provide the most innovative digital technology for mining. AM Applications for the Excellence in IIoT Application Award need to involve projects that have been introduced after January 1 2019. For more information, visit www. prospectawards.com.au

EVENT SPOTLIGHT MINEXPO INTERNATIONAL’S EXTENSIVE SHOW FLOOR SHOWCASES THE MOST ADVANCED EQUIPMENT.

NEW DECADE, NEW OPPORTUNITIES FOR MINING PROFESSIONALS AT MINEXPO MINEXPO INTERNATIONAL 2020 IS DESIGNED TO IMPRESS AND REVEAL THE LATEST TECHNOLOGIES NEEDED TO MEET THE GLOBAL DEMAND FOR MINERALS.

n the world of mining, it’s never been more important to stay competitive. As digital capabilities open doors to new possibilities, companies are embracing advanced technologies to reduce downtime, increase efficiency and improve safety. Now is the time to discover new solutions to current operational issues, invest in innovation and embrace new technology—and there’s no better place to do that than MINExpo International. The largest and most comprehensive mining industry event returns to Las Vegas on September 28-30 this year and will koyo-AD-f.pdf 1 2020/02/27 20:18:32 provide mining professionals from every segment and all over the globe an unprecedented opportunity to find all that they need to transform their mining operations and stay ahead in 2020 and beyond. National Mining Association

(NMA) is proud to announce that Komatsu’s Global Mining Business division vice president and Milwaukee, Wisconsinbased Komatsu Mining’s chief executive and president Jeffrey Dawes will chair MINExpo International 2020. “I am honoured and excited to be chairing the 2020 show. What an exciting time for our industry and a great moment to gather as one to reveal the future of mining and the latest tools and technologies to meet the world’s demand for essential minerals,” Dawes says. Held every four years and sponsored by NMA, MINExpo brings together industry-leading education with an extensive show floor showcasing the most advanced equipment, technologies, products and services from more than 2000 leading suppliers, manufacturers and service providers. The 75,000-square-metre exhibit

AUSTRALIANMINING

KOMATSU’S GLOBAL MINING BUSINESS DIVISION VICE PRESIDENT JEFFREY DAWES WILL CHAIR THIS YEAR’S MINEXPO.

hall offers a look at today’s proven solutions and the advancements that are driving change in every sector of the industry, including exploration, mine development, open pit, underground mining,

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processing, safety, environmental improvement and more. AM For a look at this year’s show features, exhibiting companies and information about attending, visit minexpo.com.

PRODUCTS

TENNANT FORGES A WIDE CLEANING PATH

ASTEC’S MINE RUNNER THRIVES IN UNDERGROUND OPERATIONS

Tennant’s 800 Industrial Ride-on Sweeper is a machine that allows users to maximise their cleaning productivity. Featuring a wide cleaning path, large capacity hopper and operatorfriendly features, the sweeper can capture everything from cement dust to heavy debris. It can withstand harsh environments thanks to its heavy-duty steel construction and high-performance dust containment. An operator can also enjoy increased comfort with the spacious cab and easy access to all sweeper controls. The sweeper features deluxe suspension operator sea, power steering and tilt steering wheel, as well as II Speed technology that matches sweeping speed to the debris type.

• tennantco.com

Astec Australia’s Mine Runner extended wheel base (EWB) model is designed to safely transport people throughout a mine. The latest model keeps maintenance costs low while taking the equipment to the next level with a higher carrying capacity that is made possible by a longer tray at the back of the vehicle. Depending on how many models are used at any one time, operators can carry anywhere from three to 15 people. “The Mine Runner EWB is the same width as the initial Mine Runner, but adding that extra length and capacity to take extra weight in the back without increasing the width,” Astec Australia national product manager John Williams says. The Mine Runner vehicle also uses hydrostatic drive like its predecessor model, offering greater reliability and lower maintenance costs. The vehicle can run for longer at a lower capital to the company.

• astecaustralia.com.au

ABB UNVEILS PREDICTIVE MAINTENANCE SOLUTION The ABB Ability Condition Monitoring for measurement devices is a digital solution that will keep continuous gas analysers under control. This ensures clean air operations as it identifies problems fast and draws attention to significant or undesirable changes in device conditions. Regular health check reports provide users with recommendations based on health status, allowing on-site personnel to leverage their own expertise and enabling remote assistance from ABB when required. “By implementing the predictive maintenance approach of ABB Ability Condition Monitoring for measurement devices, equipment can be actively monitored and managed to prevent problems from arising,” ABB global service manager measurement and analytics Christine Declerck said. “Customers are facing increased emissions regulations. ABB is committed to helping them address environmental impact through solutions like the ABB Ability Condition Monitoring for measurement devices, improving energy efficiency and increasing industrial productivity.” Predictive maintenance reduces customers’ potential safety risks and helps them avoid fines. It also lowers operating and maintenance costs due to less emergency maintenance and fewer unplanned outages.

• abb.com

AUSTRALIANMINING

POSITION PARTNERS LAUNCHES TOPCON’S SURVEY TABLET The Topcon rugged FC-6000 survey tablet powers all Topcon global navigation satellite systems (GNSS), optical instruments and MAGNET software simultaneously. IT builds on the Topcon FC-5000 field tablet, offering faster processing and enhanced functionality. “The FC-5000 was the first tablet that truly blended the power of a desktop computer with an exceptionally field-hardy design that doesn’t miss a beat in bright sunlight, rain or dusty, windy weather,” Position Partners geospatial business manager Cameron Waters said. “This latest model brings even greater processing power and functionality, offering surveyors and other geospatial professionals unrivalled performance for all field applications.” The Topcon FC-6000 has a seven-inch display and the highest environmental rating available, with the latest Intel Quad-Core Pentium processor, along with front and rear cameras. With standard 4G SIM, internal GPS and an optional external keyboard for those that prefer them over a touchscreen, Topcon’s FC-6000 is a full-featured system. • positionpartners.com.au

APRIL 2020

PRODUCTS

CAT DRAGLINE BUCKET BOOSTS FILL SPEED

DIGISHOT PLUS.4G DETONATORS SET A WORLD RECORD

The Cat double clip back bucket for dragline features an innovative design that increases fill speed and reduces bucket weight for faster cycle times and greater payload. The patented design also eliminates the high-maintenance spreader bar from the rigging system. Its wide mouth, aggressive lip angle and low front height reduce drag power required to fill the bucket. The design minimises the required fill distance for improved productivity and reduced bucket wear. The unique shape of the rear wall also enables the bucket to fill without upper rear corner voids, and it increases material density in the bucket for optimum payloads on every pass. It clearly shows the operator when the bucket is full and should exit the cut. Further, the rigging system design gives the operator better control of the bucket and reduces the opportunity for an inexperienced operator to damage it. The unique trunnion design and its location on the clipped portion of the bucket protects the lower hoist link from wear and provides quick dumping of the payload.

• cat.com/mining

Dyno Nobel has partnered with BHP Mitsubishi Alliance (BMA) to execute the world’s largest electronic blast using the DigiShot Plus.4G Electronic detonators. A total of 8144 detonators were fired in a single blast event at BMA’s Caval Ridge mine in Queensland. The blast took 14 days to prepare for, with 2194 tonnes of bulk explosive loaded into 3899 blastholes. DigiShot Plus.4G Electronic detonators are fully programmable, have 15 times more memory and feature downhole wire length and GPS coordinates. Their benefits aren’t limited to faster testing and programming, but also reduced time on bench and blast delays. “We’re able to offer customers unrivalled premium technology through the combination of our DigiShot Plus.4G Electronic detonators and Differential Energy technology,” Dyno Nobel Asia Pacfic president Greg Hayne said. “This collaboration will continue as we progress with our technology road map and look to help our customers improve their environmental impact, including reducing greenhouse gas emissions, deliver better safety outcomes and improve productivity.”

• dynonobel.com

SANDVIK OPTIMINE ADVANCES KEMI’S DIGITALISATION

GREASEMAX LABYRINTH SEAL BRINGS BENEFITS

Sandvik Mining and Rock Technology’s OptiMine digital platform is the underground operations management system of choice at Outokumpu’s Kemi chrome mine in Finland. The platform helps lift mine productivity by improving the situational picture. “By visualising mine operations and conditions in real time, we are enabling well-timed decision making and forecasting,” Outokumpu senior vice president, business area ferrochrome, Martti Sassi said. “Sandvik OptiMine and Newtrax positioning solutions will have a major role in Kemi mine’s underground operations scheduling, task management and visualisation.” Sandvik OptiMine will replace existing systems used in the management of Kemi underground operations and integrate them into one solution. OptiMine is known for its performance in demanding mining conditions, according to Sandvik vice president, automation, Riku Pulli. “Sandvik has the right global expertise and strong local support to help keep mines up and running safely and productively at all times,” Pulli said.

Labyrinth seals provide efficient sealing of housings, contributing to good bearing life when properly grease purged. A labyrinth seal needs a correct grease fill to be maintained for the best sealing effect, and preferably a positive grease flow. With hand greasing, excess grease is typically applied in an attempt to improve the sealing outcome. The excess grease builds up around the seal, creating another problem as dirt becomes mixed into the excess grease, which can then be drawn back into the seal and requires periodic clean ups. GreaseMax lubricators offer a much-improved outcome for labyrinth seal greasing and have proven results in this application. Continuous grease pressure, a correct grease fill and a positive grease flow is maintained in the seal and foreign matter is prevented from entering. The low-cost improvement can provide considerable maintenance and productivity benefits.

• dis.com.au

• rocktechnology.sandvik

AUSTRALIANMINING

APRIL 2020

EVENTS

CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@AUSTRALIANMINING.COM.AU International Uranium Conference 2020, Adelaide, July 1–2 AusIMM’s International Uranium Conference is returning for its 15th consecutive year in 2020. The conference will provide delegates with unparalleled opportunities to network with some of the world’s top uranium experts. Delegates will learn about the current state of the global uranium industry with experts presenting on the turnaround in the uranium and nuclear market. Presentations will discuss the growing global demand for more new uranium production and the opportunities to recommence standby projects and explore new projects. The two-day conference will showcase the latest innovations in the uranium industry and discuss how to prepare and position ourselves for a market upturn. • uranium.ausimm.com Queensland Mining and Engineering Exhibition, Mackay, July 21-23 Having run for more than 25 years, the Queensland Mining and Engineering Exhibition (QME) is recognised as the largest mining expo in the Sunshine State. Held in Mackay, the gateway to the Bowen Basin region, the event is right on the doorstep of some of the country’s largest coal mines. QME will feature over 250 suppliers showcasing leading products and solutions and will host a free-to-attend seminar series that will provide a unique opportunity to hear from industry professionals who will address the current needs of the industry. Sessions will cover mine management and maintenance, health and safety, coal processing strategies and

automation, future skills, policy outlook, engineering excellence and more. QME will be held from July 21 to 23 at the Mackay Showground and will be the ultimate destination for the QLD mining industry. • queenslandminingexpo.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 on a global scale. 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 capital, Kalgoorlie, 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

AUSTRALIANMINING

sector. Diggers and Dealers also features a world-class entertainment program, including a keynote address from Oxford University professor of globalisation and development Ian Golding. Previous keynote speakers have included former Prime Minister John Howard and British economist and public servant Mervyn King. It is also possible to visit sites within the Kalgoorlie-Goldfields region during the conference, by contacting companies directly. • diggersndealers.com.au Women in Industry Awards, Melbourne, August 13 The Women in Industry Awards acknowledges the exceptional women who have achieved success through their invaluable leadership, innovation and commitment to their sector. The awards recognise and reward the achievements of women working within the resources, engineering, manufacturing, process control industries and commercial road transport industries, and aims to raise the profile of women within industry, as well as promote and encourage excellence. Australian Mining, PACE, Manufacturers’ Monthly, MHD Supply Chain Solutions, Prime Mover, Trailer, Waste Management Review, Rail Express, Roads & Infrastructure Australia and Australian Bulk Handling Review have partnered to bring the event to life. • womeninindustry.com.au GMG Mining Forum, Brisbane, August 18-19 Global Mining Guidelines Group and Austmine are set to address the burning issues that are impacting the mining

APRIL 2020

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 IMARC, Melbourne, October 27-29 The seventh International Mining and Resources Conference (IMARC) will connect over 7000 decision makers, mining leaders, policy makers, technical experts, innovators and educators from over 100 countries to Melbourne. The four-day conference will give plenty of opportunities for learning, deal making and unparalleled networking, while also facilitating exhibitions and workshops. As Australia’s largest mining conference, the IMARC program will cover the entire mining supply chain and explore numerous topics such as exploration, plant and processing, social licence, workforce attraction and retention and mine optimisation. More than 400 global mining companies participated in IMARC 2019, driving strong momentum for the 2020 conference. • imarcmelbourne.com

TRANSFORM

the way you weld Make weld adjustments at the wirefeeder.

ArcReach is available with the Big Blue 500X, 700X, 800X and Dimension 650 machines when used with an ArcReach wirefeeder.

welding.com.au 1300 300 844 SCAN TO LEARN MORE

OUR TEAM,

YOUR ADVANTAGE. People you know you can count on. They might be our people, but they really work for you. Hastings Deering understands your industry, we know what keeps it moving and our expert teams know everything about the equipment we sell. Available anywhere, anytime for advice or support, our people are just one of the advantages of partnering with Hastings Deering.

CALL 1300 170 590 OR VISIT HASTINGSDEERINGS.COM.AU/AUSMIN