TECHNOLOGY MINING EQUIPMENT VOLUME 113/03 | APRIL 2021
UNDERGROUND MINING
NEXT GENERATION LIEBHERR INTRODUCES THE NEW R 9600
The next generation
Mining Excavator R 9600
The R 9600 sets new standards in open pit mining equipment – – – – – –
Cutting-edge technologies with Liebherr Assistance Systems First step towards automation with Bucket Filling Assistant Up to 20% fuel consumption reduction with smart energy management Weight-optimized attachments for maximizing bucket payload Latest cabin design with enhanced ergonomics providing a comfortable working environment Perfect match with Liebherr Mining large and ultra-class trucks
liebherr.com/ nextgeneration
TECHNOLOGY MINING EQUIPMENT VOLUME 113/03 | APRIL 2021
UNDERGROUND MINING
SMART PROCESSING
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COMMENT
MANAGING THE CRITICAL MINERALS HYPE CRITICAL MINERALS HAVE BECOME A CRITICAL TOPIC OF CONVERSATION IN AUSTRALIAN MINING. HOW CAN THE INDUSTRY MAKE THE MOST OF THIS OPPORTUNITY ON A GLOBAL SCALE?
BEN CREAGH
Ben.Creagh@primecreative.com.au
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ustralia’s fascination with critical minerals could still be considered relatively new at a national level. But the hype surrounding them is escalating quickly in response to the global demand that has been forecast for these resources in the coming years. Geoscience Australia describes critical minerals as metals and non-metals that are considered vital for the economic well-being of the world’s major and emerging economies. The supply of them is, however, at risk due to geological scarcity, geopolitical issues, trade policy or other factors. As the likes of the United States, European Union, Japan and South Korea intensify their focus on critical minerals, Australia is reacting with similar haste to become a key supplier. Australia has more potential than most to mine significant resources of critical minerals such as rare earth elements (REE), magnesium, lithium, vanadium and nickel. Our REE sector typifies the hype surrounding critical minerals, mostly due to the tense relationship between the United States and China. The US is dependent on international producers for its critical minerals, particularly REE. According to the US Commerce Department, the country imports more than 50 per cent of its annual consumption of 31 of the 35 minerals described by the country as critical. It also has no domestic production of more than a third of the critical minerals. China, in contrast, controls the majority of the world’s mined REE output and approximately 80 per cent of REE processing/separation. Moves by the US to secure future supply of REE are creating potential for trade agreements with Australia. This, and growing demand elsewhere, has pushed Australian companies to accelerate their
CHIEF EXECUTIVE OFFICER JOHN MURPHY PUBLISHER CHRISTINE CLANCY MANAGING EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALISTS VANESSA ZHOU Email: vanessa.zhou@primecreative.com.au NICKOLAS ZAKHARIA Email: nickolas.zakharia@primecreative.com.au
projects and also explore opportunities in the supply chain for processing infrastructure. Lynas Corporation, a trailblazer of the Australian REE industry long before the current hype, has signed an agreement with the US Government to build a light rare earths separation plant in Texas. Despite the distance between Australia and the US, Lynas plans to feed the proposed Texas plant with materials from the cracking and leaching plant under construction at Kalgoorlie. Lynas’ vision of a supply chain between Kalgoorlie and Texas could be a sign of developments to come for Australian companies. The next wave of Australian REE companies is emerging (see p20-21), including Hastings Technology Metals, Australian Strategic Materials and even mineral sands producer, Iluka Resources. All three have resources they can move into production, as well as concepts for the challenging processing phase and plans for how they can supply the international market. The way the Australian REE sector could rapidly develop brings back memories of how our lithium sector quickly evolved. While the lithium sector may be settling now, in hindsight, it was a case of ‘too much, too fast’ for some companies after prices fell in 2018. As Lynas warned in February, there is also a risk of overbuilding REE processing infrastructure amid the growing hype around the industry. Sounds familiar, making it a critical period ahead for Australia’s REE sector.
FRONT COVER
In this edition, we include a special focus on the minerals processing sector, including feature articles covering the products and services driving productivity in this area. This issue puts the spotlight on Australia’s rare earths industry and how two companies are planning to become a non-Chinese supplier of these materials. We look at one of the most promising gold projects in Australia, the Havieron joint venture between Newcrest Mining and Greatland Gold. This edition also reviews Liebherr’s R 9600 excavator, which is expected to be a highly popular ultra-class digger among Australian mine operators. And as usual, we cover the latest mining equipment and technology in our products section.
Cover image: CDE Global. Ben Creagh Managing Editor
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IN INTHIS THISISSUE ISSUE 26
42
12 MINING EQUIPMENT
24 MINING SERVICES
14 MINERALS PROCESSING
26 MINING EQUIPMENT
Liebherr legacy lives on The OEM’s most advanced excavator yet Data, automation part of latest capabilities Glencore, CDE and Weir share their solutions
18 INDUSTRY OUTLOOK
Greatland Gold’s emerging era Chief executive Shaun Day takes helm
20 COMMODITY SPOTLIGHT
A burgeoning rare earths sector ASM, Hastings Technology advance plans of action
22 UNDERGROUND MINING
Precise drilling made possible Introducing Epiroc’s Boomer M20
Dry hire here to stay National Group presents the case Long live Caterpillar Hastings Deering extends machine life
28 INNOVATION
Combined power of sensors Hummingbird covers human shortfalls
32 MINERALS PROCESSING
Keys to processing performance From sophisticated designs to cracking telltale signs
42 MATERIALS HANDLING
Providing best-in-class service Fenner Dunlop and Flexco’s approaches to issues
46 CRUSHING & SCREENING
Milbrae Quarries, Derrick bolster offerings The latest crushing and screening developments
52 DRILL & BLAST
E*STAR receives an upgrade Electronic initiation system gets new connectors
54 MAINTENANCE
Solutions that drive productivity JSG, AMCAP respond to maintenance needs
58 INDUSTRY COMMENT
Reviewing BHP-Austmine partnership BHP Supplier Innovation Program improves safety
60 TECHNOLOGY
Innovators break the (tech) mould Tried and tested radar systems to simulators
67 MINING SERVICES
Tougher link assemblies ITM Mining launches D10 heavy duty chains
60
68 EVENT SPOTLIGHT
Pull the curtain for 2021 Mining events reunite the industry
REGULARS 5 COMMENT 8 NEWS 72 PRODUCTS 74 EVENTS AUSTRALIANMINING AUSTRALIANMINING6 6OCTOBER APRIL 2021 2020
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. OZ MINERALS HONES IN ON 2021 COPPER GROWTH OZ Minerals is expecting major growth from its Australian assets this year off the back of strong production at the Prominent Hill copper-gold mine in South Australia. The company met its copper production and cost guidance at the Prominent Hill mine for the sixth consecutive year, delivering 46 million tonnes of the base metal in 2020. It has given OZ Minerals confidence to ramp up output across its portfolio, including the Carrapateena coppergold mine in South Australia. OZ Minerals managing director and chief executive Andrew Cole said the company had been successful in withstanding COVID-19, allowing it to continue its growth strategy. “Reflecting on the year, our
works in the fourth quarter of this year, while it looks to complete and commission a tailings pump upgrade project, construct the Western Access Road and explore automation and electrification opportunities. The company also aims to ramp up its underground mining rates at Prominent Hill to four to five million tonnes per annum and complete the site’s expansion study. Cole said the Prominent Hill expansion study would boost production and mine life by accessing deeper ore using a shaft haulage system. OZ Minerals boosted its net profit after tax to $213 million last year, up from $164 million in 2019 despite the onset of the COVID-19 pandemic.
culture enabled us to quickly adapt to the rapidly evolving COVID-19 environment, safely achieve our operational goals and advance our growth pipeline with the ramp up of our new Carrapateena mine and study updates on the Carrapateena expansion, Prominent Hill expansion and the West Musgrave copper-nickel project,” he said. “(The year of) 2021 will be a year where OZ Minerals will move into our next phase of growth with major growth catalysts at all of our assets.” Cole expects Carrapateena’s approved block cave expansion to deliver world-class potential, considering its scale, production, mine life, low-cost base and jurisdiction. OZ Minerals will begin its block cave
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.
RIO TINTO FREIGHT AGREEMENT CONNECTS PILBARA WITH ASIA Rio Tinto has started shipping its Western Australian iron ore directly to Singapore thanks to a new commercial freight shipping service. The company stated that the service from the Port of Dampier to Port of Singapore would be quicker, cheaper and cleaner than the existing route via Fremantle. The freight service kicked off in February when the vessel MCP Graz arrived at the Port of Dampier from Singapore, delivering maintenance supplies for Rio Tinto’s Pilbara iron ore operations. The freight included rail wagon wheels, wagon parts, oil and lubricants, with future shipments expected to include tyres for heavy earthmoving equipment, conveyor belts, rail wagon and locomotive parts and mining consumables. Rio Tinto expects the service to slash lead time for goods by six to 10 days, save approximately three million litres of diesel and reduce road train travel from Perth by more than 3.8 million kilometres. The mining major hopes that eventually more than half of its
PORT OF DAMPIER IN WESTERN AUSTRALIA.
Pilbara freight requirements will be delivered by the new service. “This is an important new service that connects the Pilbara to the rest of the world via the major international shipping hub of Singapore,” Rio Tinto iron ore managing director of port, rail and
core services Richard Cohen said. “It will provide a number of benefits by delivering cheaper, cleaner and faster freight to the region. “It is an important breakthrough not only for our business, but it will also provide a great opportunity for
AUSTRALIANMINING
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the local Pilbara economy by helping to unlock small business growth and supporting job creation.” The Dampier to Singapore freight service will be open for use by other local businesses in Australia’s northwest, giving them access to international markets.
THINK INSIDE THE BOX MIDLIFE SERVICE KITS AMCAP Industrial is a leading parts distributor servicing the Australian Mining, Commercial and Industrial sectors. With AMCAP Industrial’s Midlife kitting service, only one part number is required for each complete kit, with all items arriving in one package, delivered in full and on time .
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NEWS
ANGLO AMERICAN TO HALVE AQUILA WATER CONSUMPTION Anglo American has commissioned a reverse osmosis (RO) water treatment plant at the Aquila metallurgical coal project in the Bowen Basin, Queensland. The company is planning to install another RO plant, with both designed to reduce the use of fresh water in mining operations. Anglo American plans to halve its fresh water usage by 2030. Anglo American metallurgical coal business chief executive officer Tyler Mitchelson said two megalitres per day of mine affected water were being treated. “A key target in Anglo American’s
global sustainable mining plan is to reduce our reliance on fresh water by 50 percent by 2030 across our mine sites, and I’m pleased to say Aquila is currently sourcing recycled water during construction of the mine,” he said. “A planned second RO plant will to be used to recycle a further 2.4 megalitres of mine affected water – once Aquila becomes operational in early 2022, more than doubling capacity and helping to reduce the reliance on water from local sources during times of drought.” The water treatment plant at the $240 million Aquila mine is valued
at $5 million. Mitchelson said the Aquila project would exhibit Anglo American’s focus on sustainability and support 500 jobs. “Aquila will be one of the world’s most technologically advanced underground mines and will showcase our innovation-led approach to sustainable mining,” Mitchelson said. The Aquila project is expected to increase the life of Anglo American’s existing underground operations at the Capcoal complex. Anglo American invested 77 per cent ($2.83 billion) of its
total expenditure in Australia with Queensland suppliers during the last financial year. “Our Aquila project is progressing well, with support from its Queensland-based workforce and contracting partners,” Mitchelson said. “More than 90 per cent of our Aquila contracts have been awarded to Queensland-based suppliers. “Aquila’s integrated network of pipes and pumps is securing the distribution of high-quality water, which is necessary in metallurgical coal mining for equipment cooling and coal cutting operations.”
IMAGE CREDIT: ANGLO AMERICAN.
ANGLO AMERICAN EMPLOYEE TESTING THE FILTERED WATER AT A HOLDING POND.
ATLAS IRON TRUCKS FIRST SANJIV RIDGE IRON ORE Atlas Iron has hauled its first shipment of iron ore from the Sanjiv Ridge operation in Western Australia ahead of schedule. The first delivery of iron ore to Port Hedland kickstarts the company’s annual production target of four to five million tonnes. The shipment was transported using four haul trucks from MGM Bulk and CSI Mining. Atlas Iron chief executive Sanjiv Manchanda welcomed the milestone for the company, which crushed its first ore at Sanjiv Ridge in early February.
“I’m so proud of our team of Atlas staff and our contracting partners, MGM Bulk, MACA and CSI for working so tirelessly to ensure we surpassed our project targets,” he said. “It’s always a team effort, and our small team certainly knows how to get things done safely, efficiently and with agility to get a win-win outcome.” Atlas Iron is owned by Gina Rinehart’s Hancock Prospecting. The four haul trucks were painted pink to recognise Rinehart’s support for AUSTRALIANMINING
breast cancer research. “I also take this opportunity to thank our partners MGM Bulk and CSI Mining who painted their four brand new trucks and crusher, which were used today and for the duration of the project, a striking pink colour in recognition of our group and executive chairman’s commitment to supporting breast cancer research and improving patient care,” Manchanda said. “These pink trucks now add to a large amount of mining infrastructure
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in the Pilbara now pink, including trains, ships, processing plants, crushers and mining trucks.” The trucks will haul Sanjiv Ridge’s lump and fines to the Utah Point stockyard in Western Australia, with the mine expected to add five to six years to Atlas’ value chain. Previously known as Corunna Downs, the Sanjiv Ridge mine has a mineral resource of 64 million tonnes at 57.32 per cent iron and 29 million tonnes at 57 per cent iron ore reserve.
From pit to tailings
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Mill Circuits Warman centrifugal slurry pumps, Linatex ® hose and rubber products, Cavex ® hydrocyclones, Vulco® mill lining systems, Delta Industrial™ and Isogate ® knife gate valves, Accumin™ lubricators, Enduron® dewatering screens, Linard® and Linagard® wear panels, chute lining and equipment protection ®
Tailings and Fluid Management TerraFlowing™ tailings management, Warman® centrifugal slurry pumps, Multiflo® dewatering pumps and barges, GEHO ® positive displacement pumps, Isodry™ filter presses, Delta Industrial™ and Isogate ® knife gate valves, Accumin™ lubricators, Cavex ® hydrocyclones, Linatex ® hoses and spools
From material extraction to tailings, our extensive product range covers everything you need for a complete, end-to-end solution. Backed by leading material science technology, our equipment delivers proven high wear resistance. Digitally enabled, our solutions lower total cost of ownership, transform productivity, foresee risk and enhance performance. Whether a mission-critical part or an entire circuit, our engineered solutions come with unrivalled support from our extensive global service network. Get it all and more. Visit www.apac.weir or email apac.minerals@mail.weir Copyright © 2020, Weir Minerals Australia Limited. All rights reserved. The trademarks mentioned in this document are trademarks and/or registered trademarks of companies forming part of The Weir Group PLC. 202012/AU1124
Minerals | ESCO
MINING EQUIPMENT
LIEBHERR LEGACY LIVES ON WITH R 9600 EXCAVATOR THE ORIGINAL EQUIPMENT MANUFACTURER’S LATEST ULTRA-CLASS EXCAVATOR IS SET TO TRANSITION ITS RANGE TOWARDS A NEW GENERATION OF MACHINE THAT WILL SUPPORT THE EVOLUTION OF THE MINING INDUSTRY. BEN CREAGH WRITES.
A
ustralia, more than any other mining jurisdiction, can lay claim to being the unofficial home of 600-tonne class excavators as the leading market for these machines. The prolific iron ore deposits in the west and vast coal fields in the east have made 600-tonne excavators ideal for where these bulk commodities are mined. With these credentials, Australia has been the key testing ground for Liebherr’s R 9600, an excavator that has been developed to lay the foundation for this class in the future. Since early 2020, Liebherr’s first R 9600 pre-series excavators have been operating at iron ore and coal sites in Australia. After being proven during a validation period, the R 9600 has now entered the global market, with eight to be operating across Australia by the
end of 2021. Liebherr-Australia managing director, mining Trent Wehr describes the R 9600 as, clearly, the most advanced, innovative and efficient excavator that the original equipment manufacturer (OEM) has ever released. “And I would go as far as saying, that extends to any ultra-class excavator that has ever been introduced into the global mining market,” Wehr tells Australian Mining. The R 9600 not only carries Wehr’s support, but also the expectations that come with it being the successor to the company’s acclaimed R 996B excavator. Liebherr first introduced the R 996 in 1996 and then the R 996B in 2009. A quarter of a century after its launch, the R 996 is recognised as an icon of the 600-tonne class, particularly in Australia where 70 per cent of them have or are operating today, accumulating 5.5 million machine hours. As much as the R 9600 builds off
the R 996’s accomplishments, the new model is a significantly different proposition that is designed to establish a unique legacy because of how it will support the mining industry’s progression. “The R 996 has been a fantastic machine for its time, but there is no doubt that the R 9600 is moving into this new phase of where mining is heading,” Wehr adds. “We are already seeing substantial change within the mining sector. We have seen automation become a big part of mining operations and now it has become about the drive for decarbonisation – ultimately a machine like this can deliver on that vision.” Despite its future focus, the R 9600 shares many of the components that have made Liebherr’s R 9800, 800-tonne excavator popular over the past 10 years. Beyond these components, the R 9600 comes into its own. The machine is equipped with two QSK50 Cummins THE TRUCK LOADING ASSISTANT, ONE OF LIEBHERR’S ASSISTANCE SYSTEMS, HELPS THE OPERATOR ATTAIN OPTIMAL PRODUCTIVITY AND EFFICIENCY.
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engines with advanced combustion technologies. Liebherr has developed and introduced efficiency management systems for the engine and hydraulic system control to reduce fuel consumption without compromising productivity. These features are also a step towards the Liebherr Emission Reduction solutions. In standard backhoe configuration, the R 9600 comes with a 37.5-cubicmetre bucket that is ideally matched to Liebherr mining trucks. The excavator is also available in face shovel configuration equipped with a standard 37-cubic-metre shovel. The R 9600 entirely separates itself from the OEM’s past excavator release with additional technology products and services, including Assistance Systems and Semi-Automated functions. Liebherr’s advanced on-board Assistance Systems are products that are designed to support operators in becoming more efficient through analytics and actionable insights, to realise improvements in safety, maintenance and overall equipment effectiveness. The Truck Loading Assistant, for example, helps the operator attain optimal productivity and efficiency. With 99 per cent measurement accuracy, the system measures the instantaneous bucket payload and provides real-time information to the operator for efficiency gains during the truck loading process. Liebherr has also introduced its first hydraulic excavator automation product in mining with the release of
MINING EQUIPMENT
LIEBHERR’S LATEST RELEASE TO THE 600-TONNE EXCAVATOR MARKET, THE R 9600.
the company’s Bucket Filling Assistant, which provides a semi-autonomous digging function currently available as an option for the backhoe version. “We see this product as the first step in the journey towards excavator autonomous loading,” Wehr says. The development of the R 9600 is based on almost a decade of customercentric research, focussed on both field experiences with the R 996B and R 9800 excavators. Feedback and insights were collected from mine operators, maintenance crews, procurement groups and executive management teams to establish an understanding of the challenges they meet every day and
their strategies for the future. Liebherr-Mining Equipment Colmar SAS, senior product manager for excavators and Assistance Systems, George Barturen, says the development of the R 9600 has been guided by two separate research phases that ran concurrently over many years. “The technology aspect was an important separate discussion from our customers’ experiences with the R 996B and R 9800 excavators,” Barturen says. “The Assistance Systems journey for Liebherr started with understanding the customer challenges to develop the desired products needed on machines to improve safety, reliability and
effective productivity. “Liebherr then embarked on the definition and prioritisation of product developments and system integration to the machine. “The value add over the course of the developments has been the utilisation of the learnings and machine information for the ongoing and future development of enhanced machines and technology products and services for our customers.” Liebherr has analysed field information from the Australian sites alongside its partners since early 2020, learning more about the R 9600, which has validated its competitive advantages for
THE R 9600 IS DESCRIBED AS THE MOST ADVANCED, INNOVATIVE AND EFFICIENT EXCAVATOR THAT LIEBHERR HAS RELEASED.
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applications within both the local and international mining industry. The R 9600 enters the market with an expected lifespan of more than 80,000 operational hours and includes a new undercarriage which has been designed with knowledge gained from the company’s decades of engineering experience. From a maintenance perspective, the uppercarriage has been designed to allow for quick and easy access for maintainers. Enlarged walkways with handrails and non-slip perforated steps provide safe access for inspections and maintenance at all levels of the machine, including engine and powertrain components. The R 9600 incorporates a new cabin design, which provides a larger 14-cubic-metre workspace that has been developed based on direct feedback from operators and customer engagement workshops. The design has focussed on improvements in ergonomics, operator working area visibility, reducing vibration and limits noise to 69 decibels to maximise operator comfort. Liebherr-Australia R 9600 technical support advisor, John Illarietti, says the introduction of the R 9600 at the iron ore and coal sites he supports has, overall, been smooth. The OEM’s support teams have maintained a constant presence on the sites throughout the validation, which Illarietti believes has been critical for helping the customers understand the R 9600’s technological advances. “At the end of the day the clients are familiar with excavators, so for us it’s been more about the technology side of the machine, its functionality and ensuring they are using them to the best advantage,” Illarietti says. “The advanced hydraulic and electric control architecture of this machine supports enhanced machine performance and troubleshooting capabilities, making it easier and safer to maintain. “Liebherr’s on-site presence enabled us to work closely with our customer’s teams to transfer the required knowledge and provide the required support, which ensured the successful introduction of the R 9600.” And with that experience, Liebherr is ready to shed light on the excavator to the mining industry following its launch to the market. As the successor to the R 996B, the R 9600 excavator comes equipped with the required attributes to spark a changing of the guard for Liebherr in the 600-tonne excavator class. “The R 996 has a fantastic legacy and we now believe that the R 9600 is going to create the next legacy for us,” Wehr concludes. AM
MINERALS PROCESSING
PROCESSING SOLUTIONS PUMP OUT INNOVATION MINERALS PROCESSING PLANTS HAVE ENTERED A NEW FRONTIER OF DATA- AND AUTOMATION-BASED CAPABILITIES, WHILE ALSO IMPROVING THEIR CAPABILITIES FOR DELIVERING A RELIABLE SUPPLY OF REFINED RESOURCES.
T
he evolution of technology in the minerals processing sector is projecting upwards towards a safer and more productive environment. It is often objected that smart devices make us lazy in our personal lives, however, they are improving the effectiveness of minerals processing operations, making them virtually bulletproof to staff limitations and travel bans. As a pioneer in the minerals processing space, Glencore Technology is one of several companies pushing for innovative solutions to day-to-day tasks. Based in Brisbane, the company supplies solutions developed in Australia for the minerals processing, metals smelting and refining industries to Glencore’s global mining operations. While the company generally focusses on flowsheet improvements, Glencore Technology has adopted some Industry 4.0 technologies that have become vital for a post-COVID environment where remote working has become the norm. “Glencore Technology has incorporated new robotics in our cathode stripping machines,” a Glencore Technology spokesperson tells Australian Mining. “We’ve also evolved the IsaMill
maintenance system, IMIS, to be online and mobile phone-driven, giving greater access to data and continuous improvement in mill performance. “And we’ve created online calculators and 3D models to provide the market with scenario-testing and to help specify what they might need for a given feed and demand.” IsaMill uses horizontal milling, which prevents short circuits and was initially created to produce zinc at Glencore’s McArthur River mine in the Northern Territory and George Fisher mine in Queensland. “IsaMill was a key enabler for our McArthur River mine and George Fisher mines, in order to achieve the required grind size to liberate the zinc,” the spokesperson says. “These are in fact why the IsaMill was developed.” Glencore Technology is planning to install a froth pump at the Mt Owen coal operation in New South Wales, which removes air from a slurry feed. “This is about to be installed at the Mt Owen operation and we expect it’ll be highly sought after right around the world,” the spokesperson says. The company has also created a new plant that uses a Jameson Cell at Newcrest Mining’s Cadia gold operation in New South Wales. The Jameson Cell is a high-intensity
froth flotation cell that creates more value out of lower grade ore and sulphides, with Glencore Technology believing it could assist the gold industry in particular. “In a world progressively moving toward lower grades and sulphides, this could be a game changer,” the spokesperson says. “We’ve created a new Z8500 Jameson Cell for the Cadia operation. It doubles throughput capacity by using a larger downcomer and it delivers incredible results, making it ideal for large rougher applications.” Glencore Technology plans to focus on using its ISASMELT technology to recycle electronic waste, reduce its carbon footprint and help operations make more significant recoveries from lower grade orebodies.
A sense of innovation
CDE has a proven reputation as experts in modular plant and equipment solutions. The company’s regional manager of Australasia, Daniel Webber, says CDE has continued to advance its smart technology suite for minerals processing applications. Webber believes the CDE Core suite is the next leap in sensor technology. “Over the last five years, we’ve
been developing our suite of smart technologies to give customers greater control of their plant and for datadriven insights in terms of diagnostics and product development,” Webber says. “The new fourth industrial revolution technologies such as artificial intelligence, machine learning, autonomous vehicles, the Internet of Things creates the opportunity for quarrying and mining companies to fundamentally change the business model, unlocking much-improved customer service and customisation, reducing costs in the value chain, improving safety and creating opportunities.” The CDE Core suite uses sensors to continuously monitor processing equipment for predictive maintenance, increased uptime and remote access and monitoring. “Think of a monitoring system for your own personal fitness, but adapted and upscaled to monitor the health of the plant,” Webber explains. “It offers owners and plant managers real-time data about the status of the plant, from hours of operation to throughput, output and more. The ability to understand what is happening with the plant anywhere and at any time offers real comfort for the customer.”
CDE GLOBAL USES ITS MODULAR APPROACH FOR MINERAL PROCESSING PLANTS.
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MINERALS PROCESSING
Webber says CDE is developing what it refers to as WorkFlow as part of its Core technology suite. “WorkFlow uses the PLC in the plant to do procedural tasks such as the start-up process and scheduled maintenance,” Webber says. CDE Core also offers digital twinning capabilities, with the ability to design a plant in a digital 3D environment, allowing for more robust predictive maintenance analysis. This is enhanced by the suite’s WorkFlow element, which provides data on plant process flows and maintenance records. “WorkFlow provides a framework for scheduling routine maintenance,” Webber says. “Using the streamlined application, plant managers can direct operators to inspect, grease or replace components all on an agreed schedule. “It can also be used to instruct the operator to take photos, measurements and readings, which are automatically uploaded and available for the customer and our CustomCare team to access. “If the plant is not optimally performing, we can use this data to diagnose the symptom and take action before it becomes a problem.” CDE Core’s SmartTech software also provides real-time health tracking of the mineral processing plant to enable more robust monitoring.
DATA PROCESSING ALLOWS WEIR TO ENSURE MINERALS PROCESSING MACHINES AUTOMATICALLY ACHIEVE PEAK OPERATING CONDITIONS.
Webber says the connectivity of the plant enables CDE to have a lot of power with spare parts, operating costs and allows it to look for trends. He adds that CDE Core can improve a plant’s uptime, leading to a knock-on effect of productivity and efficiency gains.
“Data is powerful. At CDE, we are constantly striving to maximise output and data is key to this,” Webber says. “The predictive nature of the applications means the plant owner can maximise their investment and minimise unexpected downtime.” CDE’s customer-driven focus has
enabled its sensor technologies to evolve further. For a mining company, CDE provided a 3D model of a processing plant, which was intended for maintenance services. However, the customer found further uses for the technology.
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AUSTRALIANMINING
Web: www.lase.com.au 15
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MINERALS PROCESSING
WEIR MINERALS’ SYNERTREX PLATFORM OFFERS SOLUTIONS THAT TAKE ADVANTAGE OF BIG DATA PROCESSING.
GLENCORE TECHNOLOGY’S ISAMILL.
“Our clients have been using the technology for pre-starts, safety inductions and as a planning tool prior to a shutdown,” Webber says. “It’s a good example of when technology is designed for a specific purpose and once it’s put in the hands of the user – they find a completely different use.” The importance of sensor technology in minerals processing continues to grow, Webber continues. He says being in control of the density and pump volume in wet processing is absolutely critical. “We can control the feed with sensors, a PLC and programming between us and client,” Webber says. “We can also monitor the equipment to schedule maintenance to ensure optimal productivity. “Sensor technology is coming like a freight train and mineral processing is only getting more ever-present.” Under CDE’s mantra, the modular approach provides moveable plant and equipment for minerals processing applications at a mine compared with a traditional stick build. The company helped SIMEC build two wet processing plants at the Iron Knob and Iron Barren projects in South Australia to beneficiate low-grade iron ore. “The rapid deployment, the derisking through the modular approach, particularly through junior miners is really important to make their return on investment stack up and operate a viable project,” Webber says.
Unlocking plant synergy
The combination of sensor technology and IoT data processing has long been acknowledged for giving minerals processing plants their own ‘crystal ball’ to look into the future condition of assets through predictive maintenance. Weir Minerals’ Synertrex platform has unique abilities compared with
conventional condition monitoring systems; now it also offers solutions reaping the benefits of big data processing beyond the typical asset health solutions. Weir has seen several global customers already signing up for this unique and high-performing digital platform. The head of engineering operations at Weir Minerals, Stephen Marshall, says the Synertrex smart analytics platform optimises plant performance by delving into real-time details about each machine, allowing for not only predictive analytics but also advanced process optimisation. One example of benefits derived from advanced processing of large amounts of data is the latest process optimisation solutions, enabling automatic adjustment of closed loop control of hydrocyclones to maintain peak operating conditions without manual intervention by operators. According to Marshall, Synertrex looks at both the machine health directly, along with the assets connected to it. “For example, thinking of the slurry pump, you’re looking at the bearing housing, drive motor and gland water supply system,” Marshall says. “Compared to a conventional condition monitoring system, it’s a more comprehensive view of the entire installation rather than just focussing on one individual component.” It is a similar story for vibrating screens, where the Synertrex technology can process data to provide more comprehensive insights into machine health, process throughput and separation efficiency. “The data that we gather is used for data analytics, predictive analytics and big data analysis to provide a direction towards getting more insight over standard monitoring,” Marshall continues. AUSTRALIANMINING
“We can get more insights into the equipment health predictability in and around maintenance cycles. Just the simple fact of knowing the runtime details of a piece of equipment is valuable information for operators.” At its core, Synertrex pushes the highest level of performance out of a plant and equipment, which is achieved in part by mapping out when maintenance is actually needed. This reduces downtime and allows for smoother operations around plant shutdowns. “It provides the level of capability to run the equipment for longer before it requires maintenance and also allows better scheduling around the flexibilities of a plant shutdown, and that’s been key,” Marshall says. Synertrex platform also enables remote monitoring of processing plants for mine sites – this became vital in 2020, due to COVID-related travel restrictions and limited site personnel. “COVID has really brought sensor technology to light – it’s provided a catalyst in the drive towards
THE SYNERTEX ENABLED WARMAN MCR 550 PUMP.
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automation, sensor technology, remote operation and more process control rather than less,” Marshall explains. Weir also offers services to monitor equipment on behalf of customers. Data analytics are key to the future of minerals processing technology. Marshall says Weir works with customers to provide further process optimisation and machine insights through the combination of sensor technology and IoT data processing technology. “To have the sensors is one thing but what you do with the data is the key, and I think that we are only at the beginning of the journey in that regard,” Marshall says. “We have undertaken some evaluation of AI capability and we can see that there’s enormous potential there. “We’re actively pursuing the data analytics piece and we’re providing intelligence and insights based on that. It’s early days but it’s very much a case of watch this space for what we’re looking for in that area.” AM
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INDUSTRY OUTLOOK
DAWN OF A NEW GOLD OPERATION GREATLAND GOLD HAS APPOINTED SHAUN DAY AS ITS CHIEF EXECUTIVE OFFICER AT A TIME WHEN THE COMPANY IS LOOKING TO PUSH THE HAVIERON JOINT VENTURE TOWARDS PRODUCTION. NICKOLAS ZAKHARIA WRITES. THE MINE CAMP AT THE HAVIERON JOINT VENTURE IN WESTERN AUSTRALIA.
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he Havieron joint venture (JV) between Greatland Gold and Newcrest Mining is a gold-copper resource that potentially represents the next generation of Western Australian mines. In 2019, Havieron owner Greatland signed a US$65 million ($82 million) farm-in agreement with Newcrest to develop and explore its prospects, setting the stage to create another flagship operation in the country. Australian gold mining has enjoyed buoyant activity in recent years as M&A (mergers and acquisition) deals increased and prices soared to record levels. This culminated with last year’s $16 billion merger between Northern Star Resources and Saracen Mineral Holdings, which consolidated the Kalgoorlie Super Pit in Western Australia under single Australian ownership for the first time. An integral part of Northern Star’s expansion was former chief financial officer Shaun Day, who oversaw the company’s market cap rise from $700 million to $8 billion. Day says his time at Northern Star serves as a tremendous platform for his role as chief executive officer at Greatland. “I was really grateful for the opportunity and being part of the team that created this substantial
will largely focus on advancing Havieron into production. He also paid tribute to former CEO Gervaise Heddle, who he says put the company’s portfolio in a strong position. “The cornerstone of that vision is very much delivering Havieron,” Day says. “We are well placed to do that but to have a world-class asset in the portfolio is naturally a fantastic opportunity. “Augmenting that with additional growth opportunities. We want to be financially disciplined, but again the vision is to create a multi-mine, multi-billion-dollar organisation.”
GREATLAND GOLD CEO SHAUN DAY.
Spearheading Havieron
miner here in Australia,” Day tells Australian Mining. “It gives me a lot of large-scale mining operation experience, which is a continuation of the role at Sakari (Resources) before that. “Developing multi-billion companies from small miners into large mining houses is my background.” AUSTRALIANMINING
Listed on the London Stock Exchange, Greatland’s market cap was sitting at around £890 million ($1.6 billion) in mid March. The company is exploring gold tenements across Western Australia and Tasmania, with Havieron being the centrepiece for its growth ambitions. Day’s vision as Greatland CEO
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Newcrest CEO Sandeep Biswas, speaking in a 2021 half-year earnings call, has reinforced the leading Australian gold miner’s plans for Havieron in the coming years. “Our goal remains to realise commercial production from Havieron within the next three years,” Biswas says. “Our pre-feasibility study for the project is well underway and we expect to release these findings later this calendar year.” Newcrest and Greatland are also working together to find “the next Havieron” in the Paterson Province For Day, Newcrest’s support has been valuable to Greatland’s growth prospects.
INDUSTRY OUTLOOK
“Newcrest has been a natural fit for Havieron. Some 45 kilometres to the west is their Telfer gold mine,” he says. “We’re able to leverage that existing infrastructure, including the processing facility.” The Telfer gold-copper mine features the main dome and west dome open pits and underground mines. Its processing facility produces gold and copper using a dual train, comminution circuit plus floatation and cyanide circuits. Havieron and Telfer are set to be closely linked, with Day saying the latter’s facilities will be used under the Havieron JV. “From a Newcrest point of view, (Havieron) is a brownfield development. We can use that existing Telfer base for logistics flights. It is a reasonably remote location that actually has a fantastic infrastructure footprint,” Day says. “Having Newcrest involved is tremendous – they have a 65,000-metre drill campaign for the next six months for Havieron. The scale that they’re bringing to this is powerful and they’re a great partner.”
drive the gold price to record levels in 2020. Think COVID, US elections and recessions,” Murphy tells Australian Mining. “The strong fundamentals for the gold sector in 2020, record prices driven by global economic uncertainty, strong balance sheets and major M&A deals are still present in 2021 and likely to drive increased focus on exploration and development companies as the larger players engage in reserves replacement either by their own exploration or by
Golden opportunity
tapping juniors and explorers.” Murphy says uncertainty in international vaccine rollouts and United States politics stability may cater to high gold prices in 2021 as last year’s key drivers subside. “However, the advent of inflation and Chinese trade tensions are some factors that could destabilise the reversion to growth and spark a stampede back into gold and drive price growth,” Murphy says. Day believes Havieron’s assets of
The JV’s activities in the Paterson Province will be a key contributor of an Australian focus on gold exploration, which looks here to stay following record prices in 2020. EY M&A partner Paul Murphy says market volatility that drives up gold prices is likely to impact the precious metal. “The gold price is driven by uncertainty and volatility in the financial systems, which helped
gold and copper will continue to be a safe metal for many investors. “I think gold continues to be a sound investment in a global market which continues to see quantitative easing, which continues low interest,” he says. “Both of these are seen to be supportive of the gold price.” For Day, copper is also an increasingly attractive commodity that Havieron is set to produce. If Havieron enters production in the next three years, it will do so at a time when copper demand
BOX CUT WORKS AT THE HAVIERON PROJECT.
The Hummingbird Audio Alert System
is expected to surge from new technologies such as electronic vehicles (EVs). “One of the important aspects (of Havieron) is copper-gold. Copper is at a nine-year high and it obviously plays strong into that EV story,” Day says. “For me, part of the charm of Havieron is not just its gold, but its combination of copper and gold exposure. It’s a lovely combination of commodity exposure to the company
and its shareholders.”
Future signs
With further drilling being conducted at Havieron and a pre-feasibility study on the way, Greatland and Newcrest will be conducting box cut works at the mine. “We have commenced work on the box cut, which is the precursor to the commencement of the decline drive,” Day says. “We’re excited that’s underway. Part of the journey to get down to the orebody, the narrative, is that it’s going to take around three years to reach first ore from commencing that decline.” With a number of exploration projects in the Paterson Province, Greatland is also well placed to develop its portfolio in the region outside of Havieron. “Havieron is world class and creates this flagship asset for us – that’s sitting in the Paterson range,” he says. “We have other exploration opportunities within that Paterson Range – it’s elephant country. There’s Telfer, Havieron and now Rio Tinto’s Winu discovery within the Paterson as well.” As a promising side project, Greatland is commencing its Juri JV with Newcrest to advance its exploration in the region in an attempt to tap into the highly prospective area. “The best place to look for minerals is where minerals have been found. We strategically kept some ground in Paterson 100 per cent owned by Greatland and recently added to that footprint, which creates more high-quality targets for us,” Day says. AM
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IMAGE CREDIT: HASTINGS TECHNOLOGY METALS.
COMMODITY SPOTLIGHT
HASTINGS HAS IDENTIFIED GERMANY AS ITS PRIMARY MARKET FOR MIXED RARE EARTH CARBONATE.
RARE EARTHS TO LEAVE GLOBAL RARITY BEHIND RARE EARTHS HAVE BECOME AN EMERGING PART OF THE AUSTRALIAN MINING SCENE AS THESE INGREDIENTS FOR A GREENER FUTURE HAVE INCREASED IN DEMAND. AUSTRALIAN STRATEGIC MATERIALS AND HASTINGS TECHNOLOGY METALS REVEAL THEIR PROSPECTS IN THIS SPACE. VANESSA ZHOU WRITES. Aspiring rare earths producer Australian Strategic Materials (ASM) shares this belief, with managing director David Woodall saying that nearly all companies in Australia are producing lower value products, such as carbonates and concentrates. These products need to be further processed into metals if they are to become ingredients for electric vehicles (EVs) or wind turbines. “The metal is the product that the THE YANGIBANA PROJECT BOASTS A HIGH NDPR: TREO RATIO.
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manufacturing end users require,” Woodall says. “If they need neodymium (Nd) powders for neodymium magnets that are going into EVs and wind turbines, we can provide that. “We are going to produce oxides from the Dubbo project in New South Wales and convert all of those oxides into metals, which is different from any other critical material producers in Australia.” HASTINGS IS A TARGETING A PRODUCTION OF 15,000 TONNES OF MREC AT YANGIBANA.
IMAGE CREDIT: HASTINGS TECHNOLOGY METALS.
their rare earths projects. “The technical capability to draw on to design and build separation facilities is not as available. It took Lynas about five years to ramp up its Kuantan plant (in Malaysia) to achieve reasonable recoveries,” Morgan tells Australian Mining. “Much of the rare earths supply chain, including separation facilities and magnet making, takes place in China.” IMAGE CREDIT: HASTINGS TECHNOLOGY METALS.
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he first few months of 2021 have reinforced that the race to fulfil a future surge in demand for rare earths is gathering momentum. Even though Australia holds one of the largest resources of rare earth elements globally, it was only in 2019 that the federal government heightened its interest in the commodity. The government declared rare earths as a critical mineral, explicitly giving its support to all mining companies that plan to delve into or advance operations in this space. As the Australian rare earth mining sector matures, Lynas Corporation may no longer be the only company to capture a share of the global rare earths market outside of China. However, rare earths mining presents a unique set of challenges, given it is a relatively young commodity to explore and mine in the country. UBS mining equity analyst Daniel Morgan says mining companies don’t have a large institutional knowledge base in Australia to draw on to develop
COMMODITY SPOTLIGHT
IMAGE CREDIT: AUSTRALIAN STRATEGIC MATERIALS.
THE DUBBO POLYMETALLIC PROJECT IN NEW SOUTH WALES.
The Office of the Chief Economist predicts that wind and solar generation, which uses rare earths, cobalt and manganese, will account for 35 per cent of generation capacity in 2028. Sales of EVs are also forecast to increase by at least 25 per cent a year by 2029. Companies such as Hastings Technology Metals are confident in their rare earths offering to global markets. Its strength lies in the high NdPr:TREO (total rare earth oxides) ratio of 40-50 per cent at the Yangibana rare earths project in Western Australia. The project stands in stark contrast to the orebodies in the rest of Australia (including at Lynas’ Mt Weld operation in Western Australia), South America and China, where they hover around a ratio of 20 per cent. This gives Hastings 75-175 per cent higher value ore products than any rare earth project already in production. It also puts Hastings in a
comfortable position when competing in the supply of the most relevant critical materials needed in EVs, wind turbines and robotics. “When we first drilled the ground in Yangibana and the results came through in mid-2014, we discovered a high NdPr:TREO ratio,” Hastings chairman Charles Lew says. Lew knew that developing the process flow was not going to be simple given the lack of available expertise in rare earths processing in Australia. But it was the quality of the orebody that turned heads and captured the interest of two ex-Lynas employees. Robin Zhang, former Lynas senior project manager of development, is now part of Hastings’ management team as process engineering manager. A similar move was made by exLynas chief operating officer Jean Claude Steinmetz, who has become a non-executive director at Hastings. “(Steinmetz) was amazed at the 40 per cent NdPr:TREO ratio orebody at Yangibana and said he didn’t think any orebody was quite as spectacular as the
IMAGE CREDIT: AUSTRALIAN STRATEGIC MATERIALS.
ASM is set to produce zirconium, praseodymium (Pr), neodymium, niobium and hafnium materials sourced from the Dubbo project in the form of chemicals, powders and metals. According to Woodall, companies that only produce carbonates, concentrates and oxides will only fetch a fraction of the price of those materials in metal form. Oxide producers, for example, will be discounted by 25-35 per cent against the benchmark prices in China for their products. People who are looking into the rare earths market don’t understand this very well, Woodall says. “It makes a significant difference and is very important because companies that only produce carbonates, concentrates and oxides will only get the discounted prices,” he continues. ASM operates differently as it plans to build a plant to convert the mined products into metals in South Korea. This is part of the company’s strategy to be a rare earth metals supplier. Woodall says the facility is targeted for completion in mid-2022 and will potentially be followed by the construction of more metal plants in Australia, Europe and North America. This comes off the back of ASM’s success with its pilot plant in South Korea, where the company has proven the commerciality of its process with the support of a government grant. The expertise came from linking with a Korean university professor who knew how to metallise the critical materials. “Our process ends up being more efficient, uses less energy and importantly doesn’t use a lot of the products that are detrimental to the environment such that the standard processes use,” Woodall says. “And since we can now convert all of the materials into metal, we don’t talk to third parties or send them to China or Japan for conversion. “We can talk directly to end users in Europe, Australia, Korea or North America as we have the ability to produce high purity metals that the emerging manufacturing technologies need.” Woodall believes this is one of the biggest challenges that lies in the rare earths space. The market consolidation in China (a producer of nearly 90 per cent of rare earth metals and powders) and Japan (around 6 per cent) makes it difficult for Australian producers to compete. This is where ASM sees its opportunity to build metal plants in Australia and beyond. Others still see abundant prospects to seize the forecast growth of renewable power regardless.
(number that the Yangibana orebody offers),” Lew says. “He and (Zhang) assisted in developing the process flow and introducing our orebody to customers around the world, whether they were in Japan, China or Europe. “Through those early days of developing the process flowsheet and travelling internationally, I can see where the opportunity lies for Hastings and where our market will be in the future.” Hastings is targeting Germany as its primary market, with a contract due to be finalised with German-originated thyssenkrupp for about half of the company’s production volume (i.e. 7500 tonnes of mixed rare earth carbonate (MREC)) at Yangibana. Hastings also signed an agreement with German automotive supplier Schaeffler Technologies for 5000 tonnes of Yangibana MREC over a 10year period. With construction scheduled to start at Yangibana in the second quarter of this year, Hastings secured commitments to raise more than $100 million in February. Lew says the company is wellpositioned to supply a meaningful volume of rare earths in the market, with a view to commence production by the end of 2023. Hastings and ASM will be among the Australian miners that are supporting the global aspiration to transition into electrification and renewable power generation. This will place the Australian mining sector at the centre of the global push towards a sustainable future. AM
ASM PLANS TO DEVELOP A METAL REFINING PLANT IN KOREA.
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UNDERGROUND MINING
PRECISE DRILLING WITH STATE-OFTHE-ART RIG EPIROC’S BOOMER M20 OFFERS THE LATEST IN DESIGN AND TECHNOLOGY TO ENABLE A MORE ACCURATE, PRODUCTIVE AND SAFER UNDERGROUND DRILLING OPERATION.
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he Boomer range of underground drill rigs is designed for underground mining applications where blast hole drilling is required. Epiroc has designed this line of face drill rigs with innovation in mind, with features including battery electric driveline technology for increased efficiency and automation capabilities that enable the drills to be operated remotely. The company has unveiled its latest edition to the Boomer line-up, the Epiroc Boomer M20, which is designed for the medium segment of the mining market. Epiroc global product manager Niklas Berggren says the M20 Boomer drill caters towards the Australian mining industry “Mining customers with standard face drilling development and also this one in particular is tailor made for the multi-role functionality which is used a lot in Australia, it is commonly called drill scale and bolt,” he tells Australian Mining. According to Berggren, the drill is backed by a robust design that is built for Australian environments. Epiroc is confident in its capabilities
in local conditions, with the company planning to launch an Australian edition of the drill. “We are taking the multi-role face drill to the next level, making this application work as a multi-role face drill with internal hydraulics and protected sensors so it can withstand harsh mining environments,” he explains. Designed in Sweden, the Boomer M20’s internal hydraulic system ensures no hose breakage occurs. This allows the boom itself to deliver increased uptime and productivity, with the drill also featuring a three-row bolting coverage area. “The highest number of unplanned stops in the mining industry in face drilling is due to hose breakage because there’s a lot of hoses hanging from the boom,” Berggren says. “We have seen this issue in the industry, which is why we have focussed so hard to get the hydraulics internal.” The Boomer M20 also features Epiroc’s high performance drill plans, which provides the ability for the drill rig to create custom, downloadable drill plans at the face of the tunnel that prevents trips between the office and underground mine site.
THE BOOMER M20 FEATURES AN INTERNAL HYDRAULIC SYSTEM TO PREVENT HOSE BREAKAGE.
“The drill can also be equipped with what we call high performance development, which involves using drill plans during face drilling,” Berggren continues. “You put the holes exactly where they’re supposed to be, and this means for each blast you will actually pull longer than if you didn’t use drill plans because of how accurate the plans are. “We have seen from other places that the value of this feature is quite high and we are looking at a total cost saving of around 30 per cent with this solution.” Epiroc has also installed its Rig Control System (RCS) on the Boomer M20 to provide tele-remote operations to an underground mine through the rig’s local sensors and cameras. RCS also keeps operators out of the line of fire, allowing them to operate the drill away from the hazards at the tunnel face. “Safety has been with us since day one. It’s our top priority and we are really happy with what we have done here,” Berggren says.
EPIROC’S BOOMER M20 IS DESIGNED FOR AUSTRALIAN MINING ENVIRONMENTS.
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The Boomer M20 allows operators to keep their eyes on drilling at all times through its unique cabin design that offers optimum visibility. It features multi-functional joysticks include different modes that adjust the boom speeds of the rig. The drill rig is also equipped with safe bolting platforms to avoid any operations under unsupported rock, along with noise dampening materials in the cabin that reduce vibration and keep the noise level at just 65 decibels. Efficiency is also improved with the stage five diesel engine in the Boomer M20, while operators can be trained to control its user-friendly controls through an upcoming simulator that Epiroc is designing. “We’re expecting a strong response from the global market for this robust drill rig,” Berggren says. “It is ready for Australian environments and has been designed with Australia in mind.” The Boomer M20 will go on sale in Australia in the third quarter of 2021, with delivery in the first quarter of 2022. AM
MINING SERVICES
LONG-TERM DRY HIRE OF MACHINERY HERE TO STAY NATIONAL GROUP EXPECTS THE PREFERENCE FOR DRY HIRE TO CONTINUE TO INCREASE AS AUSTRALIA’S MINING SECTOR GOES FROM STRENGTH TO STRENGTH.
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he growth of Australia’s mining industry has positioned long-term dry hire as a highly attractive option versus purchasing equipment over the past five years. This change in the mining industry has been driven by strategies to increase production, export volumes and bottom-line profitability. As mining fleets expand, companies that are constrained by capital availability are regularly choosing to opt for long-term dry hire over purchasing. National Group managing director, chief executive and founder, Mark Ackroyd, has witnessed this shift as his company has grown over the past 24 years. Dry hire now represents 90 per cent of National Group’s business. “Dry hire gives mining companies an option to free up capital expenditure without recording big-ticket purchases on their balance sheet,” Ackroyd tells Australian Mining.
ALL THEY’RE RESPONSIBLE FOR IS FUEL, THE SUPPLY OF OPERATORS AND MINOR REPAIRS. THEY CAN USE THE MACHINE FOR AS LONG AS IT’S REQUIRED TO GET THE JOB DONE AND INCREASE PRODUCTION.” “They can continue using the equipment and give it back after 12 months, one year, two years or even more, without any ownership responsibility. “All they’re responsible for is fuel, the supply of operators and minor repairs. They can use the machine for as long as it’s required to get the job done and increase production.” It is no surprise that long-term dry hire has emerged as an appealing alternative for mining companies, given its benefits in current market conditions. National Group provides greater flexibility by offering two types of dry hire, with maintenance being an option that mining companies can
choose to take onboard themselves. In this scenario, a mining company will carry out all the minor repairs and equipment services, with only the obligation of major repairs assumed by National Group. Alternatively, National Group also offers fully-maintained maintenance in which it is responsible for managing the machines on site and conducting all equipment repairs, major or minor. This removes maintenance and safety hazards that mine site personnel may be exposed to, thereby minimising the risk for the mining company. This is also an attractive option for mine sites who do not have the resources. In both scenarios of dry hire,
NATIONAL GROUP OFFERS AN EXTENSIVE FLEET FOR DRY HIRE, INCLUDING THE KOMATSU 930E ULTRA-CLASS DUMP TRUCKS. AUSTRALIANMINING
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NATIONAL GROUP MANAGING DIRECTOR, CEO AND FOUNDER, MARK ACKROYD.
mining companies stand to gain from more accurate budgeting forecasts, greater flexibility and customisation of the equipment needed for their mining activities. National Group offers an extensive fleet, which includes a variety of large bulldozers, excavators and
MINING SERVICES
ultra-class dump trucks for dry hire. It has a fleet-wide availability of over 90 per cent, with each unit of equipment delivering up to 700 operating hours per month. “Our fleet comprises of around 300-plus units of heavy earthmoving equipment, with this number being added to weekly on average,” Ackroyd says. “We have regular interest from several Tier 1 Australian mining companies looking to hire equipment, with dozens of large and extra-large pieces of heavy mining equipment arriving soon.” Equipment such as Caterpillar 6040 excavators, Caterpillar 24 motor graders and Caterpillar 793F trucks, are all machines being added to National Group’s line up. Ackroyd says the demand for equipment hire has increased as mining companies transition to an owner-miner approach, with commodity cycles continuing to advance. His confidence in this approach stands on the strength of the mining sector, which is the top contributor to Australia’s gross domestic product. When global uncertainty shook economies last year, Australia delivered record revenues for iron ore, gold and copper. Australian Bureau of Statistics data reveals that the resources sector provided $270 billion into the economy in 2020. This represents 62 per cent of the country’s total export revenue, with iron ore exports soaring from $96 billion in 2019 to $116 billion in 2020. BHP and Rio Tinto, the world’s two largest miners, believe the strength of the iron ore market will be sustained.
The companies foresee a persistent shortage in global iron ore supply, while a soaring demand for the commodity is expected to continue due to Chinese steelmaker activity. According to BHP, a National Group customer, this puts Australia in an advantageous position for its high-quality seaborne iron ore – an essential ingredient to blast-furnace steelmaking. BHP chief executive Mike Henry says that while the world is a more volatile and uncertain place today, the global economy is rebounding strongly despite the ongoing effects of COVID-19. “In steel, for example, we expect continuing strong end-use demand to underpin production of more than one billion tonnes in China for a third consecutive year,” Henry, speaking during BHP’s half-year results presentation, says. “Add population growth and further rises in living standards to this equation, and the conditions are very promising.” Ackroyd agrees that the mining sector is in a strong place and will continue to be in the next five years. “I don’t see any impending challenges in the mining industry over the next five years. It’s the number one driver of the Australian economy and a leader in the country’s COVID-19 economic recovery,” Ackroyd says. “But regardless of the positive landscape ahead, mining always comes with a certain degree of uncertainty. Dry hire allows mining companies to operate more effectively, and with greater flexibility in both good and more uncertain times.” AM
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Since 1966, Nels Ostero Ltd. has produced high-quality sand and gravel products. To keep their vibrating screens running at peak performance, they commission our Pulse Vibration Analysis Service on an annual basis to ensure any problems are corrected before they lead to costly downtime. Pulse Vibration Analysis is designed to examine the health of any vibrating screen by detecting irregularities that could translate into diminished performance, decreased efficiency, increased operating costs and imminent breakdowns. 1-800-325-5993 | www.haverniagara.com
AUSTRALIANMINING
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MINING EQUIPMENT
AN EXTENDED LIFE FOR CAT MACHINES AND COMPONENTS CAT DEALER HASTINGS DEERING OFFERS HIGH QUALITY MACHINE AND COMPONENT REBUILDS THAT ADD VALUE AND SAVE COSTS, WHILE BEING BACKED WITH AN INDUSTRY LEADING, FULLY TRANSFERRABLE 24-MONTH/10,000-HOUR WARRANTY PERIOD.
THE CERTIFIED REBUILD PROGRAM ALLOWS MACHINES AT MID-LIFE AND AT THE END OF THEIR LIFE TO BE RESTORED TO PEAK CONDITION.
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s one of the world’s largest Cat dealers, Hastings Deering needs no introduction to the Australian mining industry. Based in Queensland and the Northern Territory, the company prides itself on having close to 100 years of brand history backed by considerable business growth. Hastings Deering sells and rents Cat machines, while also providing strong support and parts distribution services across construction and resource industries. When investing in a Cat machine, the power train and other major components are designed to be rebuilt, which allows customers to benefit from
an extended asset life. To maximise the investments of its customers, Hastings Deering offers the Cat Certified Rebuild Program for Cat machines and components. Endorsed by Caterpillar, Hastings Deering’s Certified Rebuild programs offer an ‘as new’ life for the original machine for only 50 to 70 per cent of the cost of a new machine. This allows machines including Cat wheel loaders, excavators, dozers, off highway trucks and underground mining equipment, at mid-life and at the end of their life, to be restored to their peak operating condition. Hastings Deering service marketing solutions manager Scott Richardson says the program follows stringent guidelines to ensure high-quality
HASTING’S DEERING CERTIFIED REBUILD PROGRAM OFFERS A 24-MONTH PARTS AND SERVICE WARRANTY ON ALL CAT CERTIFIED REBUILDS.
AUSTRALIANMINING
rebuilds are delivered every time. “The Certified Rebuild program has specific conditions included to maximise reusability and salvage of parts,” he tells Australian Mining. “We only use Cat genuine parts and follow up-to-date Cat reusability guidelines to ensure that the equipment is rebuilt to a standard which only Cat dealers can provide.” Outside of complete machine rebuilds, Hastings Deering now offers the benefit of the Certified Rebuild program to a single component, or group of components, expanding the program benefits even further to support its customers. “The Cat Certified Rebuild program doesn’t only cover the entire machine, it can actually cover an individual component when a smaller scope of work is required,” Hastings Deering regional manager – site performance Jason Briggs says. “If a customer was doing an onsite midlife program and replacing drivetrain components, we will certify these components when the work is completed with Hastings Deering assistance on site.” To instil further confidence in the capabilities of the rebuild program, Hastings Deering offers a Caterpillar backed 24-month, 10,000-hour (whichever comes first) parts and service warranty on all Cat Certified Rebuilds. The Cat Certified Rebuilds program features an industry-leading labour and parts warranty, which is unique to Hastings Deering and Caterpillar
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in Queensland and the Northern Territory. “Our guidelines, reusability inspections, Cat genuine parts and our specialist trained technicians allow Hastings Deering and Cat to have confidence in the final product throughout the warranty period,” Richardson says. “The warranty is transferrable as well – it stays with the machine. If a customer is to sell that asset the warranty will transfer to the next customer.” Briggs says Hastings Deering’s rebuild services can meet the specific demands of its customers, who are often choosing a machine rebuild to maximise the life of their assets. A customer recently adopted Hastings Deering’s Cat Certified Machine Rebuild program for five Cat D11 dozers with no major downtime post rebuilds. “The physical availability of the machines was 95.5 per cent,” Briggs says. “They received a rebuilt machine, backed to a new standard, exceptional results and availability. So, a very pleased customer overall.” Hastings Deering’s Certified Rebuild program ensures all relevant and necessary updates are completed, a new PIN (serial number) is issued, and a fully transferable warranty of 24 months or 10,000 hours (T&C apply) is applied for peace of mind. “No matter what you mine, nobody rebuilds better than Hastings Deering with the Cat Certified Rebuild Program,” Richardson concludes. AM
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INNOVATION
SENSING TECHNOLOGIES OVERCOME MINING HURDLES HUMMINGBIRD HAS RISEN TO MEET INDUSTRY CHALLENGES WITH BESPOKE SENSOR SOLUTIONS, DEMONSTRATING THE FLEXIBILITY AND POWER OF THESE DEVICES IN TODAY’S MINING INDUSTRY.
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t has become increasingly difficult to find a part of modern-day mining or processing where sensing technologies aren’t yet used. The use of sensors is today spread across light and heavy machinery. Their capabilities have expanded along with the pace of technological developments such as the Internet of Things and GPS technology. Hummingbird mining and industrial sales manager Scott Montgomery says mining companies are taking advantage of these capabilities by combining multiple sensing technologies to monitor several events concurrently. This has progressed from the past where sensors were widely used to monitor a specific function without being connected with other sensors and functions. For example, when it comes to monitoring truck payloads, Hummingbird sensors are placed across different axles to measure the weight distribution independently. This means an operator can tell if the load is heavier towards the front or back of the vehicle. “A lot of our sensors are underpinned by driver behaviour. For example, they’re created to help minimise the effect of operator mistakes such as speeding, excessive braking, acceleration, cornering and
HUMMINGBIRD MANUFACTURES, TESTS AND VALIDATES ITS AUSTRALIAN-MADE SENSORS IN ITS SOUTH AUSTRALIAN FACILITY.
even sudden impact,” Hummingbird engineer Emanuel Calligeros says. When it comes to tilt measurement, Hummingbird’s inclinometers display measurements on a screen in the cabin,
HUMMINGBIRD SENSORS AND MONITORS ARE DESIGNED TO COVER HUMAN SHORTFALLS AND IMPROVE EFFICIENCIES.
AUSTRALIANMINING
while their tilt switches are installed on the vehicle. These tilt switches can sense whether the vehicle has reached a pre-determined angle and trigger an alarm that alerts the operator sitting in the cabin. This allows them to take a corrective action before they’re in danger of the vehicle or machine rolling over. The Hummingbird team has also flagged an increase in incidents where a driver is unaware about a rear tipper being left in an elevated position before driving off. To handle these errors, Hummingbird combines its sensors to detect the vehicle’s speed and the rear tipper’s position, linking them to a voice output that warns the driver of the situation. Bringing it all together is Hummingbird’s audio alert system, which can take up to 16 inputs from different sensors and create a unique voice command, simultaneously
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making the system feel “human” and alerting the operator to a range of dangers and cautions. This way, its voice cuts through the constant buzzes that operators hear and must interpret quickly. “Our sensor technology can be integrated into our customers’ systems, by which they can then analyse the data to improve either safety or productivity outcomes,” Calligeros adds. One such collaboration with Teletrac Navman leads to the development of an Electronic Distance Recorder (EDR2), a solution designed for the heavy truck industry in New Zealand. The EDR2 is developed to accurately record road user chargers on independent heavy trailers. “The EDR2 innovation uses GPS technologies and measure the truck or trailer’s wheel rotation to track their location and measure their distance travelled,” Montgomery says. “Tracking the trailer location independently of the prime mover is important as they can be separated from the prime mover and left in different locations.” Despite the innovative use of sensors, Montgomery says there are some models available today that barely meet the latest International Organisation for Standardisation (ISO) standards. This has driven Hummingbird to work with its manufacturing partners to create sensors that meet the most stringent benchmarks. “There are emerging technologies that say they can improve safety and productivity, yet we hear a lot from companies that are still striving to strike the right level of safety and productivity that they actually need,” Montgomery says. “We get a lot of queries from mining companies wanting a certain function out of a machine that’s not available as an original equipment manufacturer (OEM) standard. “So, we deliver sensing and monitoring solutions that meet the needs of our customers. After all, we’re committed to support mine operations using our expertise in sensing technologies.” AM
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MINERALS PROCESSING
TRANSLATING JAPANESE EXPERTISE INTO GREATER PRODUCTIVITY MINPROVISE HAS BEEN A STEP AHEAD IN THE INDUSTRY BY BRINGING THE FIRST TWO JAPANESE-MADE ZI-2100 CONE CRUSHERS INTO AUSTRALIA. AUSTRALIAN MINING LOOKS AT THE CRUSHER’S WINNING FEATURES.
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t is universally acknowledged that Japanese equipment triumphs in reliability and innovation. Market Prospects reveals that about half of Japan’s manufacturing industry is accounted to the machinery sector. About 10 per cent, or 1.7 trillion yen ($24 billion), of Japan’s machinery production volume in 2018 was represented by mining and civil engineering machinery. This reputation wasn’t built overnight and owes to a Japanese approach of unwavering precision throughout every aspect of the manufacturing process. In the mining equipment sector, the ZI series cone crusher developed by Kawasaki Heavy Industries and marketed through its crushing and environmental equipment subsidiary, Earthtechnica, has a proven performance history. The Kawasaki design philosophy is based on its “3M” philosophy of, “Match the machine with the material”, meaning flexibility in machine design to match the material characteristics, as well as ensuring a robust structure to absorb the material impact and meet mine life changes. The ZI-2100 crusher is the evolution of the original Kawasaki cone crusher design that dates back to 1966. “The ZI series, simply put, is a combination of the legendary Cybas series and the advantages of a highpressure cone,” Minprovise managing director Graham Townsend tells Australian Mining. “Today, over 3900 Kawasaki cone crushers have been supplied globally. These machines have been engineered with Japanese precision and no compromise, to the point that it operates reliably. There are no flaws or faults in them.” Townsend’s confidence in the machines backed Minprovise’s move to claim the first two ZI-2100 cone crushers in Australia. The crusher is designed for high throughputs not just for the iron ore industry, but also in copper and gold, to name a couple more. The Japanese design and engineering of the ZI-2100 cone crusher have resulted in fewer
THE ZI-2100 CRUSHER IS THE EVOLUTION OF A KAWASAKI DESIGN THAT DATES BACK TO 1966.
wear points, more reliable components and an automated capability. An operator can change the crusher speed or setting remotely and safely without having to stop or interrupt the crusher, giving it greater controllability without any downtime. The third-generation automatic control system allows several operating conditions under different modes. This, combined with the resulting machine uptime, ensures that mine operators can meet rising production targets.
Standout crusher features
The reliability of the ZI-2100 crusher is strengthened by Earthtechnica’s
clever choice of components. To start with, the ZI-2100 cone crusher uses spherical bearings in lieu of a conventional spider bushing, setting it apart from other machines. Townsend says the spherical bearing keeps the main shaft aligned with the centrical assembly of the machine for the whole of its life. “Other crushers don’t have a spherical bearing. And the spider bushing commonly found in crushers is prone to damage, potentially causing the shaft to be misaligned. A spherical bearing can last for 20 years, while a conventional spider bush only has a one- to two-year life,” Townsend explains. “If you have a spherical bearing, your machine shouldn’t fail under normal conditions regardless of it operating in maximum performance.” Another advantage of a spherical bearing is that the component allows the crusher’s main shaft to perform various motions smoothly. It provides a wide surface contact area to perform smooth motions, bringing improved efficiency and minimising stress on the crusher. With an upper bearing in top shell and lower bearing in bottom shell, bearing loads are evenly distributed and able to receive more crushing forces. Townsend says it makes the ZI2100 crusher a more stable machine under harsh operating conditions. “When presented with tramp or
MINPROVISE HAS ORDERED THE FIRST TWO ZI-2100 CONE CRUSHERS IN AUSTRALIA.
AUSTRALIANMINING
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other potentially damaging feed material, the main shaft assembly drops to discharge foreign material,” Townsend says. “Thanks to the hydraulically adjusted and automatable design, the gap setting returns to its original position much faster than any other crusher in its class, minimising production losses and oversized production travelling downstream.” The unique design of the ZI2100 relief valve and accumulator arrangement ensures that the main shaft returns back to its operating position at a regulated speed and eliminates head bounce or hammering typically experienced in other machines. The 2100mm head diameter, 750kW of installed power and unflappable reliability due to the spherical spider bearing and strong hydraset design makes the ZI-2100 a true tough application machine. This reliability and the finite control gives ore processing and predictability efficiency beyond others.
Crushing track record
The reliability of the ZI series cone crusher has been proven and tested in the mining industry since 1966. It is widely used in the diamond mining sector in Africa, where at least 14 units are operating in Botswana, South Africa, Namibia and Lesotho, according to Kawasaki. The ZI series cone crusher’s global footprint extended to Western Australia when Minprovise supplied two ZI-1800 crushers to a Pilbara iron ore mine a few years ago. As Australia’s iron ore sector continues on a prosperous tangent off the back of tight supply in Brazil and rising steelmaker activity in China, Townsend believes the ZI-2100 cone crushers will support rising local production targets with less maintenance and downtime. Minprovise has been supporting the mining and quarrying industries since 2004. “We bought the first two ZI2100 cone crushers in Australia as proof of our confidence in this machine. They built a winner,” Townsend says. AM
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MINERALS PROCESSING
ROTARY EQUIPMENT DRIVES PRODUCTIVITY MCLANAHAN’S ROTARY EQUIPMENT OFFERS PROVEN PERFORMANCE AND SOPHISTICATED DESIGNS FOR MINERALS PROCESSING APPLICATIONS IN AUSTRALIA.
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or more than a century, McLanahan has developed and designed rotary equipment for the minerals processing industry. The company is highly regarded for its rotary scrubber and trommel equipment, which are both key components of mineral processing operations that impact the value of the final product. The physical process of improving and upgrading minerals has not changed a great deal over time, but the design process is significantly more sophisticated as we consider the longterm sustainability of the equipment and the operation it is used in. In 2010, McLanahan installed a combination rotary scrubber screen at an iron ore operation in the Pilbara region of Western Australia. This equipment offers a two-in-one solution that combines a rotary scrubber and trommel. “McLanahan’s rotary scrubber screen combines both machines into one, where a customer uses the scrubber
MCLANAHAN’S ROTARY SCRUBBER SCREEN COMBINES A ROTARY SCRUBBER AND TROMMEL.
part of the barrel to essentially wash the ore and liberate the contaminants through attrition, then the screen section allows us to take a specific size cut of the material,” McLanahan director of sales and marketing APAC Chris Knowles tells Australian Mining. McLanahan personnel have continued to engage and collaborate with the customer since the first installation, with their field service team attending all maintenance shutdowns and their engineering team monitoring it’s wear life. This engagement is used to identify further improvements to the equipment. “Our staff in Perth helped measure operating conditions so we can help predict the sort of maintenance windows and predict wear life to give them a little more certainty towards the machine availability,” Knowles says. Since 2011, the customer has installed additional rotary scrubber screens across its two operations, cementing McLanahan’s success in providing robust and reliable mineral processing solutions. “That particular customer was one of the first customers seeing the value of upgrading the iron content,” Knowles says. “It was about getting a value product to new markets and competing on a value scale in the iron ore market. “Since then, they’re running two modules, four scrubbers at 3000 tonnes per hour and they have significantly higher availability due to design optimisations.” McLanahan senior mechanical engineer Ben Freeburn says the customer was largely focussed on the need for longer uptimes, which the rotary scrubber screen achieved. “We have worked closely with that customer to come up with preventative measures to give them the uptime they need,” he tells Australian Mining. “The original 2010 machine’s rotary screen had eight weeks life, through continual improvement we can now achieve 24-week intervals.” As the resources sector has adapted to new technologies, McLanahan has adopted a more sophisticated approach to equipment design and long-term usage. Recently, McLanahan has been AUSTRALIANMINING
MCLANAHAN’S SELF-ALIGNING TRUNNION FEATURES INTEGRATE BARREL JACKING ASSEMBLY, PARK BRAKE AND ASSOCIATED SAFETY SENSORS.
successful in securing contracts to design and manufacture rotary scrubbers and screens for Australian iron ore producers. While each application and machines offered were slightly different, the key similarities around operability and long-term lifecycle management were the same. In terms of design, discrete element method modelling was used to simulate particle flow and retention. McLanahan has relied on Industry 4.0 technologies to maintain optimal support for its clients during the COVID-19 pandemic, Knowles continues. “Industry 4.0 offers the infrastructure and therefore the opportunity to share more data more often with our customers, building digital representations, using animations and models to simulate fabrication, assembly shipping and integration into the overall plant,” Knowles says. “The ability to collaborate in this way also builds trust, which is important when face-to-face meetings are not always possible.” According to Knowles, maximising the lifespan and maintenance schedule of the rotary scrubber screens is enhanced by computer-based condition monitoring and remote data access. “For OEMs like McLanahan, it is important to remain relevant as the
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customers operating landscape changes and that means we must ensure we can deliver a connected mineral scrubber so that machine is able to click into the connected mine and form part of the customers overall connected ecosystem,” Knowles says. Condition monitoring and remote data access is now a critical inclusion on all rotary equipment as operational data becomes more critical to business decisions such as long-term inventory management, maintenance preparation and ultimately production certainty. McLanahan has also used Industry 4.0 technologies to deliver a selfaligning trunnion assembly on the rotary scrubber screens installed in the Western Australian iron ore plants. These self-aligning trunnions include integrated barrel jacking assembly, park brake and associated safety sensors. This innovation is a result of collaborating with our customers and gathering data from their plants. The collected data suggested that rotary scrubber barrel alignment has the most profound impact on wear, trunnion tyre damage and premature fatigue failure. “We believe this is a pivotal innovation in maintaining drum alignments over the machine’s lifecycle. As an Australian manufacturer we find it important to be driving higher up the value chain, delivering greater longterm value for Australian miners and mineral processors,” Knowles says. AM
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MINERALS PROCESSING
THEJO OFFERS DIVERSE SOLUTIONS IN MINERALS PROCESSING DEDICATED TO EXPANDING ITS MINERAL PROCESSING OFFERINGS IN AUSTRALIA, THEJO ENGINEERING IS TAKING A CLIENT-FIRST APPROACH WHEN SUPPLYING CUSTOM-DESIGNED SOLUTIONS TO THE MINING INDUSTRY.
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hejo understands it is critical for every processing plant to have its mill running as efficiently as possible and the role innovation plays in ensuring this. To help processing operations achieve optimal productivity, Thejo works in close contact with mining companies to design, manufacture, install, monitor and improvise mill liner performance for their operations. Thejo chief operating officer Manoj Joseph Kallarackal says the company’s experts begin by analysing the operating conditions and the specific details of what its mining partners want. “From this data we are able to gauge a rough idea of the direction we would take before finalising the designs,” Kallarackal says. Thejo uses state-of-the-art engineering design and simulation software to create its designs. Operating out of its head office in Chennai, India, the company sends its design to each client based on the simulations and the operational feedback received from site. Kallarackal says the first step of the process for Thejo is guiding its mining partners through the decision-making process and responding with alterations to the designs, if needed. The second step is identifying the optimised choice of material to be used for making the mill liners. Thejo offers mill liners in rubber, as well as composite of metal and rubber. THOR – R mill liners are manufactured from specially formulated rubber compounds, which are a time tested superior blend of natural and synthetic rubbers. The T800 rubber formulation series has proved its robustness over time, through installations across a wide range of minerals and sizes of mills. In comparison, the THOR – M mill liners are manufactured from high-wear and abrasion resistant alloy castings or alloy steel plates integrally moulded with T800 rubber compounds. The alloy steel takes the harsh operating impact and wear, while the rubber provides absorption of the impact energy, reduction of noise and
weight compared with full metal liners. With India being a leading producer of superior quality natural rubber, Kallarackal says THOR – R mill liners provide several benefits over metal alternatives. “The fundamental challenges clients face with metal and composite mill liners is that they are very heavy, making it difficult to handle and install, consumes higher power, and is noisy during operations. Whereas, rubber liners are a lot lighter,” Kallarackal explains. “There are many advantages clients could derive, if they could consider rubber options, wherever possible. “We have been working closely with three mines in Western Australia who previously used composite liners, but have today achieved extended wear life with THOR – R liners. It is a significant breakthrough in terms of economics and productivity.” When it comes to sizing, Thejo provides trommels and screen panels under the branding of ‘GRATOR’, which are designed and engineered
with decades of experience. Kallarackal says the company’s objective is to provide reduced cost-per-hour tonnage in separation, reduction, sizing, washing and dewatering applications to clients. Clients are constantly on the lookout for extending the life of products. “Through our continued R&D, we have achieved significant success for a very large mine in Western Australia, which required us to improve the wear life, efficiency, eliminate pegging and blinding issues of their screens,” Kallarackal explains. “Our custom engineered rubber screen panels for a trommel of a SAG mill delivered 33 weeks of operational life as against 10 weeks achieved by competitors. This resulted in scheduling longer periods between shutdowns, thereby enhancing the grinding circuit availability, increasing productivity. “We pride ourselves in doing this work and have dedicated personnel who spend time with the clients,
THEJO’S GRATOR TROMMELS ARE DESIGNED AND ENGINEERED WITH DECADES OF EXPERIENCE.
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take feedback, implement and monitor the improvements.” For slurry handling operations, the company also offers WARDOG wet abrasion resistant sheeting, CERALINE flexible ceramic panels and ANAKONDA range of hoses and pipes. The company’s range of HIPO filtration solutions are established globally as the preferred spares for Larox-Outotec, Metso, Diemme and Andritz Pressure Filter Presses. HIPO rubber diaphragms, plate pack seals, feed ports, pinch valve sleeves, PP plates, vats, grids and hoses are utilised by major clients such as BHP, Vale, Glencore, Karara, Tata’s, Accelor Mittal, Jindal, Molymet, Ingredion, Imerys across the globe, through both a direct and distribution network. With its modern manufacturing, research and development facilities, Thejo is established as a specialist manufacturer of engineered polymer products. “Thejo products are subject to stringent process and quality control parameters,” Kallarackal says. “They are designed to deliver superior properties of resilience, wet abrasion resistance, tear and tensile strength, cut and tear resistance of the highest standards.” Kallarackal says Thejo’s team is constantly searching for new technological improvements, ideas and products that complement operations in the mining industry. “We are proud to say that our products are comparable with the best in the world,” he says. “One of the latest product options we now offer is called Sustainable Synergetic Solutions (SSS).” SSS provides safe work environments, focussing on quality, reliability and cost effective engineering solutions that ensure Thejo’s products and services perform above and beyond the expectations of customers to increase efficiency and productivity. By continued presence and growth in Australia, backed by high-quality products and service, Thejo has its eyes set on becoming the go-to company for minerals processing solutions. AM
MINERALS PROCESSING
THINKING INSIDE THE BOX: BROKEN SCREEN DIAGNOSES TYLER ENGINEERED MEDIA MANAGER, HAVER & BOECKER NIAGARA, STEVE FAIR, OUTLINES WAYS A MINERALS PROCESSING OPERATION CAN REDUCE DOWNTIME.
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magine you’re in the midst of peak production. Material output is at its prime and systems hum along smoothly. But then a section of wire cloth breaks. The operation grinds to a halt until a technician completes the repair. It’s bound to happen at some point, but it will happen less frequently by checking some tell-tale signs. Here are four steps to minimise downtime and promote a smooth operation:
Step 1. Ask an expert
When excessive screen wear occurs, a screen media expert can quickly analyse the operation to find a solution. And, if screens are wearing quickly, there’s likely a better screen media solution. Polyurethane screens, as an example, manage wear well, but some perform better than others. A screen media expert will examine your media, and explain your options. For instance, open-cast polyurethane will last 1.5 to two times longer than injection moulded.
Step 2. Check to see if the section has moved
How do the hooks look on the screen sections? If there are shiny areas, it could be a sign that the section
is loose and moving back and forth during operation. Also, ensure that the bar rail liner is in good condition and the tension rail bolts are tight. Consistently monitoring the torque helps determine the cause of some problems since improper tensioning leads to premature breakage. It’s also essential to look at the machine as a whole and take several aspects into consideration, such as if there is a bolt in every hole. Areas without bolts are susceptible to breaking. Beyond checking the torque values, using the correct section size is vital on side-tensioned screens. To check, begin by measuring inside the vibrating screen from sideplate to sideplate. If the measurement is 72 inches, for instance, subtract 1.5 inches to determine the outside hook dimension. From there, measure the length of the tension rail and ensure the section matches that dimension.
Step 3. Look at the camber
Check the camber on the screen deck and the bar rails for wear. On a double cambered deck, make sure the centre hold down is being used. The camber gives the section the down-and-out tensioning required
HAVER & BOECKER NIAGARA PROVIDES ON-SITE INSPECTION OF VIBRATING MACHINES AND SCREEN MEDIA.
TYLER ENGINEERED MEDIA MANAGER STEVE FAIR.
to keep it in place. Every bar rail should be supporting the section. If the screens aren’t tensioned correctly or the centre hold-down bar isn’t being used, breakage will happen sooner rather than later.
Step 4. Inspect the bar and tension rails
Are they in good condition? It is important to ensure the bar rails are not worn. Even if you put new liners on a worn bar rail, they can’t support the section. Also, monitor the tension rails that hold each screen section in place. Worn or bent tension rails need to be replaced. If the rails are worn, speak with
your OEM to have them replaced and avoid turning to local fabricators for the replacement. While often cheaper, you’re sacrificing quality because local fabricators frequently use substandard material and can put the wrong bend on the rail, which shortens the section’s life. OEM parts are made specifically for each machine, so there’s never a worry about them not fitting precisely as intended. Check, too, that the bar rail liners are in good condition and that no areas are missing, which also can lead to premature breakage. Even if all of these steps are done correctly, there could still be a problem if the wrong screen media is being used for the application. Talk to your screen media expert to see if there is a better solution for your application. Some manufacturers have certified technicians who provide on-site inspection of your vibrating machine and screen media, as well as training to help a team learn the best way to install screen media. Many also use vibration analysis software for a more detailed analysis, with some systems able to monitor as many as 24 channels of data in real time. That combination will keep an operation running smoothly and minimise downtime. AM Steve Fair is the Tyler Engineered Media Manager at Haver & Boecker Niagara. He works with customers to identify screening challenges, improve their screening applications and increase screening efficiency.
HAVER & BOECKER NIAGARA ADVISES TO REGULARLY INSPECT THE SIDEPLATES OF THE VIBRATING SCREEN FOR SIGNS OF WEAR OR CRACKING.
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MINERALS PROCESSING
DELIVERING REAL-TIME MINERAL PROCESSING SOLUTIONS BLUE CUBE SYSTEMS’ AUSTRALIAN 2021 RE-LAUNCH WILL FOCUS ON DRIVING CLIENT GROWTH BY SELLING AND SUPPORTING FAST IN-LINE MINERAL ANALYSERS FOR MINERAL BENEFACTION APPLICATIONS IN THE AUSTRALASIAN REGION.
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ineral analyser equipment provider Blue Cube Systems has opened its new office in Perth,
Western Australia. Despite COVID-19 delaying Blue Cube’s re-launch in Australia last year, the company is dedicated to growing its position in the country’s mining industry. The small, but very experienced local team consists of three, with two of these employees already in Australia and a third member still in South Africa waiting for COVID-19 restrictions to ease before joining the team.
BLUE CUBE PROVIDES CLIENTS WITH THE ABILITY TO QUICKLY MAKE INFORMED DECISIONS, OPTIMISING ITS PROCESS IN REAL-TIME.
Blue Cube Australasia regional leader Stuart Cullum says calibration is achieved by its mineral analyser technology through the comparison of the spectral profile of a sample to that of samples with known composition. “We sold the first unit in Australia in 2006; therefore, we have quite a long run in the region,” he says. Cullum asserts that its previous relationship with a local distributor in the region was vital to building the base for the company in Australia. “During this time, with our distributor, we managed to sell 32 MQi mineral analysers in Australia and the surrounding islands. To date, 27 of those are on mineral processing plants, with 23 of them active on a regular basis,” Callum says. Consequently, the decision to establish the office in Perth is because of its proximity to the majority of Blue Cube’s slurry analyser installations. Blue Cube Systems’ mineral analysis technology includes the MQi product range. The range includes models that can be used for slurry applications, such as flotation and leach operations, as well as wet or dry magnetic, electrostatic and gravity separation. “Our technology allows us to calibrate against any quantifiable parameter that displays optical differences,” Cullum says. “We’re not limited to mineral or elemental analysis, we can do both at the same time, including lighter elements, as well as other quantifiable parameters with the same unit all in the same stream. “Australia has various metal industries and the mining industry is not partial to any one particular mineral. The presence of iron ore, gold, coal, base metals and lithium, as well as others, provides an ideal outlook for the future.” This technology will enable the company to grow significantly in the Australian mining sector, particularly owing to the strong diversity of the sector. The benefits of Blue Cube MQi include maximised mineral recovery, extensive applications, no hazardous components and ongoing innovation. Through its proven product AUSTRALIANMINING
DURING THIS TIME, WITH OUR DISTRIBUTOR, WE MANAGED TO SELL 32 MQI MINERAL ANALYSERS IN AUSTRALIA AND THE SURROUNDING ISLANDS. TO DATE, 27 OF THOSE ARE ON MINERAL PROCESSING PLANTS, WITH 23 OF THEM ACTIVE ON A REGULAR BASIS.” reliability and solid international support services, Cullum says Blue Cube provides clients with the ability to quickly make informed decisions, optimising its process in real-time. The build quality for the products is robust and can handle the harsh conditions of a minerals separation plant, with its output via analogue signals or industrial protocols. The outputs are updated at 15-second intervals and follow process trends closely, which Cullum says differs
BLUE CUBE SYSTEMS IS NOW OPERATING OUT OF ITS NEW OFFICE IN PERTH.
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from other models in the industry. “We have a cloud of data that I refer to as a brain. It is able to interpret the data, within the operating range, and give customers a prediction of what is flowing in the stream, in real-time. It allows for a very robust and dynamic way of analysing the process stream,” Cullum says. “We see it as a positive because the ore and the minerals that are being processed aren’t all the same. We update our calibration to stay in tune with that and make sure the information we are providing the client is up to date and as accurate as possible.” Through Blue Cube Systems’ proven product reliability and solid international support services, the company is set to continue helping clients across Australia and the globe in many different industries. “The next five to 10 years for us will primarily be focussed on growth, and increasing the number of clients throughout the Australasian region, with all of our current clients in WA. We have only just got our first installation happening on the east coast,” Cullum says. “If this all pans out the way it should, it will be a worldwide first for this measurement online and in real time.” AM
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MATERIALS HANDLING
LOCALLY MADE CONVEYOR PRODUCTS FENNER DUNLOP’S BRISBANE BRANCH IS A CENTRAL SOURCE FOR AUSTRALIANMADE CONVEYOR PRODUCTS, IDLERS AND PULLEY SUPPLY THAT SUPPORTS CUSTOMERS ACROSS THE COUNTRY.
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n upgrade of Fenner Dunlop’s Brisbane manufacturing facility two years ago came at an ideal time to support mining and other industries it supplies. With the COVID-19 pandemic, many overseas supply lines have been disrupted in terms of supply chain security. Fenner Dunlop has been able to fill this gap and satisfy supply requirements through local manufacture. The Brisbane facility is an example of Fenner Dunlop’s commitment to providing Australian-made components. The facility is equipped with local idler and pulley manufacturing, as well as providing customer support through engineering and service. The local manufacturing capabilities provide reduced lead times and quick turnaround for shutdown and breakdown scenarios. Despite the increased overseas competition, Fenner Dunlop remains established as one of the world’s largest manufacturers of conveyor belts in the mining and materials handling markets. Fenner Dunlop is capable of design and supply of complete conveyor systems across the country, providing a single point of accountability for
FENNER DUNLOP’S BRISBANE MANUFACTURING FACILITY OFFERS LOCALLY MADE CONVEYOR PRODUCTS.
clients’ complete conveyor projects. With a local range of products at the branch in Queensland’s capital, this has not only ensured shorter delivery times, but has invested in local manufacturing, creating jobs. “The Brisbane branch has grown through a range of local manufacture and new products, as well as additional engineering resources,” Fenner Dunlop Queensland regional manager Brendon Harms tells Australian Mining. Idlers are a vital component for conveyor belts that handle products including mined ore. Their quality is critical in supporting belts in
THE LOCAL MANUFACTURING OF IDLERS AND PULLEYS ENABLES LEAD TIMES AND QUICK TURNAROUND.
AUSTRALIANMINING
harsh environments, including those common at mine sites and processing plants in Australia. Fenner Dunlop has supplied idlers in Brisbane for over 15 years and is also highly regarded for its rollers used in both surface and underground mine sites. Since upgrading the facility, Fenner Dunlop has now introduced Brisbanemanufactured pulleys, which offer bespoke solutions for specific materials handling applications. According to Harms, there are significant advantages for manufacturing these components locally. “Pulleys are a critical component of the complete conveyor system and hence the reason why we’ve put this plant in place,” he explains. “We are able to control the quality in house and the pulleys that are made here in Brisbane are highly engineered. This includes the highest level of quality assurance in terms of materials, welding and fabrication processes.” Harms says a major benefit of local manufacturing is the added speed of moving products to market as it cuts down on shipping times. “The Brisbane plant is designed for short, flexible runs during manufacture, rather than a long production line style of operation,” he says.
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Having a proven track record in conveyor components, Fenner Dunlop has earned strong customer feedback for its products and services. “With commodity prices going up and down it allows our customers to be flexible on ordering projects on a shorter lead time and also reduces our customer requirements for stockholding,” Harms says. Fenner Dunlop also offers 24/7 support services, project management and sales out of its Brisbane branch. “It helps us reach our local customers. The Brisbane base allows access to several of our customers’ head offices in Brisbane, with branches in Mackay, Emerald and Townsville to support our regional clients as well,” Harms adds. Fenner Dunlop operates nationwide with manufacturing and distribution centres located across Australia. For Harms, local manufacturing provides benefits for the rest of the industry. He says it’s beneficial for the company’s employees as it creates additional opportunity and jobs. “It also flows onto our suppliers because the more pulleys we make here, obviously the more bearings and local steelworks we buy, so there are flow-on effects for the market in general which is good for all Australians,” Harms says. AM
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MATERIALS HANDLING
TOP THREE THINGS TO LOOK FOR IN PULLEY LAGGING FLEXCO SUGGESTS THREE THINGS THAT MINE OPERATORS SHOULD LOOK OUT FOR IN SELECTING THE RIGHT SUPPLIER AND PULLEY-LAGGING PRODUCT FOR ITS INTENDED APPLICATION.
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s the market becomes more saturated with lagging options, it is hard to know who to trust when it comes to selecting a superior pulley-lagging product. However, there are three main signs to look out for to ensure you are making the right choice. If you choose a lagging that doesn’t hold up to your application, unscheduled downtime will become an inescapable problem on site, and you’ll end up with disgruntled clients.
1. Is the lagging internally or externally tested?
It is all too easy to test lagging in house and even easier to position those results to suit a certain product. It’s best practice to look for a supplier who tests their product externally to get independent results. We’ve made a list of which tests are most important as follows: tensile strength, rubber elongation, bonding strength and chemical composition of tiles. The first three are pretty standard, but you may not have considered the fourth.
FLEXCO FLEX-LAG FULL CERAMIC AFTER 20 YEARS.
The truth is, the chemical composition of tiles is important to ensure durability and alumina content, while also validating that they bond to the rubber as powerfully as possible. If ceramic tiles crack or begin to fall out, it is a type of failure that can lead to unscheduled downtime. This testing should always be compliant to site specifications and, even more importantly, should remain unchanged from batch to batch. Whether you pay for a poor, medium or high-quality lagging, you should be able to ensure you get the same quality of lagging each time you place an order.
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2. Best-in-class manufacturing capabilities
A supplier with highly capable manufacturing operations has many benefits. The first is that you will be able to customise your lagging solution. Sometimes an off-the-shelf solution is not appropriate. Companies that manufacture with a high degree of sophistication allow you to discuss your unique and dynamic situation to a regional sales representative, who can convey the message straight to the manufacturing manager to produce your order exactly how you require it. When slippage occurs, it causes strain on many parts of your conveyor. Quite often this means you need a solution right now. The ability to produce lagging solutions quickly, while also maintaining a large inventory of standard configurations is also something to investigate with any lagging partner. It’s also important to understand where your product is coming from. Sometimes to get to a certain price, the quality of lagging is greatly reduced, and many times unsafe practices are used. Be sure to ask these questions of your vendor to ensure your organisation knows the origins of the product in which they are investing: Am I supporting ethical manufacturing processes? Does the manufacturing facility use reputable suppliers of rubber and ceramic? How do I know if quality assurance processes have been AUSTRALIANMINING
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FLEXCO FLEX-LAG FULL CERAMIC.
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followed correctly? Can I ensure my product will arrive as I specified, and on time?
3. Quality assurance
The third and arguably most important factor to look out for is quality assurance. Manufacturing lagging is a big feat – there are varieties of different processes and functions, which ultimately means a variety of different challenges, which can result in a defective product turning up on site. As a result of all the moving parts – it’s almost necessary that your lagging provider has a dedicated quality assurance engineer. Without the expertise of an engineer checking your lagging for quality issues before it is shipped to your facility, you may encounter issues further along the line when the pulley is already lagged and installed on site. An iron ore mine site in the Pilbara of Western Australia was aware of the importance of their lagging choice, employing Flexco to ensure they can protect their head pulley and combat belt slippage. Flexco lagging was applied as part of the site spec on a 1600mm belt width running at five metres per second, 24 hours seven days a week. Flex-Lag was the specified product
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of choice for this large mine site. The lagging was specified as a precaution to protect the steel pulley drum and combat belt slippage. The 80 per cent coverage dimple ceramic Flex-Lag was installed in 2001. The lagging boasted the following benefits: the moulded ceramic dimples grip the belt’s underside, for positive traction and no slippage. Eighty per cent tile coverage features the highest coefficient of friction available in lagging materials – two to three times the friction of rubber resulting in lower energy costs and the cold vulcanisation process makes on site, in-situ installation fast, simple and efficient and cheaper than other alternatives. Although the main goal was to protect the pulley and combat spillage, the most astounding feature of the product was the increased cleaning efficiency of the primary cleaner. The near-perfect condition of the lagging after nearly 20 years in service has allowed the primary belt cleaner to have superior blade-to-belt contact. Another result that was unexpected from the site was the longevity of the lagging given the harsh iron ore material being conveyed. Installed in May 2001, this lagging has proven to last nearly 20 years, not uncommon for Flex-Lag. AM
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CRUSHING & SCREENING
DERRICK REMOVES BLIND SPOTS FROM GOLD PROCESSING USING ITS FINE SCREENING EXPERTISE IN GOLD PROCESSING, DERRICK HAS SIMPLIFIED A PREVIOUSLY ARDUOUS MAINTENANCE PROCESS AND TRANSFORMED A PROBLEM THAT ORIGINATED AT A CUSTOMER’S GOLD PROCESSING PLANT INTO A MAJOR SUCCESS STORY.
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errick’s penchant for continual innovation in fine screening technology has led to development of the G-Vault urethane interstage screen to replace the wedge wire interstage screen. Wedge wire screens have traditionally required rigorous maintenance, which has created worker dissatisfaction. For example, a Canadabased mining company faced resignations from workers due to the responsibility for daily maintenance
G-VAULT WORKS AS A DIRECT BOLT-IN REPLACEMENT FOR THE MINE’S CURRENT WEDGE WIRE SCREEN.
of wedge wire screens. Troubles such as this have plagued the carbon-in-leach (CIL)/carbon-inpulp (CIP) and resin-in-leach (RIL)/ resin-in-pulp (RIP) gold processing methods for many years. Backed by 70 years of experience in fine screening, Derrick was determined to improve gold processing methods. Its research led to development of the G-Vault urethane interstage screen, which has changed the way gold is recovered. “Our G-Vault urethane interstage screen is non-blinding and has up to 20 per cent higher open area to allow more throughput, which eventually leads to increased production,” Derrick new product applications specialist Patrick Stasio tells Australian Mining. But it is not only the innovative G-Vault that Derrick has delivered to the gold processing industry, it is also a new development process that made the G-Vault screen a reality. In Derrick’s design process, dimensions and process information from the mining company’s current interstage screen are used by Derrick engineers to design the appropriate G-Vault screen to fit into their processing plant. By working closely with the mining company, Derrick’s design team ensures that the custom screen meets the customer’s needs. Using a computer program, the custom retrofit screen is drawn from start to finish to occupy the same footprint as the wedge wire interstage screen it will replace. The G-Vault retrofit screen is then fabricated and shipped to the mine site as a direct bolt-in replacement for the mine’s current wedge wire screen. Replacement is made even easier by the customisable design of G-Vault. One G-Vault screen comprises several modular screens and cartridges. “The Derrick team has designed G-Vaults from as small as two square metres to as large as 24 square metres, depending on the current interstage screen at the mine site. We can design custom solutions for AUSTRALIANMINING
A G-VAULT SCREEN COMPRISES MODULAR SCREENS AND CARTRIDGES, MAKING REMOVAL EASIER.
them,” Stasio says. “The modular screens give the mine site flexibility. When a site needs to replace a section of the G-Vault screen, they only need to replace the one or two affected cartridges instead of replacing the entire wedge wire screen. “The G-Vault on-site procedures are similar to the current wedge wire procedures they already have on site. We are not rewriting procedures. This familiarity makes for an easy on-site adaptation process for installation.” Such simple maintenance contradicts the demands of the wedge wire screen, which needs to be fully replaced or power washed when it loses effectiveness. Stasio says the G-Vault urethane screen saves costs, time and labour. He does, however, concede that the release of G-Vault has been met with skepticism. He says that problems involving the use of wedge wire interstage screens have lasted for such a long time that many operators don’t believe they would all be resolved with just one product.
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“We’ve spoken with mining companies and confirmed that most are having the same problem with wedge wire screens everywhere,” Stasio says. “So now it’s about re-educating site operators to have a different outlook on gold screening with regards to interstage screens.” The G-Vault screen has exceeded many user expectations, with the screen now installed in eight countries. Its urethane material lives up to its rough and tough reputation as a high-tolerance synthetic screen in the gold processing industry. From increasing gold recovery to reducing operating and maintenance costs, the G-Vault is making its mark on gold processing. As a world leader in developing state-of-the-art solutions to improve operations and increase recovery, Derrick is committed to the gold processing industry. Innovative solutions offered by Derrick are reducing waste and raising efficiency to help propel the industry to greater heights and higher profitability. AM
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CRUSHING & SCREENING
CRUSHING CONTRACTOR FLOURISHES AS NEWCOMERS JOIN MOBILE FLEET MILBRAE QUARRIES, A FAMILY-RUN QUARRYING AND MINING SERVICES BUSINESS, HAS EXPANDED ON THE LOCAL CONTRACT CRUSHING MARKET – BOLSTERED BY THE ACQUISITION OF TWO PRIMARY MOBILE JAW CRUSHERS SUITED TO LARGE-SCALE QUARRYING AND MINING OPERATIONS. DAMIAN CHRISTIE WRITES. THE MILBRAE BUSINESS GROUP SPECIALISES IN A RANGE OF SERVICES THAT ENCOMPASS QUARRYING, MINING SERVICES, ROAD TRANSPORT (PICTURED) AND MORE.
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ilbrae Quarries is part of a privatelyowned group of companies that provide specialist services in quarrying, mining and concrete manufacture and supply across New South Wales, Queensland, Victoria and the Northern Territory. Its headquarters are based in Leeton, in the New South Wales Riverina district. Established in 1969 as a small trades service business, PA Woods and Co has evolved into an important competitor in the mining services industry, providing contract crushing services to many big players Australia wide. From humble beginnings, the company consolidated its quarrying business in 1999 to become Milbrae Quarries Pty Ltd. “The company name ‘Milbrae’ comes from the first property that we bought near Leeton – we commenced quarrying on the site, and when we started out our office was just a telephone on a pole in the middle of a paddock,” Chris Woods, the managing director of the company today, recalls. “Nowdays the Milbrae site acts as our company headquarters and is home to our mechanical, engineering, transport and drill and blast teams. “The property’s original name was
BROTHERS CHRIS (RIGHT) AND BRETT (LEFT) WITH THEIR FATHER PETER WOODS (CENTRE) AT THE ENTRANCE TO MILBRAE QUARRIES.
‘Millbrae’ with two ‘L’ letters in it, but we are a race horsing family and my father, Peter Woods, insisted that we drop one letter out of it to get seven – so that’s why it has one ‘L’ in it,” Woods laughs. “A number of famous racehorses had seven letter names.” While the business name may be short and to the point, it is attached to a very impressive organisation that has grown considerably over its three decades of operation. The Milbrae Business Group today employs more than 200 people across its businesses, and its assets include four fixed plant hard rock quarries, 20 AUSTRALIANMINING
road base pits, sand operations, a precast yard, seven concrete plants and a fleet of mobile crushing plants and mobile concrete batching plants. Having founded the business more than 50 years ago, Peter Woods now enjoys a well-earned retirement, but continues to take an interest in the growth of the operations. Milbrae is actively managed by Peter’s two sons Chris and Brett. Chris is the company’s managing director, overseeing the performance of the business as well as the mining services activities, while Brett primarily drives the operational side of the business. Both Chris and Brett have sons
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involved in the business, ensuring that Milbrae will continue well into the future.
Extractive services
Milbrae is a vertically integrated enterprise. Its operations begin with being able to win material via in-house drill and blast or mechanical methods, crushing and screening the material either in its fixed plant operations or via one of its 17 mobile crushing trains, conditioning material via pugmills, transporting crushed material to users via its transport fleet through to producing ready-mixed concrete and pre-cast concrete panels for end users.
CRUSHING & SCREENING
Chris Woods and his regional operations manager Scott Gillieatt estimate that on the hard rock quarrying side of the business, the annual output across the four sites would be in excess of one million tonnes of blue metal aggregates, and sand and gravel. The company’s construction materials products include: • 5 /7/10/14 and 20mm aggregates and blends, both precoated and raw. • 5 mm and 10mm river gravel. • 20mm and 40mm road base. •R MS-specified products such as select fill, MB20, DGS and DGB road bases. •R ail ballast. •S pall, gabion and beaching rock. •S ands including river, pit and mortar sand. •R eady-mixed concrete. In addition to its company-owned operations, Milbrae has also built for itself a highly successful contract quarrying and mining business. “Initially we designed and built three-wheel plants consisting of primary and secondary crushers, all electrically driven to service our satellite pits,” Chris Woods explains. “We would mobilise our mobile crushing train to site, crush material to build our stockpiles to use for customer sales for a period of time, and the crushing equipment would then be moved to another site.” As a result, outside of the Riverina operations, the company has operated up and down the eastern seaboard – including northern and southeastern Victoria, the whole of New South Wales, Queensland and the Northern Territory. “Our largest growth area that
THE HYBRID LT130E CAN RUN ON AN EXTERNAL ELECTRICAL DRIVE OR AN INTEGRATED ENGINE AND GENERATOR PACKAGE.
we have experienced was contract crushing for mine operators, with beginnings in the Mt Isa area utilising the company-built wheel-mounted crushing plants,” Woods explains. “Milbrae was initially involved with several smaller mining operators, before becoming involved with Xstrata and Glencore. It was the biggest increase we had in personnel and equipment. “We have conducted contract mining operations at Mt Isa Mines, George Fisher mine, Mt Cuthbert, Handlebar Hill mine and then up in McArthur River mine amongst others. “This experience drove Milbrae to explore mining opportunities in New South Wales, and we have since conducted work at operations owned by Evolution Mining, Newcrest, Aurelia Metals, Tronox, CMOC,
Alkane Resources and CBH.” Due to the logistics of operating remotely from its core region, the Milbrae Business Group established its own aviation service. It operates a turboprop Pilatus PC12 NG to support its operations throughout the country. Able to take aboard a complement of nine people, the aircraft can also be converted to handle cargo. The PC12 is able to operate from remote dirt landing strips commonly found in regional Australia and it has been essential in supplying parts to remote locations. “Since COVID-19 began to impact our operations, the PC12 has been critical in allowing crews to be flown directly from home locations to mine sites without transiting hotspots,” Woods adds.
Contract quarrying services
Milbrae’s growth has been impressive for a company that had humble beginnings, conducting mobile crushing for Leeton Shire Council 35 years ago. Today, it produces several million tonnes per annum output from its mobile crushing business and in excess of six million tonnes in its contract mining services division. Milbrae regularly undertakes mobile crushing services for approximately 15 shire councils across New South Wales, Queensland and Victoria, along with a number of government departments and private entities. In addition, Milbrae has supplied product for numerous projects including: •A ustralian Rail Track Corporation and John Holland specification ballast. •A rmoured rock for large water catchments. •H eavily bound road bases for transport for NSW, including on-site incorporation of binder via pugmill. •B 80 concrete mixes for transport for NSW. •P re-cast panels for various private projects, including a shopping centre in Wangaratta and Quest Apartments in Griffith. Milbrae also contributed to the Hume Highway Woomgara Alliance, in which it provided mobile crushing works on a nine-kilometre dual carriageway and four bridges. It supplied about 290,000 tonnes of blue metal granite and 490,000 tonnes of regular granite for the project, with its mobile gear crushing at a rate of up to 320 tonnes per hour (tph). “The Riverina region is booming at the moment due to the great conditions in the agricultural
THE LT130E’S EASY SPLIT ADVANTAGE UTILISES HYDRAULIC CYLINDERS TO LIFT THE CRUSHER AND FEEDER ABOVE THE CHASSIS FOR TRANSFER TO A STANDARD TRAILER. AUSTRALIANMINING
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CRUSHING & SCREENING
industry,” Woods adds. “There are a number of infrastructure projects underway, including major highway projects, feed lots, several solar farms as well as a rapid expansion being undertaken in the poultry industry, resulting in new chicken farms being opened here. We’ve seen demand for road bases and concrete double over the past year, and we’ve probably never been busier in our history.” Any successful mobile contract crushing service is only as good as the equipment that it operates. Over the years Milbrae has used a variety of different makes of mobile crushing plant but since providing mining services, it has identified Metso Outotec as its crushing supplier of choice. The company has progressively upgraded its inventory so that Metso Outotec’s renowned line-up of Lokotrack crushers now make up nearly half of its tracked mobile fleet. Milbrae has worked with Tutt Bryant Equipment (TBE), the national distributor of Metso Outotec’s Lokotrack and Nordtrack ranges of mobile crushers and screens, for the past seven years. The company’s Lokotrack crushing fleet comprises two 63-tonne LT120 jaw crushers, one LT106 jaw crusher, four 43-tonne LT300HP cone crushers and seven 55-tonne LT1213S impact crushers. The Metso fleet will work in conjunction with Milbrae’s closed circuit wheeled plants to form the core
of the mining services fleet into the future, Woods states. “Our wheeled crushing plants have proven themselves time and time again while undertaking mining projects, so we believe that the Metso tracked equipment complements the wheeled plants,” he says. “The wheeled plants can undertake high volume static works, where feed material is readily available at the crushing location, such as being trucked from underground, while the tracked Metso equipment will undertake projects where flexibility in crushing location is required, such as crushing material located in large volume stockpiles, or at a moving face.” Woods says Milbrae is drawn to the Metso line-up because it has a
strong reputation for reliability and robustness. “We believe that Metso is one of the best producers of plant and equipment in the world,” he says, “The early days were a little challenging but Tutt Bryant made a commitment to improve their back-up service and customer relations, and the relationship has come a long way, particularly with people like Wayne Kruger (Tutt Bryant Equipment’s technical sales representative for the Metso tracked plant) who had a handson crushing background. “That’s always a big plus when people like Wayne have worked in crushing, it helps the sales person understand the key challenges that the customer faces on the ground.” Scott Gillieatt agrees with Woods’
MILBRAE QUARRIES’ CONTRACT CRUSHING OPERATIONS ARE ESTIMATED TO HAVE AN ANNUAL OUTPUT OF ONE MILLION TONNES.
THE MAXIMUM OUTPUT OF THE LT130E, IN THE RIGHT CONDITIONS, CAN BE UP TO 1000 TONNES PER HOUR.
AUSTRALIANMINING
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comments. “We recently had the opportunity to have three machines of similar capacity from different brands in our fleet crushing side by side on a client site, and the Metso outperformed the other machines, providing a higher and more consistent throughput,” he says. “The Metso machine was more robust, leading to Metso being our machine of choice. We also find that the parts have a longer service life, the wear is noticeably better as well, and this is coupled with the excellent service that Wayne provides.”
Heavy-duty duo
The most exciting development for Milbrae is that it has recently purchased two Lokotrack LT130E hybrid mobile jaw crushers, which are suitable as a primary crusher in largescale quarrying and mining operations. For optimised energy efficiency for crushing operations, the hybrid LT130E can run on an external electrical drive or, in locations where this is not possible, an integrated 403kW Caterpillar C15 engine and 500kVA generator power package. The LT130E incorporates Metso’s renowned Nordberg C130 jaw crusher for large-scale quarrying applications. It is Metso’s largest standard mobile jaw crusher, with a feed opening of 1300mm x 1000mm (51” x 39”) for coarser feed material, and its heavy-duty design can manage the hardest materials. A small nip angle and kinematics ensure aggressive
CRUSHING & SCREENING
crushing along the whole length of the crushing cavity and for all rock conditions. The maximum output of the LT130E, in the right conditions, can be up to 1000 tph. This large-scale unit is easy to adapt to existing processes. It is equipped with an adjustable hydraulic main conveyor and an advanced Metso intelligent crusher automation (ICr) control system. A wireless Metso ICr remote monitoring system or an interlocking cable can connect the unit to other Lokotrack crushing and screening plants. All maintenance locations are easily accessible, making daily routines easier and safer. The LT130E can be optimised to move smoothly between sites. All the electric and hydraulic connections have quick couplings for easy disassembly. Optimised lifting points, along with user-friendly and safe hydraulic features reduce downtime, while an easy split feature makes portability and set-up easier. For contracting purposes, the plant can be set up within a matter of hours. The easy split advantage utilises hydraulic cylinders to lift the crusher and feeder above the chassis for transfer to a standard trailer. Like regular Lokotrack mobile plants, the chassis of the LT130E can be driven to the trailer via remote control. As this article went to press, the two LT130Es were expected to be delivered and commissioned at Milbrae’s operations by March. The first of the units will go straight to work in Milbrae’s contract mining operations. The second, according to Woods and Gillieatt, is slated to be used at an internally owned site, allowing it to be rapidly mobilised for future mining projects. While the LT130E has previously been trialled and demonstrated by TBE at Lima South Quarry in Victoria, these are the first units bought by an Australian quarrying producer. Wayne Kruger says this is an important milestone because “Milbrae will have the two biggest Lokotracks in NSW. Besides mobile cranes, the LT130E is the biggest piece of mobile equipment that Tutt Bryant has ever sold.” “The LT130E fits our model for contract mining and crushing perfectly,” Gillieatt says, adding the LT130E’s automation capabilities will also enhance Milbrae Quarries’ productivity in the pit. The LT130E can be remotely programmed by an operator in a nearby loader or excavator, which in addition to raising efficiency in the pit increases safety and removes risk for operators on the ground. “The feedback we get from clients
is ‘Our people need it (remote control) on the ground, next to the machine’,” Kruger says. “Our operators typically operate our current fleet of LT120s via remote from the excavator cabins,” Gillieatt says. “This provides an increased level of safety. We are all aware of the hazards of silica in mining, removing the need to have an operator physically walk over to the machine to change a setting greatly reduces their exposure.”
THE LT130E HAS A FEED OPENING OF 1300MM X 1000MM.
Dedicated service
With Metso mobile gear constituting 50 per cent of its fleet, to say Milbrae Quarries has a “good” relationship with TBE would be an understatement. While Milbrae has a mechanical and maintenance division that looks after the upkeep of all its plant and equipment, Woods and Gillieatt say that TBE’s aftermarket service is invaluable. “Our partnership has been so successful because of the robustness and ongoing technological advances of the Metso gear,” Gillieatt says. “We’re also really happy with the service and maintenance side of things. The servicing comes into that as a complete package. The TBE technicians are in constant contact with our own mechanical department. They’re great on the service, and their equipment is innovative and very user-friendly as well.” Kruger says that a major selling point of the Lokotrack plant for many quarry producers is TBE’s assurance package. “We provide regular technical assistance and warranty inspections. We provide an extended warranty with the equipment – 10,000 hours or five years, whichever comes first. Tutt Bryant is also the only one that offers that type of extended warranty in the market. “Further, we do on-site commissioning training and we’ll always provide over the phone technical support and advice.” “Tutt Bryant Equipment and Metso are improving their support and back-up services all the time,” Woods concludes. “They are always asking for feedback about how they can improve their equipment. “I think you would say that over the years Metso has proved to be reliable and we consider them to be the better machines in the industry.” With that sense of optimism, it is likely that Milbrae’s LT130Es and other Lokotrack mobile plant will continue to be a mainstay of the company’s quarrying, mining and contract crushing businesses for many years to come. AM AUSTRALIANMINING
SPECS - METSO LT130E LOKOTRACK TRACKED JAW CRUSHER
Main features
Crushing unit Feed opening Feed hopper Feeder Main conveyor Process control Engine Generator
Nordberg C130 jaw crusher 1300mm x 1000mm (51’’ x 39’’) 11m3 B13-50-3V H14-16E with adjustable height Metso IC900 Caterpillar C15 (403kW) 500kVA engine
Transport dimensions Weight 103 tonnes* Width 3500mm Height 3.9m Length 21.5m
*Split unit combined weight and depending on options selected.
Options include: • • • • • • • • • •
Metrics remote monitoring system. ICr remote control. Easy split, hydraulic legs for dismantling the crusher and feeder units. Rubber plates for feed hopper. Rubber bottom for feeder. Side conveyor H8-7E. Magnetic separator for main conveyor. High pressure water spraying system. Dust encapsulation for conveyors. Hydraulic boom and hammer.
Source: Metso Outotec/Tutt Bryant Equipment.
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DRILL & BLAST
E*STAR CONNECTOR ENSURES RELIABILITY AT ALL TIMES AUSTIN POWDER LAUNCHES NEW CONNECTORS FOR THE E*STAR ELECTRONIC INITIATION SYSTEM, FEATURING INNOVATIVE CAPABILITIES THAT ENSURE EASE OF USE AND SAFETY IN HARSH CONDITIONS.
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inding a missing connection can be a painstaking, timeconsuming exercise. That is why Austin Powder focussed on creating a rugged new connector for its E*STAR electronic initiation system. The new connectors are ergonomically designed with built-in features to provide an easy-to-use, reliable industry solution. So much innovation is packed into the new E*STAR connectors to ensure the highest standard of usability, reliability and safety. Using the new connector with duplex bus line wire eliminates the need to split wires when making a connection, saving time and decreasing the chance of wire damage. With E*STAR, the connection is made by simply placing the duplex wire into the connector (in any polarity) and snapping the lid shut. “The new E*STAR connectors are leading the industry with their innovative ‘double connect’ capability on both the leg wire and duplex wire. The double connect capability
allows for eight contact points on the detonator leg wires and eight contact points on the bus lines. The new E*STAR connector effectively ensures a 100 per cent reliable connection of all wires within the connector, at all times,” Austin Powder global manager – electronic initiation systems, Campbell Robertson, explains. “Blasters can also perform through-connector testing without opening the connector, streamlining the testing procedure.” The new connectors also make both detonator-to-logger and detonator-to-branch connections faster and more reliable. Wire type and length are identifiable at-a-glance because of standardised colour-coding. The connector’s back is flat with ample surface area so that the delay time or other pertinent information can be noted. Built with field conditions in mind, the connectors’ robust construction includes an all-weather-resistant seal, ensuring E*STAR detonators will function as intended even in the rain. The grip provided by anti-slip
E*STAR CONNECTORS WERE BUILT WITH FIELD CONDITIONS IN MIND.
AUSTRALIANMINING
E*STAR DETONATOR CONNECTIONS ARE EASY TO USE, EVEN WITH GLOVED HANDS.
contours and the robust flip-top hinge makes it possible to open and close the connector even while wearing gloves. In fact, a blaster can open the connector using just one thumb, yet once closed, the connector is sealed and secure from dirt, debris and
E*STAR DETONATOR CONNECTIONS ARE ROBUST AND ALL-WEATHER RESISTANT.
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moisture ingress. At Austin Powder, the details matter in all that the company does. The new E*STAR connectors are just an example of how Austin Powder is working to ensure that its products contribute to safe, predictable and optimised results. AM
The ZI-2100 is here! Australia’s leading supplier of crushing equipment and services is proud to announce that the ZI-2100 Cone Crusher is in stock, in Perth. Proven Japanese engineering and design quality from Kawasaki Heavy Industries, supported locally by Minprovise.
Key Features include :
General Specifications :
High performance crushing chamber design
Max. feed size: 350mm
Feed distribution plate
CSS range: 10-50mm
Spherical Bearing for Spider Bushing
Nominal capacity: 515-2050 tph
Replaceable Main Shaft Sleeve
Motor power: 750kW
Overload Relief System
Head diameter: 2100mm
Automatic Operating Control System
Weight: 93,900kg
Contact Minprovise today Tel: 08 9359 6800 or Email: sales@minprovise.com.au
w w w . m i n p r o v i s e . c o m . a u
MAINTENANCE
SKF-LINCOLN GREASE INJECTOR RAISES MINING PRODUCTIVITY SKF AND JSG INDUSTRIAL SYSTEMS HAVE UNVEILED THE LATEST GENERATION SINGLE AUTOMATIC LUBRICATION SYSTEM INJECTOR, THE SKF-LINCOLN SL-6, FOR THE HIGHEST PERFORMANCE.
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ith higher demands on productivity, less time for maintenance and no tolerance for unplanned stops, lubrication performance has become the key to machine uptime and efficiency. This focus is particularly relevant for heavy equipment where high loads, vibration, dust and dirt present extreme operating conditions. According to SKF, a leading global bearing and lubrication system
RELIABILITY REINVENTED WITH THE NEW SKF LINCOLN SL-6 INJECTOR.
manufacturer, poor lubrication causes about 36 per cent of all premature bearing failures, leading to costly repair and maintenance that causes unnecessary downtime for mining and industrial operations. JSG Industrial Systems, a subsidiary of the John Sample Group, has been a distributor of SKF-Lincoln lubrication systems since 1961, becoming its largest lubrication system partner globally. SKF and JSG have introduced the new SKF-Lincoln SL-6 grease injector, the latest generation of single-line automatic lubrication system injector focussed on providing efficient lubricant distribution in harsh environments for dump trucks, excavators and other mining and construction equipment. The patented SKF-Lincoln SL-6 injector has been designed with ease of use and fast maintenance in mind. It has outstanding leak protection and service life, even with harsh EP (extreme pressure) greases. The SL-6 can easily be retrofitted to existing single-line lubrication systems. Quick maintenance features include a highly visible red indicator pin, an adjusting screw to adjust lubrication rates requiring only basic tools, and a hex-shaped body to maximise working space, making for easier service and maintenance. For optimal lubrication performance, the injector’s vent and reset speed is faster than any other injector in the market, according to SKF. The design of the injector creates a daisy-chain reaction where the venting and reset of the first injector in the system causes the adjacent injector to vent and reset setting off a chain reaction through the entire system until every injector has vented and reset. Leaking injectors can cause under-lubrication of a bearing and grease bypass. The improved sealing AUSTRALIANMINING
THE SKF LINCOLN SL-6 INJECTOR CAN EASILY BE RETROFITTED INTO EXISTING AUTOMATIC LUBRICATION SYSTEMS.
THE SKF LINCOLN SL-6 INJECTOR RETROFITTED INTO AN INJECTOR BANK.
technology of the SL-6 injector reduces the risk of leaks, and in the unlikely event of a failure, the grease is bypassed to the bearing. Repair is then possible by simple replacement and service of two components. Describing the benefits of automatic lubrication, SKF states in its product press release: “Lubricating manually takes extra time, requires the machine to be stopped, and tends to swing between wasteful initial over-greasing and, over time, damagingly low lubrication.” A proper lubrication system makes sure lubricant constantly flows to bearings, pins and bushings. It lubricates machines while in motion, overcoming loads and allowing grease to protect all wear surfaces. “The SL-6 injector and SKFLincoln lubrication systems help customers to take a giant step toward increased productivity. With less maintenance, less time spent on
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manual greasing, reduced grease consumption and longer component life, customers will see an immediate return on their investment,” SKF states. JSG Industrial Systems uses its vast application engineering resource base, as well as original equipment manufacturer (OEM) factory specifications to determine the correct lubrication system needs for customer applications. The company takes the complete range of SKF-Lincoln lubrication solutions to market and combines this with in-house engineering expertise and extensive application experience to deliver solutions tailored specifically to customer needs. JSG provides access to the supply of SKF-Lincoln lubrication systems through a network of national partners covering system scoping, design, installation and commissioning with comprehensive aftersales support. AM
“Simple, creative and engaging solutions for your training needs to get your students skilled fast”
FUTURISTIC INDUSTRIAL TRAINING WITH BESTECH Modernisation of industrial technology has pushed the demand for advanced training solutions to produce workready graduates. This drives us to commit to deliver stateof-the-art technical training aids to support the industry. Bestech is the leading technical training equipment supplier to the mining education sectors. We offer tailor-made, cutting edge solutions to meet your training requirement. • Mining Equipment Simulator • Fluid Power Training Equipment • Electrical Testing Panel Email: enquiry@bestech.com.au
GLOBAL TECHNOLOGY LOCAL SUPPORT
Phone: (03) 9540 5100
MAINTENANCE
AMCAP MIDLIFE SERVICE KITS BENEFIT ROY HILL ROY HILL HAS USED AMCAP INDUSTRIAL’S DUMP TRUCK MIDLIFE SERVICE KIT TO DELIVER SAFER WAYS TO CONDUCT BUSINESS, WHILE ALSO IMPROVING WORKPLACE PRODUCTIVITY AND REDUCING COSTS.
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MCAP has partnered with iron ore major Roy Hill to develop a custom solution that leverages its unique distribution model for midlife service kits to improve how parts are delivered for major assets. Servicing the company’s fleet, the midlife service comprises 17 individual job lots to change out over 250 individual components, including injectors, turbos, steering cylinders and all the widgets in-between.
The large fleet of dump trucks were a highly desirable asset class to target for optimised parts delivery as the age of the fleet has been hitting their hours on major component change-outs in their lifecycle. With AMCAP supplying all required materials in one purchasable product number, Roy Hill improved productivity through the reduction of purchasing individual materials for the midlife service. “This translated into a reduction in receipting throughput, fewer
AMCAP’S MIDLIFE KITS ARE A ‘JEWEL IN THE CROWN’ FOR THE COMPANY. THE KITS CAN HOLD BETWEEN 300-500 LINE ITEM PARTS.
AUSTRALIANMINING
system transactions for our warehouse operators and improvements to the quality of parts delivery to the maintainer through the secure custom designed container, identifiable shelves, draws and hose racks, which made managing parts during the midlife service a smother operation for the maintainer,” the company states. AMCAP has supplied service kits to Roy Hill for the past twoand-a-half years, supplying around 300 kits per month. It is now one of several large iron ore companies that AMCAP partners with. Roy Hill’s overall model is to identify and deliver products and services that minimise downtime of mining assets by working closer with maintenance strategy teams. AMCAP’s competitive component prices have also allowed it to establish a buyback delivery model, which has provided the iron ore company with a credit for unused parts retuned in the service kit. As a result of this initiative, it offers a more cost-effective purchasing strategy solution than if it purchased parts through conventional means. “For a cost-driven business such as ours, these types of initiatives are enormously valued,” the company states. AMCAP’s Midlife Kits are a ‘jewel in the crown’ of the company’s parts distribution model, offering a number of benefits, including a unique material number instead of potentially 50-100 material numbers being ordered individually. The company also provides logistical cost savings through handling and transport of a single line item, as well as the accuracy of having all parts consolidated within the kit. The kits are packaged appropriately in bespoke cabinets and containers, ensuring they are securely delivered on site. The kits can hold between 300-500 line item parts, with a total volume of up to 1400 line items as a total package. Each kit is individually itemised per operation, and all parts within the kit are broken down to support individual operations. With the cabinets designed to be compact and positioned on the
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platform, it provides technicians with access to all parts and components, reducing personal risk of injury. Safety at Roy Hill’s site has also improved during parts of transportation and material handling because of AMCAP’s kit. “These all-in-one service kits circumvent problems arising from large individual delivery volumes of components that are less organised across numerous pallets causing movements in transportation or employee mishandling,” the company states. “The kit meticulously layers each operation systematically into individually labelled draws, racks and containers within the standardised modular TEU housing. “This enables a neat and secure arrangement of parts, which saves the headache that every maintainer knows when it comes to organising parts for their major jobs into operations.” As AMCAP delivers these parts strapped down with custom-designed handles and cable ties for safer handling of individual components, the maintainer’s ability to safely handle each item has dramatically improved. AMCAP business development manager Barry Neale says by partnering with Roy Hill the company has further researched and developed its kitting services. This framework has provided an opportunity to utilise different parts sourcing options of OEM and non-OEM products to optimise the cost of the finish product to the customer, while still retaining comparable quality. “A true market leader in the industry and sets the bar on what specialised kitting services can achieve, which sets them apart when choosing suppliers,” Roy Hill states. Neale reinforces that the relationship with Roy Hill will reap benefits for AMCAP as it goes from strength to strength. “The learnings from this exercise and some of our engagement with large miners in Western Australia has placed AMCAP in a very favourable position to deploy some of these technologies and learnings across the board,” Neale says. AM
Introducing the Lokotrack® LT130E™. The largest Metso-Outotec Mobile Jaw Crusher in the country, weighing in at 133,000 Kg. An extremely robust primary crusher built by heavy-duty steel elements. The mobile jaw crusher can operate electrically with an external power source or by using an onboard diesel generator when no external power source is available. High quality electrical components for efficient and reliable use. External power supply can be connected for complete electric use.
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JORD INTERNATIONAL, BHP DRIVE FILTER PRESS MAINTENANCE INNOVATION BHP HAS COMMENCED ITS FIRST SUPPLIER INNOVATION PROGRAM PILOT PROJECT WITH JORD INTERNATIONAL TO COLLABORATE ON ESTABLISHING A NEW INDUSTRY BENCHMARK FOR FILTER PRESS MAINTENANCE.
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ord International has been awarded a contract at the BHP Mitsubishi Alliance (BMA) Caval Ridge mine in Queensland’s Bowen Basin to implement a unique solution for improving filter press maintenance processes and safety. The project is the inaugural pilot awarded through the Supplier Innovation Program challenge process, which BHP launched in June 2020 in partnership with Austmine. The first challenge was focussed on safety at BMA and garnered the interest of 235 suppliers across Australia, with 21 providing expressions of interest to put forward a solution. Jord was selected as the standout submission from a highly competitive final field of nine mining equipment, technology and services (METS) companies that presented a proposal to BMA. This open innovation and
collaborative challenge process is being replicated at other BMA sites in Queensland, along with BHP’s Western Australian Iron Ore (WAIO) and Olympic Dam operations in South Australia. Jord will now have the opportunity to work hand-in-hand with the fixed plant maintenance team at the Caval Ridge mine to pilot its solution. If successful, it will potentially establish an industry benchmark for a known issue across the industry. The solution proposed by Jord will eliminate the man and machine interaction with the development of a belt cartridge installer, which is self-contained in a lightweight steel body that allows lifting by the overhead gantry crane. The cartridge will also enable forklifts to transport it while on the ground. This process will remove the operator from the filter area. BHP group procurement officer James Agar says the Supplier
Innovation Program enabled the mining company to crowdsource a broader range of unique and innovative solutions to business challenges. “With filter press belt replacements, it is a time consuming task with lots of manual handling. While there are processes in place to control the risks around that task, the new solution proposed through this innovation program eliminates the need for maintainers to be in physical contact with the filter press altogether,” Agar says. Jord International general manager – minerals, Kevin Barber, says: “The (Supply Innovation Program) process was very open with feedback shared and accepted by both parties. “It has been a great opportunity to be engaged in solving a problem that you would otherwise not have been aware of.” Jord senior design engineer Craig Samuel adds: “Creating a safer environment is the pinnacle of an
THE JORD TEAM: (L-R) CRAIG SAMUEL, MYRA WALKER, MARK THOMAS, KEVIN BARBER, DAVID RICAPITO AND SIMON EVANS.
AUSTRALIANMINING
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engineer’s ethos and it’s incorporated in everything we design.” BHP acting vice president procurement excellence Amanda O’Conner says: “We look forward to partnering with Jord to implement a successful solution eliminating safety risks and ensuring our people go home safe every day.” The Supplier Innovation Program builds upon the BHP and Austmine strategic partnership, which is focussed on bringing people and resources together to maximise value-chain opportunities and further strengthen the competitiveness of the Australian METS and mining sectors. The program forms part of BHP’s commitment to supporting regional supply chains and the economic diversification and sustainability of regional communities across Australia. As the industry shifts towards more remote and technologicallyenabled operations, the ability to build and leverage local capability, and continue to demonstrate our social value contribution, will be critical to both our competitive advantage and reputation. The Supplier Innovation Program allows BHP to crowdsource a broader range of unique and innovative solutions to business problems. It represents a significant shift from the tender methods traditionally used to engage suppliers. The program makes it easier for the METS sector to access project opportunities, access new avenues for collaboration and to put forward solutions while retaining intellectual property. BHP and Austmine are partnering on a number of challenges within the Supplier Innovation Program, focussing on areas such as reclaim tunnel cleaning, port safety, conveyor roller handling and oversize rock detection. We look forward to sharing more information about the results of these challenge processes over the coming months. AM To keep up to date with the Supplier Innovation Program visit Austmine’s webpage.
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SAFEGUARDING MINING OPERATIONS IN CYBERSPACE AS THE MINING INDUSTRY EVOLVES WITH NEW TECHNOLOGIES, DIGITAL TRANSFORMATION PROVIDER ASG GROUP EXPLAINS WHY ROBUST CYBER SECURITY IS A NECESSITY.
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he COVID-19 pandemic has brought a wave of Industry 4.0 technologies to the forefront of the mining industry. With travel restrictions being a recurring theme over the past 12 months, mining companies have been forced to adapt. During the pandemic, miners have adopted technologies that allow for remote operation of activities on site via the internet. And like any device connected to the internet, ‘smart’ mining technologies carry cyber security risks. A cyber attack on a mining operation could potentially derail productivity and cause huge issues for the entire operation. ASG Group has provided IT solutions and services to multiple industries since the company was founded in 1996. For mining, this includes digital transformation services that boost returns on investment, support for enterprise applications like SAP, Oracle and Microsoft, as well as consulting services throughout the transformation journey – including cyber security services. The company can also assist with sustainability goals through cloud migration, automation and process optimisations. ASG Group national security lead Adam Misiewicz says the mining
ASG GROUP HAS PROVIDED IT SOLUTIONS AND SERVICES TO COMPANIES SINCE 1996.
industry has grown more open to the adoption of autonomous technologies to support the productivity and efficiency of operations. “Mining today relies on interconnectivity and autonomous technologies to collect, process and fuse data – essential to support a wide range of decision making such as how to optimise production,” Misiewicz tells Australian Mining. “Remote sites and thousands of devices all running on shared technologies over wireless connectivity can present vulnerabilities – any weaknesses can open up opportunities for hackers and other malicious threats.” These threats include espionage, insider threats and ransomware, which can all result in significant financial losses for a business. “This is where experience with technologies, best-in-class expertise, and strong implementation is so important in mining,” Misiewicz says. “The spotlight is often on mining and resources companies to prove they are being socially responsible – cyber security plays a huge role in this.” For Misiewicz, two major challenges for cyber security are common in the mining industry. This industry’s focus on legacy systems with a hesitation to patch or upgrade due to downtime and weak access controls, such as identity management and encryption. AUSTRALIANMINING
“The combination of both creates significant vulnerabilities, which if left exposed, can be used to create damage,” Misiewicz says. “This is where ASG can help.” As an IT provider for enterprise and government organisations, ASG Group is experienced working with critical environments and infrastructure. “Today, we have security specialists located around the country performing services related to cyber risk and compliance, cyber defence and managed security services,” Misiewicz says. “We are one of the few providers that delivers its security services from local shores using sovereign capabilities to support our national security, bolstered by partnerships with leading security software and service vendors.”
Digital technologies in a mining environment are often connected to complex and hazardous machinery. If remote access to these machines is not managed correctly, serious injuries can occur. “Interconnectivity, the cloud, digital technologies (IoT, mobility, 5G) and the interaction between these elements creates its own risk,” Misiewicz says. “And in mining, if things go wrong, the consequences may be a matter of life and death. “This absolutely elevates the need to understand risk across the entire business, with a view to implementing controls that reduce risk to the lowest possible acceptable level.” Misciewicz recommends that miners re-assess their investment strategies and consider optimising their processes, while considering tools that take advantage of their digital environment. “Cyber threats today are indiscriminate and impact just about every single sector. The impact of a successful attack today is magnified because of all this connectivity,” he says. “This can lead to operational, reputational financial damage and can impact customer or consumer confidence. “Due to the most prevalent threats in this industry – ransomware, phishing, insider threats, espionage – it is everyone’s responsibility to play a role in reducing these threats. “It’s a business problem, not an IT one and each one of us should be educated in how to recognise the early stages of an attack, or how our actions leave us vulnerable.” AM
CYBER SECURITY RISKS CAN LEAD TO HUGE CONSEQUENCES FOR A MINING OPERATION IF NOT ADDRESSED.
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TECHNOLOGY
PUTTING SIMULATION AT THE CENTRE OF OPERATOR TRAINING THE MINING INDUSTRY’S PROSPECTS ARE HEAVILY RELIANT ON THE PEOPLE THAT MOVE IT FORWARD. BESTECH SUPPLIES HEAVY EQUIPMENT SIMULATORS THAT HELP MINING COMPANIES FULFIL THEIR HIRING AND TRAINING NEEDS TO KEEP MOVING.
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here are more than 100 mining projects with completed feasibility studies in Australia. These projects combined will potentially create more than 22,000 jobs for equipment operators. Given that employees are regarded a company’s best long-term assets, the Minerals Council of Australia (MCA) believes it is important to prop them up with modern training without compromising safety and efficiency. In fact, the industry body views training as one of its priorities for 2021 and beyond. This reflects a change in the mining sector, as well as evolving industry and employee expectations of mining roles, according to the MCA. “The industry recognises that a diverse workforce demands flexible training and education options and invests millions of dollars every year to equip employees with the skills they need for a fulfilling career,” the MCA states in its policy agenda Advantage Australia, released in February. “From graduate programs to retraining for older workers, the industry turns regularly to local training that supports education providers in the regions.” As a local supplier of technical teaching equipment, Bestech Australia recognises the challenge that the industry faces in hiring and training
the right candidates. The company has extensive experience in supporting local universities, technical and further education (TAFEs), and registered training organisations’ (RTOs) industry-based learning program with high-end training aids and simulators. Bestech product specialist Graeme Nicholls says that a wide variation in technical aptitudes, including psycho-motor, sensory/perceptual and cognitive abilities, exists in candidate hiring pools. “The candidates who possess the suitable technical aptitudes are expected to complete the training in a shorter amount of time and possess higher skill levels at the end of their training program,” Nicholls tells Australian Mining. “Therefore, by choosing to train the candidates with the right aptitudes, they will become genuinely proficient in operating the equipment once they completed the training.” Simlog personal simulators are great training aids that address workforce shortages and produce skilled heavy equipment operators. It is a PC-based simulator that connects students in the classroom to the virtual working environment as they develop new skills and learn the correct and safety-conscious habits. Bestech has supplied the Simlog equipment simulator to multiple TAFEs and RTOs across Australia
THE SIMLOG SIMULATOR COMPRISES A SIMULATION CHAIR, MANUAL JOYSTICK AND DISPLAY MONITOR. AUSTRALIANMINING
and New Zealand. Globally, Simlog has gained a reputation for its success in equipping people with relevant skillsets, including universities or TAFE students and residents of correctional facilities. A career and technology centre in South Carolina in the United States, for example, has set up a lab with multi-purpose simulators, including for backhoe loaders, hydraulic excavators, bulldozers and wheelloaders. This is part of a course that develops career-ready graduates and reduces the local industry’s training cost. “Instructors, who have used Simlog simulator as a learning tool to teach their students, have reported the simplicity in evaluating the technical aptitudes and performance of each students through the simulation manager,” Nicholls says. “This enables them to train more students at a significantly lower cost and improve the standard of their teaching.” The simulator set-up only comprises a simulation chair, manual joystick and display monitor. They are designed to work together to deliver a modernised yet streamlined training. A Simlog skid steer loader simulator, for instance, features vertical or radial lift path types and two skid steer loader combinations. The skid steer loader can be equipped with either buckets or forks to simulate real-world equipment. On the other hand, a Simlog hydraulic excavator simulator features an articulated dump truck in a dynamic terrain with life-like materials. This is designed to provide students with real-world experience and teach them how to operate the equipment safely in the field. All Simlog simulators impart realworld operator skills, from basic to advanced levels, while drawing upon real-world equipment functionality. The importance of training and retraining employees boils down to maintaining the highest level of safety for all employees on site.
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SIMLOG TRAINS USERS TO OPERATE EXCAVATORS AND OTHER EQUIPMENT.
The next generation
An on-site accident, however minor it is, can instigate an operational shutdown to allow for a thorough safety audit and accident investigation. “All these actions will hamper the mining operation,” Nicholls says. “Therefore, heavy equipment Mining Excavator R 9600 operators must be proficient and qualified in operating the equipment properly and in a safe manner. The Simlog simulator can train operators with the right technique to operate the equipment. “It is also a great, entry-level training simulator that can test whether a candidate is fit to be trained as an equipment operator before putting them on the real equipment. “For experienced operators, the simulators can be used for verifying and renewing their skills, as well as learning new techniques to meet higher standards.” Students can learn and complete the The course at their own pace without R 9600 sets new standards in open pit mining equipmen any supervision, thanks to an inbuilt performance indicator that measures their performance. The performance indicators provide precise measurements such as execution time, loading accuracy, driving speed and maximum tilt angle, while climbing or descending and more. “Mining is a high-risk industry and they care about production and operational efficiency above all costs. Simlog’s heavy vehicle simulators can offer affordable, cost-effective training with the flexibility to train users across many different equipment,” Nicholls says. AM – – – – – –
Cutting-edge technologies with Liebherr Assistance Systems First step towards automation with Bucket Filling Assistant Up to 20% fuel consumption reduction with smart energy management Weight-optimized attachments for maximizing bucket payload Latest cabin design with enhanced ergonomics providing a comfortable working environment Perfect match with Liebherr Mining large and ultra-class trucks
2036-001_21 AZ Adaption R9600_AustralianMining_235x297_02.indd 1
THE MINING INDUSTRY HAS MOVED TO A NEW PHASE FOLLOWING THE MINING BOOM, ONE WHERE PRODUCTIVITY, INNOVATION AND SAFETY HAVE EMERGED AS ITS KEY PRIORITIES TECHNOLOGY MINING EQUIPMENT VOLUME 113/03 | APRIL 2021
UNDERGROUND MINING
SMART PROCESSING
DESIGNING INTELLIGENT INFRASTRUCTURE
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TECHNOLOGY
A SMARTER WAY TO HANDLE REMOTE INVENTORIES ADVANCES IN RADIO FREQUENCY IDENTIFICATION TECHNOLOGY HAVE CREATED NEW POSSIBILITIES FOR INVENTORY MANAGEMENT IN REMOTE MINES.
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mong its many applications, radio frequency identification (RFID) technology can be used to monitor inventories in real time and to send automated replenishment orders to suppliers. eCommerce expert Zac Gray says this may be particularly interesting for remote mines looking to streamline their inventory management process. “The possibilities with RFID for inventory management are very varied and robust,” says Gray, who is the manager of marketing – digital business programs & eCommerce at Industrial Solutions Australia, part of Motion Asia Pacific. “By using RFID labels and installing a RFID portal at the entrance of your warehouse, you can track the movement of anything from spare parts to tools and equipment. “In the case of remotely located warehouses, this means your employees can have 24/7 access to the products without having to hire store supervisors across multiple shifts.” A containarised RFID-enabled storage solution provided by Motion Asia Pacific and its technology partner, Inventory Control Systems (ICS) – the Australasian reseller of CribMaster – shows just how robust the RFID technology can be. ICS national sales manager John Meaney says the solution first emerged when a major mining and construction equipment manufacturer sought the assistance of one of Motion Asia Pacific’s businesses to manage its inventory of fasteners across different project sites. “The client was interested in
using CribMaster’s CribX Vend, which are shipping containers fitted out with vending machines and CribMaster hardware and software solution to provide 24/7 inventory tracking,” Meaney says. “In consultation with Motion Asia Pacific, we took this a step further by equipping the containers with CribMaster’s AccuPort RFID portals with badge readers to enable automated check-in and checkout and better control on product movements. “In this system, the products are not necessarily placed inside vending cabinets. They can be placed on normal shelves, giving the site more flexibility for storage.” He further elaborates on how the system helps streamline inventory management. “All of the products inside the container are applied with traceable RFID tags containing critical information like product details and batch information. When employees pass through the AccuPort, they scan their ID badges and proceed to collect the products they need,” he explains. “As they exit, the RFID portal identifies the products they are removing, and the data is automatically recorded on the company’s system for realtime budgeting and compliance purposes. When the quantities reach below set values, the system sends automatic replenishment notifications to the vendor to replenish the products.” Cost savings from minimised warehouse staffing was a key benefit for the company, as Gray further elaborates. “Since deploying the solution, they have been able to save an estimated $3000 per month from RFID control of
AUSTRALIANMINING
ACCUPORT RFID PORTALS WITH BADGE READERS ENABLE AUTOMATED CHECK-IN AND CHECK-OUT.
fasteners alone,” he says. “They are now looking to expand the solution to include products in safety, hydraulic fittings and hoses. We are also in the process of integrating data from the AccuPort with their enterprise resource planning (ERP) system to ensure better inventory and compliance control.” Robustness and adaptability are other features of the RFID-enabled storage solution, according to Gray. “You can expand your storage space infinitely by connecting multiple shipping containers with the one AccuPort RFID portal,” Gray continues. “We can also customise the inside of the shipping containers to fit anything from hand tools and power tools to spare parts and personal protective equipment (PPE). The CribMaster RFID tag solution enables us to print RFID tags in a
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variety of shapes and sizes based on the tools’ shape and surface materials.” Gray is also quick to clarify that the containerised solution is just one of the many bespoke inventory control solutions made possible with RFID. “There are many more possible solutions for inventory control that we can implement alongside our partners in ICS and CribMaster. While the containerised solution has benefits for companies in need of flexible storage spaces, the AccuPort can also be deployed with existing brick-and-mortar warehouses,” he says. “It all comes down to the requirements of the end user. Whether they are looking to automate their vendor managed inventory or gain higher inventory accuracy, we help them achieve those objectives.” AM
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SAFE AREA MONITORING FOR EQUIPMENT IN AN INCREASINGLY AUTOMATED INDUSTRY, PILZ AUSTRALIA ENHANCES THE SAFETY OF MINING EQUIPMENT WITH ITS RADAR DETECTION SOLUTION.
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ining companies are susceptible to a plethora of hazards that naturally arise from the harsh conditions they operate in. Whether it be heavy and complex machinery or zones that are vulnerable to the unpredictability of nature, companies are increasingly looking for new ways to protect staff while maintaining productivity. As the mining industry shifts towards autonomous machinery, German-based company Pilz is leading the way in providing safer monitoring systems to companies around the world. A prevalent issue within mine safety has been companies’ limited ability to utilise technology capable of productive area monitoring that withstands the rigorous ‘rain, hail and shine’ nature of mining operations, while also effectively protecting staff working in proximity to hazardous zones within sites. Pilz, however, has a solution for this through the use of the PSENradar, Safe Radar system, which in its own words “allows for safe area monitoring in harsh environments.” Previously, many companies have used safety scanners that incorporated infrared technology in applications that require area monitoring. In these instances it was found that the devices can be susceptible to environmental factors, such as dust, moisture and sunlight, often rendering
them ineffective on mine sites. The PSENradar, Safe Radar system, on the other hand, uses radar technology that is perfect for use in harsh environments. The system consists of up to six sensors and a control unit that monitors areas of up to 15 metres wide and four metres deep. It is capable of achieving up to Safety Category 2 (3 for outputs), SIL 2 or PLd. For Stevenson, the biggest advantage of the product, apart from its ability to be used in harsh environments, is its versatility, as the device can be mounted to mobile or fixed equipment. The detection area can also be easily configured to cater for the shape and size of the required area to be monitored. “It can be mounted on a moving vehicle where in the mining industry you often want a safe perimeter,” he says. “In the event a person comes into an unsafe area, it sets off an alarm and/ or shuts down the equipment within the monitored area.” Pilz is currently working closely with a major stacker/reclaimer OEM for an order of machines being delivered to one of Australia’s major mining companies. In this instance they were looking for a solution to replace the mechanical “cow catcher” they currently use. The “cow catcher” relies on physical contact with an object or person to alert them of a safety issue. The Pilz radar system was the perfect solution for this application as it alerts of a
THE LBK SAFE RADAR SYSTEM IS IDEAL FOR HARSH MINING CONDITIONS.
AUSTRALIANMINING
THE PILZ LBK SAFE RADAR SYSTEM CAN BE MOUNTED TO MOBILE AND FIXED EQUIPMENT.
safety issue without contact and brings the machine to rest prior to a collision occurring. Given the prominence of advanced machinery and robotic systems, the radar system combines two safety functions to ensure both machinery and operators are protected. The detection function consists of a pre-alarm zone, which is used to alert approaching objects and/or to prepare the machinery for shutdown. This is followed by the hazard zone, which places the machinery into a safe condition when someone enters the dangerous area, while the restart function inhibits the restart of the machinery if there are operators still within the dangerous area. The size of the protection zone can be configured to be wide or narrow, in both the vertical and horizontal plains depending on the area that is being monitored, and if required a muting function of the entire system or individual sensors is possible. A smart sensor being used accurately detects and tracks motion through computing the distance of moving personnel in real-time when they may be approaching unsafe areas. Most notably for mining companies,
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however, is the device’s ability to withstand the elements, including smoke, dust, shavings, machining waste and splashes. The result is a dramatic reduction in false alarms at mine sites, which often lead to the freezing of production and prevention of plants operating at optimum efficiency. Pilz plans to release additional models of the PSENradar, Safe Radar System later this year with enhanced network, IO and safety features. For Pilz, the opportunity to safely protect mining companies’ personnel and machinery has always been a priority and the ability to do this in a way that withstands the rigours of mine sites has opened the door to greater opportunities. “It’s about providing solutions. Where we couldn’t fully do this previously because of environmental factors, this device has given us the ability to offer a solution more suitable to the harshest of environments,” Stevenson says. While the small radar heads may pale in size when compared with the magnitude of machinery on mine sites, their purpose remains imperative to the safe and efficient operation of mines around the world. AM
MINING SERVICES
ITM ROLLS OUT TOUGHER LINK ASSEMBLIES ITM’S HEAVY DUTY CHAINS GIVE MINING OPERATORS A STEP ABOVE IN DOZER DURABILITY AND UPTIME.
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ining equipment faces tough working conditions through the constant digging, drilling and transporting of materials through sites. Reliability is a key facet of keeping operations running smoothly and having components that can handle harsh mining environments is essential. ITM Mining has engineered a solution and has launched the new ITM D10 Heavy Duty Link Assembly, which is targeted
THE 50 PERCENT EXTENDED WEAR LIFE IS NOT JUST IN THE LINK ASSEMBLY, BUT FOR THE ENTIRE UNDERCARRIAGE SYSTEM.”
to improve reliability. For high-wearing and abrasive applications, ITM’s D10 Heavy Duty Link Assembly provides an extended wear life and improved performance. In the words of ITM group managing director Adrian Battley, the D10 Heavy Duty Link Assembly emerged from “customer requirements for a more durable link assembly with a longer service life.” Battley also adds that, although the chains are similar in design of the standard model, the FEM analysis has shown that by increasing the material in critical areas of the track link and pin, stress levels have reduced in these areas. “In addition, we have increased the diameter of the track pin by three millimetres, which results in less bending under load and lower contact pressure with the track bush,” Battley tells Australian Mining.
ITM D10 HEAVY DUTY LINK ASSEMBLY COMPARED WITH THE STANDARD D10 LINK ASSEMBLY.
“All of this combined, creates a link assembly with increased strength, eliminated cracking and reduced risk of hot joints.” The D10 Heavy Duty Link Assembly is built for popular mining dozers, including the Caterpillar D10 and Liebherr PR 776. Recent field tests have proven
the ITM D10 Heavy Duty Link Assembly offers in excess of 50 per cent increase to undercarriage life, compared to standard chains. Furthermore, results are showing that the 50 percent extended wear life is not just in the link assembly, but for the entire undercarriage system. According to Battley, this goes back to the true nature of ITM’s philosophy: to make customers’ lives easier by simplifying the science of the undercarriage. The company offers a system which may look uncomplicated, but it’s made up of many different components that all work together to create the most streamlined, powerful undercarriage. ITM Mining is the industry’s undercarriage specialist and operates Australia wide. AM
THE ITM D10 HEAVY DUTY LINK ASSEMBLY OFFERS A 50 PERCENT INCREASE TO UNDERCARRIAGE LIFE.
ITM’S D10 HEAVY DUTY LINK ASSEMBLY.
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EVENT SPOTLIGHT
MODERN MINES FROM EXPLORATION TO REHABILITATION FOR OVER 40 YEARS, THE AUSTRALASIAN INSTITUTE OF MINING AND METALLURGY (AUSIMM) MILL OPERATORS CONFERENCE HAS BEEN A KEY EVENT FOR THOSE IN THE MINING AND WIDER RESOURCES INDUSTRY.
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hen the Mill Operators Conference was established in 1978, it started as a humble event held in regional mining towns that provided a gathering point for operational employees. Over the past four decades, the event has grown to a level that regional towns can no longer accommodate its size, and in 2021 will be held in Brisbane, Queensland (and online) on June 23-25. Despite the growth of the event, its focus remains humble, providing a conference that discusses operational rather than academic topics for miners from all aspects of mill operation. This includes reviewing mining operations from the exploration and development stage, right up to the rehabilitation of mines at the end of their operating life. Newcrest Mining principal metallurgist David Seaman says the event is also about providing a consistent opportunity for networking with peers about conference content. “The Mill Operators Conference really brings the minerals processing community together,” Seaman tells Australian Mining. “The event is first and foremost a conference about mill operators and not academically or design focussed, it actively encourages operational speakers from the industry to make it relevant to those working in process plants and those supporting the industry, including suppliers and applied researchers.” This includes topics such as how plant operations are running within the modern mine, the flotation method within minerals processing and the management of tailings waste. “Majority of the papers are on plant improvements, which is a big drawcard for a lot of mill operators and suppliers coming to the event to pick up ideas on improving,” Seaman explains. Mineralis principal consulting engineer Katie Barns says the event is an opportunity for the mining industry to show its progression to internal and external stakeholders. “Typically, attendees discuss existing operations and how they are
KATIE BARNS, 2021 MILL OPERATORS CONFERENCE CO-CHAIR, PICTURED LEFT WITH 2018 AWARD RECIPIENTS.
operating, whether they have expanded or changed anything and where they have made improvements,” Barns says. “Mill Operators really shows that the industry is always progressing. People who don’t know a lot about the industry can think it’s quite a stagnant industry but really, it is one that is constantly developing. “For younger metallurgists or operators and those new to the industry, seeing the technology that’s out there, how plants progress and how operations are changing and growing gives them really good insight. “Geographically, mining is very spread out, so Mill Operators gives a good opportunity to get a snapshot of what is going on when you cannot physically go out there to see (it) for yourself.” A diverse range of keynote speakers will again headline this year’s event, including Ausenco chief technical officer Greg Lane, BHP Nickel West principal – business development James McQuie and Curtin University’s Teresa McGrath. The speakers will present on topics from their area of expertise over a range of commodities, which cover minerals processing and applied research. “If we look at the balance of our keynotes, it is very interesting,” Seaman says. “Lane is a longstanding comminution and minerals processing expert, who has designed and commissioned a lot of big and small mines within and outside Australia. AUSTRALIANMINING
“Our second keynote McQuie has been in the nickel industry for at least 25 years. You don’t hear from the nickel industry all that often within Mill Operators Conference so it will be fascinating to hear his take on the journey. “The final keynote McGrath comes from a research background, but very much applied research. She supports a lot of gold operations worldwide and is responsible for holding a large database of information and expertise across operations, helping them (to optimise) their plants.” Mill Operators also provides a platform for operators to review the latest technology and equipment. In the past, the conference has featured equipment launches from some of the
industry’s biggest original equipment manufacturers (OEMs). With the 2020 conference delayed due to COVID-19, AusIMM has reached 80 per cent capacity of attending suppliers that would show off their latest equipment and work, as of February 2021. “We get amazing support from industry suppliers at this conference, it gives us an opportunity to see what has been developed by suppliers, where their technology is going and we can question them and find out how it can help us in future,” Barns says. As with AusIMM’s other 2021 conferences, Mill Operators will be held in hybrid format, with the opportunity to attend in-person in Brisbane, or online from the comfort of any home or office in the world. Whether attending in-person or online, conference delegates will have the opportunity to tune into keynote speeches, attend networking events and view the latest equipment, technology and research papers. “Even after having to postpone, Mill Operators still has the support of exhibitors and sponsors, even some new ones which is fantastic,” Barns says. “It’s nice to see people know this conference has such a great reputation and that they want to be involved despite the challenges we might face ahead.” AM To find out more on AusIMM’s Mill Operators Conference 2021, visit: www. ausimm.com/mill-operators.
MILL OPERATORS CONFERENCE 2021 IS EXPECTED TO ATTRACT MORE THAN 600 ATTENDEES.
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WOMEN IN INDUSTRY AWARDS
AMBASSADOR SETS THE SCENE FOR 2021 AWARDS WOMEN IN INDUSTRY AMBASSADOR RACHAEL ASHFIELD DISCUSSES HER CAREER AT IFM AND THE IMPORTANCE OF THE WOMEN IN INDUSTRY AWARDS.
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elcome to my first column as ambassador for the Women in Industry Awards. I am currently the marketing manager at an advanced automation company, and my career has been
JODI MOFFITT, OF ROY HILL, WON THE EXCELLENCE IN MINING AWARD LAST YEAR.
challenging yet rewarding so far. I started out as the executive assistant to the managing director. My training and experience had provided me with a career in administration, but I felt I had more to be achieved. Then five years ago, I was appointed as marketing assistant. As I grew within the role, I was seeking newer and more exciting challenges, and as a result invested a lot of time learning many aspects of the company’s product offering. This proved to be quite complex and challenging, but extremely rewarding. I am now in my fourth year as marketing manager and firmly believe that the more you strive, the more you will be fulfilled within your career. In 2020 I was nominated by my peers for the Women in Industry Awards. This was a surprise to me, and I was honoured that my colleagues felt so highly about my efforts. The nomination itself was extraordinary, and then to reach the list of finalists and subsequently win the award was a personal and career defining highlight. The Women in Industry Awards recognise outstanding success in industries traditionally dominated by men, including manufacturing, mining, engineering, transport and logistics and waste management. My aim as ambassador is to
THIS YEAR’S AWARDS CEREMONY WILL TAKE PLACE ON AUGUST 19 IN MELBOURNE.
IFM MARKETING MANAGER RACHAEL ASHFIELD.
encourage you to nominate for these fantastic Awards, so that you receive recognition for your efforts in building a strong, well-defined and lasting business. Women bring alternative viewpoints and experiences to a business which often fosters creativity and change. Yet the career pathway for women can be quite challenging, especially in an industry that is not highly represented by women. The Women in Industry Awards give you an opportunity to highlight key aspects and career defining moments in your many years of success and dedication. The journey is extraordinarily rewarding, and when you have been
with a company as long as I have, you can dig deep into the knowledge base that you have built and realise you can contribute exponentially to your company, and industry more broadly. I look forward to celebrating all of your success at the 2021 Women in Industry Awards. AM Nominations for the 2021 Women in Industry Awards, to be held on Thursday August 19 in Melbourne, are now open. Visit www.womeninindustry.com.au to submit a nomination.
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EFD’s HydroFloat™ Separator radically improves the traditional sulfide processing circuit through Coarse Particle Flotation. Unlike conventional flotation, the HydroFloat Separator recovers particles as large as 800 microns with as little as1% mineral surface expression. By rejecting the balance as “coarse” tailings, much of the recirculating load is eliminated, thus greatly increasing mill capacity… with NO loss in mineral recovery! • Grind coarser at same recovery • Reduce coarse values lost to tailings Call 613 8401 7400 • Increase throughput E-mail efdau@eriez.com • Reduce primary grinding power consumption or visit EriezFlotation.com • Generate coarser tailings
See us at AUSTMINE 2021 26-27 May in Perth | Stand 227
Rejects only those particles that have no hydrophobic surface expression
AUSTRALIANMINING
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2021
AUSTRALIAN MINING PROSPECT AWARDS
N E P O W O N S N O I T A R E I G N M I N I E R MIN P M ’S HE O A I N USTRALS FOR TLS STRY A
D ERA DU R A IN N I W G A D M IN au . m o S c N A CES a r d s . O w R a t P c pr
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EVENT SPOTLIGHT
AUSTMINE 2021: HARNESSING INTELLIGENCE THE MINING SECTOR CAN START TO GET EXCITED ABOUT THE ARRIVAL OF AUSTMINE 2021, IN WHICH INDUSTRY PROFESSIONALS COME TOGETHER TO DISCUSS THE WAY FORWARD. industry support through sponsorship and attendance. “We are thrilled with industry response to the conference. As Australia’s reputation as a mining technology hub continues to grow, so too do the number of exhibitors and attendees,” Gibbs Stewart says. “Our principal sponsor is BHP, with whom Austmine shares a strategic partnership. Industry confidence from BHP and valued conference sponsors guarantees Austmine 2021 will advance the interests of the METS sector and fast-track technology adoption in mining.”
Agenda
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ustmine will host the largest gathering of mining and mining supply companies in Australia since COVID-19 began at its conference in Perth, Western Australia, next month. Austmine 2021: Harnessing Intelligence is a world-leading mining innovation conference sponsored by BHP. It will explore the importance of optimising the interaction between people, processes and technology across the mining value chain. More than 50 mining innovation and technology experts will highlight the latest developments in the mining and mining equipment, technology and services (METS) sectors across two days on May 25-27. Austmine chief executive Christine Gibbs Stewart says there has never been a more important time to gather as an industry to discuss the way forward, with the Australian METS and mining sectors leading the creation and adoption of new technologies. “We have a unique opportunity to continue to lead in this area, particularly as other mining nations
AUSTMINE 2021 WILL BRING THE INDUSTRY TOGETHER FOLLOWING THE INTERRUPTIONS OF COVID-19 LAST YEAR.
look to Australia for guidance in a new COVID world,” Gibbs Stewart says. “After a prolonged period of online operations and decreased opportunities to network, this is the first major opportunity for the industry to come together since the pandemic occurred. “Austmine 2021 will serve as the goto event to hear what’s next in mining innovation from high-calibre speakers and will provide an opportunity to connect with like-minded individuals to drive further value for the METS sector, and the mining industry more broadly.” Gibbs Stewart says the conference theme, Harnessing Intelligence, will progress the innovation conversation. “We can go to new, unexplored heights as an industry by harnessing our collective intelligence,” she says. “This is not just about leveraging data and information; it is optimising interactions between humans and machines. “As intelligent systems and new technologies develop at a rapid pace, ensuring that the right people and processes are engaging with it will drive value into the future.” The conference is receiving strong AUSTRALIANMINING
Over the two thought-provoking days, technology experts and mining decision makers will explore the importance of optimising the interaction between people, processes and technology across the mining value chain. The conference will facilitate networking and collaboration, delivering quick-fire tech-talk sessions, ensuring the latest innovations are showcased to key decision makers. The sessions will discuss the topics of harnessing intelligence, intelligently optimising operations, water and tailings, creating a zero-impact future, the power of data, energy sources, technology advancements underground and optimising connectivity.
Speakers
The high-calibre speaker line-up features local and international mining and METS experts including keynote speaker, BHP asset president at Western Australia Iron Ore (WAIO), Brandon Craig. He successfully led BHP’s iron ore assets through the COVID-19 impacts of 2020 and into 2021, with the business achieving record half-year production. The Austmine 2021 speakers are listed in the box on the right.
Events and exhibits
The Industry Leaders’ dinner and awards provides an opportunity for the community to reconnect
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and strengthen relationships. The prestigious awards recognise and celebrate the most innovative and successful METS and miners of the year. Austmine’s Ideas Exchange program will also return to this year’s conference after great success with its initial debut in 2019. Ideas Exchange provides the opportunity for miners and METS to work with Austmine Innovation Partners to tackle some of the key industry challenges. AM For more information, or to register for Austmine 2021, visit www.austmineconference.com.au. THE AUSTMINE 2021 SPEAKERS ARE: • Johann Reps, Alcoa • Anthony Murfett, Australia Space Agency • Brandon Craig, BHP • Steven Coughlan, Byrnecut Group • Michelle Ash, Dassault Systemes • Elizabeth Lewis-Gray, Gekko Systems • David Gray, First Quantum Minerals • Robert Grant, Fortescue Metals Group • Amanda Lacaze, Lynas Corporation • Eduardo Coloma, Maptek • Adrian Beer, METS Ignited • Courtney Christensen, Newcrest Mining • Suresh Vadnagra, Newcrest Mining • Alex Bates, Newmont Australia • Rob Humphryson, Novo Resources Corp • Andrew Cole, OZ Minerals • Penny Stewart, PETRA Data Science • Andrew Rouse, PYBAR Mining Services • Matthew Holcz, Rio Tinto • Javier A. Orellana, Rockwell Automation • Barry Fitzgerald, Roy Hill Holdings • David Moult, Yancoal.
PRODUCTS
THYSSENKRUPP JAW GYRATORY CRUSHERS UP FOR THE CRUNCH thyssenkrupp’s jaw gyratory crushers have been designed to accept large oversize feed to limit the primary crushing downtime and use of rockbreakers. This keeps a fleet of mobile equipment moving. The state-of-the-art design also enables high throughput rates and high crushing ratios at low operating and maintenance costs. The new series of machines adds additional benefits for servicing time and safe working. The machine also features a robust design and high-power drive motors with heavy duty ratings. Other key characteristics of the design include optimised crushing chambers for direct feed and hydraulic main shaft adjustment for wear compensation and overload protection. This is backed by thyssenkrupp’s one-stop-shop service for asset management, spare parts, servicing and revamps. thyssenkrupp’s jaw gyratory crushers offers significant benefits for ore processing operations.
M2P ENGINEERING OVERHEAD PROTECTION SYSTEM M2P Engineering’s overhead protection system (OPS) is designed as a modular system to be deployed within an ore pass at underground base metals mines. The inflatable OPS is Australian made and provides a safe, efficient and cost-effective overhead protection solution that can be installed and commissioned in less than an hour. The modular design allows individual modules to be disconnected from the overall system while maintenance teams proceed higher up the ore pass, meaning the OPS is offering fall prevention to the ore pass lining at all stages. M2P Engineering is a leader in manufacturing inflatable safety products within the mining industry. It works on solutions to not only offer improved safety but also efficiency.
• m2pengineering.com.au
• thyssenkrupp-australia.com
EMERSON NEXT-GEN RUGGEDISED COMPUTING
KOMATSU ULTRA-CLASS TRUCK TOUCHES DOWN
Control Logic is now offering Emerson’s new range of industrial PCs (IPCs), the RXi2-BP. The powerful, expandable and reliable industrial computers offer new processor choices, increased and faster storage, improved graphics and enhanced security features. Emerson uses the latest AMD Ryzen family processors and supports up to 16 gigabytes of ECC RAM, four to six Gigabit Ethernet interfaces, and industrial grade high-speed solid-state drive (SSD) storage to complete the high-performance design. These features make the RXi2BP IPC the perfect platform for running industrial applications in any environment. The RXi2-BP IPC delivers compact, rugged, mid- to high-range performance computing capabilities to run Human-Machine Interface (HMI), historian, and analytics applications right at the machine to enable improved real-time control of operations and better integration into plant-wide systems.
The Komatsu 930E-5 ultra-class dump truck has been released in Australia. It is capable of hauling up to 304 tonnes and uses a 2014-kilowatt engine. Komatsu’s engine platform and drive system management technology also give the 930E-5 an advantage in emissions over previous models, while the new generation cabin is designed to deliver both comfort and safety. The 930E-5 reduces the volume of fine particles in the air by 80 per cent to achieve its high level of fuel efficiency using a high-pressure fuel injection system, which aids the haulage process. Komatsu’s KOMTRAX Plus 2 remote monitoring system is included as standard with the 930E-5 and is bolstered by the company’s national service and support network.
• komatsu.com.au
• controllogic.com.au
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PRODUCTS
GAME-CHANGING LOAD VOLUME SCANNING
A DRILL DESIGNED FOR DRILLERS
The Loadscan load volume scanners (LVS) accurately measure loads and generate 3D scan images that clearly indicate underloading, enabling corrective action (including operator training and coaching) to be taken. It uses scanning technology that is combined with Loadscan’s proprietary software to measure precise material volumes in a truck or trailer. The scans indicate if there is carryback in the bins, enabling it to be deducted from shift tallies. This improves load reporting accuracy and allows carryback to be scraped out. Loadscan has also developed a payload calculator to determine value lost due to underloading. Loadscan invented and patented the original LVS more than 20 years ago and has continued to be a market leader in dependable load information.
RTDrill has unveiled its latest down-the-hole hammer drill rig, the RTD32, which is now available across Australia through Cram. The latest in the range of RTDrill’s surface crawler drill rigs is suitable for drilling diameters of 105-203 millimetres and a net drilling depth of 40 metres. It features a 403 kilowatt engine options in the Tier III and Tier IV models, along with a 1000 cubic feet per minute (CFM) compressor. The drill features a tilting and slewing system mechanism that allows operators to drill in all directions, even horizontally if necessary. The crawler can move at speeds up to 1.9-2.62 kilometres per hour and has up to 60 per cent gradeability. At a compact 12.55-metre length and 2.5-metre width, the RTD32 provides cost-effective operation, transport and maintenance.
• l oadscan.com
• lets-roll.com.au
SANDVIK UNVEILS TORO LH410 LOADER
CAT ROLLS OUT 7495 ERS
Sandvik’s Toro LH410 loader features a superior lift height and revamped technologies for underground mining applications. The Toro LH410 is based on the Sandvik LH410 loader, but with significant aspects overhauled to cement its best-in-class productivity performance. This is achieved in the Toro LH410 ramp speeds, fast bucket filling and superior lift height for easier truck loading. Sandvik has also included its intelligent control system, which features a seven-inch touch screen display that is used as a user interface. Sandvik offers multiple diesel engines to power the Toro LH410, including a fuel-efficient Tier II diesel engine and the flagship stage V engine. The stage V engine uses passive diesel particulate filter (DPF) regeneration that activates during normal operation, which minimises downtime, while the machine’s modulating engine brake allows for improved braking and vehicle control downhill.
The new Cat 7495 electric rope shovels (ERS) combines multiple upgrades to improve operating efficiency by 10 per cent. With 100plus years’ experience in rope shovel design, Caterpillar has included enhancements including an increased frame durability and improved serviceability in the new ERS. It can reduce cost per tonne of material moved by as much as 15 per cent and also features HydraCrowd, a fully adaptive control system. HydraCrowd features a tybe-enclosed hydraulic system to reduce stress on the front end of the shovel components, replacing conventional maintenance heavy cable arrangements. The life of the lift propel gear has been nearly doubled with the propel gear case for the 7495, which allows it to run in extreme operating conditions.
• rocktechnology.sandvik
AUSTRALIANMINING
• cat.com
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EVENTS
CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@AUSTRALIANMINING.COM.AU West Coast Fever pre-season games | Kalgoorlie-Boulder | April 7-11 Principal partner Gold Industry Group, the City of Kalgoorlie-Boulder and the Western Australian Government are supporting the West Coast Fever preseason games in Kalgoorlie-Boulder. Fever will play opposite the Sunshine Coast Lightning in two matches on April 10-11 at the Goldfields Oasis Recreation Centre. The community will have the opportunity to interact with the Fever players on their tour of the Goldfields as they host a free open training session, community clinics and visit a number of mine sites. The tour comes following last year’s success as the club took elite netball to the region for the first time. The Gold Industry Group is a proud supporter of netball across Western Australia, with support from Gold Fields, Northern Star Resources, St Barbara, Newmont, AngloGold Ashanti, Ramelius Resources and the Perth Mint. • goldindustrygroup.com.au 2nd Digital Mines 2021 | Online | April 20-22 The 2nd Digital Mines 2021: Building Fully Autonomous Mines from Pit to Port recognises the force of digitalisation in changing the nature of companies and their interaction with employees, communities, government and the environment at every step of their value chain. This year’s conference will deep-dive into the latest advances on intelligent mining and how world-leading mining companies are implementing theirs.
They include Resolute Mining’s Syama gold mine in Mali, Boliden’s fully autonomous underground mine and Vale and BHP’s next-generation autonomous mining. The conference will feature speakers from BHP, Roy Hill, Fortescue Metals Group, Rio Tinto, Alcoa, Minerals Research Institute of Western Australia, ABB Australia and Codelco. Delegates will also catch an exciting glimpse of the new frontier of mining in space. • claridenglobal.com Life of Mine Conference | Brisbane and online | April 28-30 AusIMM and the University of Queensland will join forces to host the fifth Life of Mine Conference in 2021 following four years of successful events. Being held in Brisbane and online, this hybrid event will allow delegates to safely attend the event in-person or online should travel restrictions still be in place. The Life of Mine Conference will explore the full life-cycle of a mine, from the exploration to rehabilitation phase, as well as address current and future challenges impacting the mining value chain. A key aim of the conference is to promote leading examples of applying approaches that enhance outcomes, increase efficiencies and improve effectiveness in addressing challenges in the present and years to come, including cost and production pressures, technical factors and societal and community expectations. Conference themes include integrated mine planning; sustainability outcomes; incorporating societal and
AUSTRALIANMINING
community dimensions into design, operation and rehabilitation; strategies for improving closure outcomes; influence of global trends on the future of the industry; approaches to produce viable post-mining economies and more. • lifeofmine.ausimm.com Austmine 2021: Harnessing Intelligence | Perth | May 25-27 Austmine’s world-renowned mining innovation conference will return in 2021, creating a key gathering point for industry leaders, change-makers and innovative thinkers. The 2021 theme of harnessing intelligence will provide the opportunity to reflect, discuss and consider the future of the mining industry following a period of significant disruption due to the COVID-19 pandemic. Austmine 2021 will explore the importance of interaction between people, processes and technology over three days of keynote speeches, interactive sessions and panel discussions. The event has also welcomed BHP onboard as its principal sponsor for 2021, highlighting the major miner’s continued commitment to technological excellence in the Australian mining equipment, technology and services (METS) sector. • austmineconference.com.au Mill Operators Conference | Brisbane | June 23-25 AusIMM is running the Mill Operators Conference for the 15th time, offering it in a hybrid format this year. This conference will focus on best practice in all areas of plant operations
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practice and management, tailings and water management and geometallurgy. AusIMM chief technical officer Greg Lane, BHP Nickel West principal – business development James McQuie and Curtin University senior research fellow Teresa McGrath are among the keynote speakers who will be presenting at the event. Mill Operators will welcome more than 600 industry professionals to hear from leading experts, participate in robust discussions, view the latest mining innovations and meet with their industry peers at networking events over the three days. • milloperators.ausimm.com BULK 2021: Australian Bulk Handling Expo | Melbourne | September 8-10 The Australian Bulk Handling Expo, conference and awards will bring the bulk handling industry together into a standalone exhibition in 2021. It will share the same location as MEGATRANS, which integrates intrinsically with the logistics and multimodal freight sector. BULK2021 is supported by the Australian Society for Bulk Solids Handling (ASBSH), which will host an industry conference, while the trade expo will showcase the latest in bulk materials handling equipment and technologies. Exhibitors include Vega, SEWEurodrive, Mideco, Bonfiglioli, Minprovise and ESS Engineering. BULK2021 will take place at the Melbourne Convention and Exhibition Centre over three days. BULK2020 ticketholders will be able to use their tickets to join the rescheduled expo. • bulkhandlingexpo.com.au
Automation system PSS 4000 – “Building block system"
u A multi-master communication concept u Scalable, decentralised hardware structures u An easy-to-use, multi language configurator u Joint programming for safety and automation in a single tool
Melbourne • Sydney • Brisbane • Auckland
Ph: 1300 723 334
Ph: 03 9560 0621 Fax: 03 9574 9035 www.pilz.com.au safety@pilz.com.au
FOR OPTIMAL MINE WATER MANAGEMENT — UNDERGROUND TO SURFACE — Rely on our rugged Godwin range to get the job done. The role of quarrying and mining in our economy has never been more important. So, ensure your operation is getting the most out of your investment by choosing a top performer for your dewatering needs. With more than 100 years as the industry leader in pump manufacturing, Godwin, a Xylem brand, designs, manufactures, services, sells and rents diesel pumping products that are efficient, reliable and targeted to your specific requirements.
Xylem’s rental fleet, world-class application expertise, and proven 24/7 service and support are ready to meet your planned and emergency pumping needs. We maintain a large rental fleet comprising electric submersible pumps, portable diesel driven pumps and accompanying accessories Australia wide. And our parts inventory is one of the largest in the industry, allowing us to deploy all necessary equipment for rental, sales and service without delay — no matter where you are.
Get Godwin dewatering solutions working for you.
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