Australian Mining - September 2016 by Prime Group

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EARTHMOVING EQUIPMENT UNDERGROUND MINING VOLUME 108/8 | SEPTEMBER 2016

ULTRA CLASS TRUCKS

THE LATEST MINING MACHINERY

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COMMENT

INNOVATION’S ISSUES IN IMPLEMENTATION

MINERS NEED TO DO MORE THAN TALK ABOUT INNOVATION, IT’S TIME TO ACT. companies are behind where they believe they need to be. According to the report, many Australian operators are in the early stages of innovation, implementing what Deloitte termed ‘Core’ level innovation, they are still far from implementing truly transformational innovations. No one wants to take that leap, or are willing to be industry leaders just yet. “We want to be first to be second,” one major said. Some even see no need to make serious change, with one major miner reported as stating, “[Our] focus is not really on innovation but on reducing costs; cost reductions have brought minor innovations but no big revelations.” The attitude from some is essentially, ‘why bother try to innovate, as our lack of effort to date has not yielded anything innovative’. It’s little wonder we are behind where we should, or need, to be. It’s time for the industry to do more than just talk.

ast issue I went on a bit of a rant on how miners need to be innovative, and employ COLE LATIMER innovation in their everyday cole.latimer@primecreative.com.au business or be left behind. It is no surprise to anyone in the industry that innovation – be it technology, processes, methodology, or the way in which they collaborate – is what will separate successful miners from the rest of the pack in the future. While it’s all well and good to talk about how necessary it will be for the future of the industry, these are empty words unless the sector takes stock and begins to actually implement new ways of doing things. I’ve spent the past week pulling apart Deloitte’s recent mining innovation report covering innovation in Australia, Canada, and Africa’s respective resources industries, and honestly, I was mildly surprised. The industry often talks about the leaps forward it is making in terms of automation and productivity, but when it comes to new ways of thinking, many of the major miners – in their own words – are lagging well behind where they believe they should be at this point in the industry’s trajectory. Although Australia is well ahead of Canada and Africa in terms of practical innovation and innovative thinking, even miners, juniors, explorers, and service

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AUSTRALIANMINING

SEPTEMBER 2016

FRONT COVER

In this edition of Australian Mining, we focus heavily on the latest equipment slated to hit both open cut and underground mines, ranging from new ultra class trucks, to graders, massive excavators, and new underground haul trucks. We also get a glimpse at ground breaking machinery, such as Caterpillar’s first ever hard rock longwall shearer. We break down Deloitte’s recent innovation in mining report, uncovering how and why the industry innovates, and what will be the drivers for the next stage of the sector’s transformation. Safety is also under the spotlight, as we showcase the recent QLD Mining Health & Safety conference and preview the upcoming Safety in Action show held later this month.

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CONTENTS

PILBARA SPOTLIGHT THE CONTRACTOR CONUNDRUM Rio Tinto is changing the face of its Pilbara workforce

PERSONNEL

12-13

32-35

MINESITE VEHICLES

TRUCKS & TRANSPORT

THE AGE OF ULTRA CLASS TRUCKS The latest in heavy haul trucks

WAGES AND EMPLOYMENT IN A FLUCTUATING MARKET Breaking down the latest Hays Salary Survey

A NEW LEVEL OF UNDERGROUND HAULAGE A sneak peek at Atlas Copco’s new underground trucky

SAFETY

SAFETY & INNOVATION SHINE IN QLD The latest from the QLD Safety Show

STAYING SAFE IN THE WORKPLACE A preview of Safety in Action 2016

POWER GENERATION & DISTRIBUTION COMPACT IP GENERATORS Making power mobile

18-20 MINESITE CONSTRUCTION A NEW FACE FOR MINING CONSTRUCTION How new technologies will revolutionise the industry

INNOVATION

22 40-41

AUTOMATION & REMOTE CONTROL THE PROTECTED MINING PLANT How to reduce operational integrity risk with automation

24-27

EMBRACE INNOVATION OR DIE Mining is at an evolutionary crossroads

LITHIUM

42-45

EARTHMOVING EQUIPMENT

IS A LITHIUM PRODUCTION BOOM AHEAD? Will there be a gold rush in lithium?

RAISING THE GRADER New motor graders

NEW MINING SHOVEL Next gen shovels and excavators

DIGGERS & DEALERS

A HARD ROCK FIRST Cat develops hard rock ‘longwall shearer’ NEW EXCAVATORS Hitachi launches new excavator series

RISING GOLD, RISING MOODS AT DIGGERS Is a resources recovery underway?

31 46-47

REGULARS

INDUSTRIAL COMMENT 8

NEWS 10

PRODUCT SHOWCASE 48-51 AUSTRALIANMINING

SEPTEMBER 2016

PROSPECT AWARDS 52

EVENTS 54

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INDUSTRIAL COMMENT

ESTIMATING THE ‘COST’ OF FUEL TAX CREDITS IS A TRICKY BUSINESS IN CALLING FOR AN END TO FOSSIL FUEL SUBSIDIES, CRITICS OF AUSTRALIA’S FUEL TAX CREDITS SYSTEM HAVE HIGHLIGHTED ITS COST TO AUSTRALIAN TAXPAYERS AND THE BUDGET BOTTOM LINE, BUT WHAT ARE THE ACTUAL COSTS? UNIVERSITY OF MELBOURNE PROFESSOR DEPARTMENT OF ECONOMICS, JOHN FREEBAIRN, WRITES.

n calling for an end to fossil fuel subsidies, critics of Australia’s fuel tax credits system have highlighted its cost to Australian taxpayers and the budget bottom line. The Greens have said that ending fossil fuel subsidies to big mining companies would save Australian taxpayers A$21 billion over the forward estimates (the next four years). On the ABC’s Q&A program, Greens deputy leader Larissa Waters said her party advocated: “getting rid of the A$24 billion over the forward estimates – that’s four years – in free money that goes to the fossil fuel sector in things like cheap diesel and accelerated depreciation. These numbers are drawn from policy costings produced by the Parliamentary Budget Office (PBO) ahead of the July federal election. The PBO’s 2016 post-election report, which details the budget impacts of various election commitments, notes that “the most significant Greens’ commitment that contributes to the increase in the budget balances is the

commitment ‘An end to Fossil Fuel Subsidies’. This commitment is expected to increase the underlying cash balance by $23.1 billion and the fiscal balance by $24 billion over the 2016-17 Budget forward estimates period.” The Greens propose abolishing fuel tax credits for all industries except agricultural businesses, ending accelerated asset depreciation for aircraft, the oil and gas industry and vehicles (except for those used for agricultural purposes), and a range of other measures. Opinions differ on whether fuel tax credits constitute a “subsidy” or not. Most fuel users have to pay a fuel excise of 39.5 cents per litre. But businesses can claim exemption from this obligation in certain circumstances. This exemption takes the form of a credit for the fuel tax (excise or customs duty) that’s included in the price of fuel. These tax breaks include fuel excise exemptions for off-road use of fuel by the mining industry and primary producers. There’s also a partial rebate for large trucks (over 4.5 tonnes), the

AUSTRALIANMINING

owners of which pay a road usage charge rather than the excise. The PBO has estimated that the Australian Greens’ proposal of abolishing the fuel tax credit for all industries except agricultural businesses would increase the budget balance by about A$4.5 billion a year.

Unpacking the assumptions

However, it’s worth detailing the assumptions that u nderpin these calculations. First, the PBO says its costing assumes that business fuel usage does not change as a result of the policy. As the goal of a higher tax is to reduce fuel use and pollution, the PBO’s reported estimate will therefore be an overestimate of the revenue gain. Also, uncertainty about the future means that all such revenue estimates are far from guaranteed. The PBO notes that “removing eligibility for claiming business fuel expenses has the potential to have a negative impact on the economy as it could increase costs across the production chain. However,

SEPTEMBER 2016

consistent with ‘Charter of Budget Honesty Guidelines’, broader macroeconomic implications have not been included in this costing.” Many consider the 39.5 cents a litre fuel excise a crude form of user-pays fee to cover the cost of government expenditures on public roads. The revenue raised by fuel excise of $17.8 billion and state taxes on motor vehicles of $9.5 billion for 2014-15 more than cover federal, state and local government spending on road construction, maintenance and other related costs. This is the logical argument put forward by representatives of the mining industry for exemption from the fuel excise. They note that the mining industry builds and maintains its own roads. A similar argument applies for fuel used by primary industry for off-road purposes. Others argue that fuel taxes help encourage people to use less of it, and thereby reduce pollution. However, a 39.5 cents per litre tax represents a very large tax per tonne of CO2 equivalent. If the fuel excise was regarded just as a tax on greenhouse gas emissions, the 39.5 cents per litre represents a tax of more than $150 per tonne of greenhouse gas from the combustion of fuel – several times higher than the Gillard government’s $24 per tonne carbon price, and the even lower European Union pollution permit price. It is stretching credibility to say the fuel excise is just a tax on pollution. I’d argue in favour of the position taken in the 2010 Henry tax review, which recommended a roughly revenue-neutral reform package, replacing the current fuel excise and state motor vehicle taxes with a road user charge, a congestion tax and a pollution tax. With this reform, the mining and agricultural industries would be exempt from the tax components on fuel for road funding and for congestion, but would pay a component for the external costs associated with greenhouse gas emissions. AM This article was originally published on The Conversation.

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NEWS

THE LATEST MINING NEWS AND SAFETY AUSTRALIAN MINING PRESENTS THE LATEST NEWS AND SAFETY AFFECTING YOU FROM THE BOARDROOM TO THE MINE AND EVERYWHERE IN BETWEEN. VISIT WWW.MININGAUSTRALIA.COM.AU TO KEEP UP TO DATE WITH WHAT IS HAPPENING. CIMIC WIN COAL CONTRACT EXTENSIONS CIMIC’s Thiess and Sedgman subsidiaries have won $105 million worth of Queensland coal contract extensions. Sedgman has won a three year extension to continue operations at the Red Mountain Joint Venture mine’s coal handling and preparation plant in the Bowen Basin. Valued at $75 million, the contract continues Sedgman’s operation and maintenance of the CHPP until June 2019, with the potential for another two years on top of this. Thiess has also won a contract

expansion for its mining services at the Jellinbah Group’s Lake Vermont coal mine, which will see it design and build an additional processing module at the site’s CHPP. Generating around $30 million in revenue for Thiess, the contract will see Sedgman provide engineering, procurement, construction, and commissioning of the module – which is expected to be completed in late 2017 – while Thiess will continue to operate and maintain the facility for the remainder of the contract term. CIMIC executive chairman Marcelino

Fernandez Verdes said the Lake Vermont win is a great demonstration of the combination of Thiess and Sedgman’s expertise. “The Lake Vermont expansion demonstrates the value of the CIMIC Group’s capability, drawing together the best of Thiess and Sedgman’s expertise,” Verdes said. Sedgman has worked for the RMJV since 2007. A Thiess Sedgman joint venture delivered a CHPP for the Jellinbah Group in 2007, and expaended the facility in 2012. Thiess has operated the Lake Vermont mine since 2008.

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

FOUR KG GOLD NUGGET DISCOVERED IN VICTORIA

CAT EXPANDS UNDERGROUND MINING TRUCKS

An Australian prospector has discovered a massive 145-ounce gold nugget worth more than $250,000. Dubbed ‘Friday’s Joy’, the nugget was found with a Minelab metal detector in an already work-over area at the southern edge of central Victoria’s Golden Triangle, an area well known for yielding gold, finding the top of the nugget only around 30cm below the ground. The prospector who found the nugget wanted to stay anonymous. “I thought it was rubbish at first, maybe an old horseshoe,” the man said,“I was in total disbelief as I didn’t think nuggets of this size were still around.” An avid prospector – having prospected for more than ten years – the man had an agreement with his other gold prospecting enthusiast friends to split the proceeds on any large gold item found when they went prospecting together. Upon the find, he was unsure of what to do at first. “It’s like catching a big fish and not knowing what to do with it,” he said. “I washed it in water, covered it in aluminium foil and kept it in my oven on the first night.” The man did not intend to quit his job and retire, instead aiming to buy a van and travel around Australia, sightseeing and prospecting. The nugget is currently in a bank vault, with a replica in construction. Plans for an auction are also underway. Minelab’s regional sales and marketing director Fraser Kendall said the company was thrilled a customer made such a discovery. “He was prospecting in an area that others had clearly worked over and this just goes to show that there’s plenty of gold still coming out of Victoria,” he said. Kendall added that the nugget was on par with the 159.3 ounce ‘Cindy’s Pride’, and surpassed prospector Mick Brown’s 87-ounce ‘Fair Dinkum’ gold nugget found last year near the Wedderburn, around 200km north of Melbourne; it was later auctioned for $175,000.

Caterpillar Underground Machinery has acquired the IP for Ground Force Worldwide’s underground articulated truck designs. The agreement provides Cat with additional designs in the 20 tonne and smaller payload class. “The Ground Force AT18E (18 tonnes payload ejector) and AT20 (20 tonnes payload) remain available for immediate order via Ground Force Worldwide. The company will showcase the AT18E at MINExpo 2016,” according to Cat. It comes as Cat announces it will discontinue manufacture of its room and pillar equipment, and track drills.

AUSTRALIANMINING

SEPTEMBER 2016

According to the company, it is part of a move to pursue ‘s”trategic alternatives, including a possible divesture, for its room and pillar products”. “These moves, which align with Caterpillar’s ongoing restructuring, will allow us to focus resources on those areas of the business that provide the highest, sustainable growth and best long-term returns,” Cat group president for Resources Industries, Denise Johnson, said. The underground mining products under strategic review include continuous miners, feeder breakers, coal haulage systems, highwall miners, roof bolters, utility vehicles, and diesel vehicles. Production of tracked drills will also be discontinued. However, it has increased its focus on the hard rock space, unveiling an underground hard rock longwall miner. Last year Cat also acquired the designs for Specialised Vehicle Solutions’ underground trucks, which has been transformed into the new Cat AD22, which is currently underground field trials.

PILBARA SPOTLIGHT

www.flexco.com

PILBARA SPOTLIGHT

RIO TINTO CONTRACTOR CONUNDRUM: THE NEW NORMAL IN THE PILBARA? RIO TINTO IRON ORE’S DECISION TO USE CONTRACTORS FOR ALL EXTERNAL HIRES FROM NOW ON WILL HAVE IMPACTS FELT WELL BEYOND THE PIT. COLE LATIMER WRITES

n late July Rio Tinto announced plans to change the way it worked. Along with a complete change in its organisational structure; bringing in new department heads, such as iron ore head Andrew Harding making way for Chris Salisbury; combining some divisions and splitting out others; the miner also implemented a new recruitment protocol for its iron ore operations. Rio Tinto has announced it will now only hire contract labour for its iron ore operations. “Iron ore is implementing a new recruitment process that takes account of continuing market volatility,” Rio Tinto said in internal documents. “The aim is to ensure we closely manage headcount, maintain flexibility and promote internal talent where possible.” It is understood, as part of this new protocol, all external hires will be filled by Category 1 contractors through the contract service providers Workpac, Skilled, and DT Workforce. This decision will run across

all roles, the miner stating it “will be looking to use contractors for engineering and other professional roles”, with the exception of manager, superintendent, and frontline supervisory roles. However, the miner will make exceptions relating to indigenous employment, trainees, graduates and apprentices. It went on to state, “The process takes account of speciality roles that require a lot of experience and skills to ensure we do not put any component of the business at risk.” “The new recruitment process also requires leaders to place a priority on internal talent development by offering acting or secondment arrangements for principal, senior, specialist, advisory, and technical roles.” A Rio Tinto spokesperson confirmed changes were made by the miner around its iron ore hiring protocols. Unions immediately slammed the decision. “The message that is preached by Rio is one of local jobs and supporting the communities that they operate out

of,” a union spokesperson said, “The reality is we don’t see this in practice. Contracting roles are an insecure form of employment and come with lesser wages and conditions than full time roles. This decision does nothing to support local Pilbara communities who are already struggling.” “The same communities who are providing Rio with record tonnage and profits.”

The impact on the ground

An unnamed worker based in Tom Price called the decision a poor one, both for the workers and the town. “This decision by Rio Tinto to turn to contractors is worrying,” he told Australian Mining. “People are scared, there is no security at all.” Rio Tinto emphasised that current roles will not be affected by the decision, stating “all existing employees will retain their roles within the business” and that no Rio Tinto employees would be made redundant to make way for contractors. This isn’t the first time Rio Tinto has had this accusation thrown at it.

LOCALS ARE CONCERNED THE INCREASED NUMBER OF CONTRACTORS WILL LEAD TO A RISE IN FIFO WORKFORCE

AUSTRALIANMINING

SEPTEMBER 2016

Last year CFMEU Mining and Energy general secretary Andrew Vickers directly addressed the miner at its AGM, stating that the growing proportion of casual labour hire roles in coal mines was affecting job security, which in turn discouraged workers from speaking up about safety concerns. “A growing proportion of jobs in coal mines are now filled by labour hire contractors rather than permanent positions – well over a third of jobs in many mines,” Vickers said at the time. “This is a bad outcome for workers, who have little job security and don’t enjoy the same pay and conditions as permanent employees, but it’s also a disaster for mine safety. “Contract workers know they could lose their job in an instant if they raise a concern about safety that might impact production and this fear is leading directly to accidents.” CFMEU members attending the AGM raised statistics from Hunter Valley mines which showed that contract workers, who at the time represented 35 to 40 per cent of the workforce, accounted for 66 per cent

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of Lost Time Injuries (LTI) over the previous 12 months, approximately double the LTI rate of permanent staff. “Mining companies like Rio Tinto might like the control they have over a casualised workforce – but it’s a dangerous trend,” Vickers said. “We urge Rio Tinto to prioritise permanent, secure jobs in all its operations.” The Pilbara worker also raised concerns over safety, stating a contractor workforce is less likely to raise issues of safety for fears it could cost them their jobs. “The contractors may keep quiet over potential safety issues, because as a contractor you will say nothing, you won’t speak up [if it may risk your job]. “Everything is about the dollar, and it’s the people on the ground, the ones on the bottom, that get hit the most.”

Contractor concerns

Contractors and labour hire supply companies were mixed in their response to Rio Tinto’s decision, speaking to Australian Mining from the sidelines of Diggers and Dealers, they stated that they understood the economic reasoning behind, but by narrowing their worker resource pool to only three providers they are missing out on wider skills sets. Barminco CEO Peter Stokes explained more operators are turning to contract workforces as they are able to quickly ramp up, or down, as the operation needs, and can bring new eyes to a site. “Contractors often have their own fleet and are able to scale

quite quickly,” Stokes told Australian Mining. “Mining companies are also looking at the hunger of contractors to drive their business, and as they often have experience from a number of different sites they can not only bring new eyes to a business, but they also bring what they’ve learned – best practices – from other sites,” he said. “They see it’s not an us and them, but about working with contractors to bring a new level of productivity.” Ausdrill COO Andrew Broad agreed with Stokes, telling Australian Mining “we’re seeing no fundamental shift in how contractors are being used”. “In times of uncertainty such as this, people often leave the industry for more stable work outside of mining, so contractors are brought in to fill these gaps,” Broad said. He went on to say contractors are also evolving in their offering to work more collaboratively with miners. “There needs to be flexibility in contractor offerings [if the contractors are to stand out],” he said. “For instance we are working with junior miners, and instead of the traditional pay structure we have been drilling for equity in the eventual project…it’s about being innovative.” Hays state regional director Chris Kent also said Rio Tinto’s decision to focus more on contract workforces isn’t remarkably different from what is happening across the rest of the industry. However, “It is unrealistic Rio think that just three agencies can supply everyone they need, especially when it

comes to specialised roles,” Kent told Australian Mining. “Also, they are limiting their candidate pool to those willing to work on a casual basis through agencies in this current economic climate. “This will work for unskilled and semi-skilled workers, but when it comes to those with a skilled trade a degree of flexibility will be needed.” Another mining labour hire firm also questioned the decision, stating that by using just Workpac, DT, and Skilled as preferred contractors Rio Tinto limited itself in its potential pool of workers. “There’s also the fact that by using contractor labour hire, they’ve got a workforce that is willing to move the moment they get a better contract means they’ll constantly have to fill that gap,” they told Australian Mining.

The price on Tom Price

Rio Tinto’s push for a casualised workforce seems as though history is repeating itself, but it is not just the workers who are affected by this decision. There is also expected to be a major impact upon the town, one from which it may take years to recover. “No one here sees it as a good thing at all, it will devastate the Pilbara. It may take about 12 months for the impact of this decision to be felt, but it will take years for the towns [of Tom Price and Paraburdoo] to recover,” the local worker told Australian Mining. There is also fears that these contractors – due to the insecurity of their own long term jobs at the site – will decline to move to these regional

towns, “It will have a snowball effect, as contractors won’t want to move their family to the town if they can’t be assured of a future at the mines,” the worker said. However, Rio Tinto has stated it remains committed to the region. “We remain committed to a full and vibrant town in Tom Price,” Rio Tinto said in an official response to its change in recruitment protocol. “While we do not have all the answers today [on whether the miner will implement a FIFO contractor workforce for Tom Price], the strategy we use to bring the Category 1 contractors into the business will include a focus on the residential community and keeping our Tom price team members based locally in the Pilbara.” Is Rio Tinto’s movement merely the first in the industry, with other majors likely to follow suit? While it will allow the miner to navigate this period of ongoing economic depression and commodity volatility the impacts upon the full time workforce, and more importantly regional towns, are yet to be known. The fact remains that it does indicate the industry is hiring again, but the days of ‘the company man’ are likely numbered, as mining falls in line with the global casualising of workforces. The labour hire decision’s impacts will be felt far beyond the company’s grounds, and it must take care as it navigates new, unknown waters in the Pilbara. AM

THE DECISION GOES BEYOND THE PITS, ONTO LOGISTICS AND THE PORTS

AUSTRALIANMINING

SEPTEMBER 2016

PILBARA SPOTLIGHT

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MINESITE VEHICLES

THE AGE OF ULTRA TRUCKS KOMATSU’S NEW ULTRA CLASS TRUCKS ARE READY TO HIT AUSTRALIA’S MINES.

omatsu Australia has released the 980E4 electric drive haul truck. With a payload capacity of 362 tonnes, the 980E-4 is powered by a Komatsu SSDA18V170 Tier 2 engine, rated at 2611 kW which in combination with GE Mining’s dual IGBT electric drive system provides a top speed of 64 kilometre per hour. According to Scott Harrington, Komatsu Australia’s national product manager, mining, this engine provides one of the lowest brake-specific fuel consumption (BSFC) rates in this truck class. Applications for this truck include iron ore, coal and other resources requiring bulk material movement when matched to large loading tools, to deliver the lowest possible costper-tonne. As with other trucks in Komatsu’s ultra class electric drive haul trucks range, the 980E-4 was designed and

developed by Komatsu America Corp, and is manufactured at its Peoria operation in Illinois for customers around the world. “Komatsu was the first to introduce AC drive systems for ultra-class mining trucks in 1996, and has ever since continued to demonstrate to our customers in Australia and globally the incomparable performance and reliability that Komatsu trucks provide,” Harrington said. “In addition to the truck’s fuelefficient engine and Invertex II AC control group, the 980E-4 features multiple disc oil cooled (wet disc) brake design, Payload Meter 4 and frame castings in high stress areas,” he said. A number of components will remain common to Komatsu’s 960E2 truck being the; engine, radiator, alternator, retarder and cab. However certain major components have been designed specifically for the new 980E-4, engineered for the 362 tonne rated payload.

AUSTRALIANMINING

Major component changes include larger wheel motors, GDY108C based on the proven GDY108B design. The new wheel motor is longer to accommodate the 44 inch rims and includes a number of gearing and bearing design changes. Hoist cylinders, steering cylinders and suspension cylinders have all increased in capacity. This will enable Komatsu to maintain a known rated hydraulic system pressure and Komatsu component design life targets. An interesting metric a number of customers are now monitoring is the labour hour to machine operating hour ratio. The reliability features and maintenance-friendly design of Komatsu electric drive trucks provides customers with lower labour hour to machine operating hour ratios. The 980E-4 features removable power module design, simple hydraulic design with one common tank, removable pump sub frame,

SEPTEMBER 2016

oil cooled multiple disc brakes providing reduced brake wear and maintenance requirements compared to dry disc brakes, less lubricants than similar class trucks and advanced machine diagnostics including the Komtrax Plus satellite communication system. The 980E-4 can also be fully integrated with management systems such as Modular Mining’s Dispatch and MineCare products. The new 980E-4 truck measures eight metres high and weighs in at over 625 tonnes when loaded. The first commercial fleet of the new 980E-4 has now begun delivery at an overseas mining operation with an initial fleet size of 30 plus units to be delivered this year. Komatsu are also working closely with a number of Australian customers for the introduction of this new model in the near future. AM

SAFETY

SAFETY AND INNOVATION SHINE IN QLD COAL WORKERS’ PNEUMOCONIOSIS AND FATALITY RISKS WERE HIGH ON THE AGENDA AT THIS YEAR’S QUEENSLAND MINING INDUSTRY HEALTH AND SAFETY CONFERENCE. SHARON MASIGE WRITES.

his year’s Queensland Mining Industry Health and Safety Conference took place in the Gold Coast for the first time in its 28-year history. Nearly 600 industry leaders attended the three-day event which hosted a wide range of keynote addresses, industry presentations, and trade displays from companies including Glencore, Kinnect, Wormald, Safety Equipment Australia, and Caterpillar. Attendance was the highest it has been in two years. The theme, “A past forgotten is a future repeated”, focused heavily on learning from past mistakes made in the industry, with the two biggest topics of the conference surrounding the re-emergence of coal worker’s pneumoconiosis (CWP) and fatality risks. Conference chair Greg Dalliston said the event’s strong turnout embraced the opportunity to share industry knowledge and learn about emerging issues. “Repeating the same mistakes and not learning from the past has the potential to put our workforce at risk, and is also a waste of time and resources,” he said. “The conference provides a vital opportunity for industry to learn from past mistakes and to go back to mine sites armed with new processes that tackle issues head on.” The event was opened by Queensland minister for natural resources and mines, Anthony Lynham, who late last year initiated a formal inquiry into CWP, or black lung, after new cases of the disease were confirmed, with the CFMEU also claiming a former miner has died as a result of complications from black lung. Earlier this month, the QLD government launched a parliamentary review into black lung’s resurgence in the state, with the development of a parliamentary select committee to look into the issue. They will have the powers of a parliamentary committee to call witnesses, hear evidence, and gain access to relevant documents related to the disease, with the main priority, Lynham said, of “fixing the issue”. The event featured keynote addresses from mine safety consultant, barrister, and former Queensland

Resources Council chief executive Susan Johnston on whether safety can be improved in challenging times; University of New South Wales professor Michael Quinlan on the pattern causes of death and disaster in the mining industry; Peabody Energy Australia vice president safety, health, and environment Andrew Clough on History, Geography, and Zero Harm; and professor Malcolm Sim who prepared the main review into black lung for the QLD government, highlighting several deficiencies in current efforts to safeguard coal mine workers from potentially developing the disease. Innovation was another major focus during the event, culminating at the Innovation Awards ceremony which recognised the best emerging practices for eliminating health and safety risks. An innovation by Anglo American outbye superintendent Mark Gleadhill – a portable chilled air device that tackles heat stress in underground mines – received both the coveted Innovation Award as well as the People’s Choice Award. As heat management is one of the key issues in underground mines the device is a mine compliant, compressed air driven, quiet portable “air conditioner”, capable of providing additional cooled air to different areas including refuge chambers, crib

rooms, and chemical containers. Anglo American’s winning innovation was one of ten finalists, with first prize including a trip to America to tour the Mine Safety & Health Administration in Virginia, and participate in the Denver-based SME Annual Conference & Expo early next year. Highly Commended went to Glencore’s Ernest Henry Mine for its long-hole drill rod handler initiative, which tackles both the risk working at height and of acute injury through awkward lifting. One of the finalists included Hastings Deering D11 Track installation tool. The engineering services team behind the device devised a design for the installation of the tracks on a Track Type Tractor (TTT) which used the machines drive system and removed the need to pull the track with a forklift or equivalent machine. This process change eliminates the risk of pulling the TTT off its support stands, minimising the safety risks associated with pulling the track with a chain which could result in chain failure. The tool reduces the number of service personnel required to perform the task, improves the alignment of the track with the sprocket, improves installation time and efficiency, and reduces installation cost.

Another one of the finalists was Incitec Pivot’s Phosphate Hill Operations for their Ammonia Draining System Without Fugitive Ammonia Losses. The automated vaporiser blow down system eliminates the risk of ammonia release into the atmosphere. It has other benefits including monitoring and automatically closing an actuated valve based upon vaporiser pressure, line temperature, inferred water content in vaporiser and level of receiving vessel and other plant emergency conditions; eliminating potential of human error from blowdown sequence over a 12-hour period; and providing DCS control based or operator-initiated valve shutdown in the event of a plant trip or emergency condition. The conference had a continued emphasis on health, with the Health Program Award going to Yarrabee Coal for its multi-disciplinary prevention and management program tackling workforce health risks. They were also awarded a $1,000 donation to their charity of choice. For another year, the event allowed industry leaders to share knowledge, best practice and learn about emerging technologies that ensure workers make it home safely at the end of every shift. AM

LIVE TRAINING DEMONSTRATIONS WERE CARRIED OUT AT THE EVENT

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SEPTEMBER 2016

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SAFETY

STAYING SAFE IN THE WORKPLACE THIS YEAR’S SAFETY IN ACTION EVENT WILL HIGHLIGHT THE IMPORTANCE OF MENTAL AND PHYSICAL HEALTH IN THE WORKPLACE.

he largest workplace health and safety event in Australia, Safety in Action, will take place in Sydney from September 6 – 8 at the Sydney Showground, exhibiting the latest innovations, products, systems, and seminars to promote employee safety. This year’s theme is “Keep your workplace safe” with the event hosting more than 5000 decision makers in Workplace Health and Safety (WHS) across government, manufacturing, construction, resources, transport, and engineering industries. More than 100 exhibitors will attend the event including Australian Safety Wholesalers, Black Dog Institute, SAI Global, and the Canberra Institute of Technology. Keith Barks, general manager at Informa Australia – who are jointly presenting the event with the Safety Institute of Australia (SIA) – said it is estimated that more than 2000 workers die from work related illnesses annually. “[This] highlights the urgent need for national improvements to prevent and reduce the number and severity of injuries and illnesses in the future,” he said. Untreated mental health conditions cost Australian workplaces approximately $10.9 billion per year; comprising $6.1 billion in presenteeism, $4.7 billion in absenteeism, and $145 million in compensation claims. Therefore business owners and organisational leaders play a critical role in driving practices that promote mental health in the workplace. While creating a mentally healthy workplace is everyone’s responsibility, mental health is a leadership issue, and change must start at the top. As a result, mental and physical health will be one of the major focus areas in the exhibition’s seminar series, with presentations from Beyondblue, SafeWork NSW, Myosh, Mayo Hardware, and Aframes Safety discussing new research, regulatory compliance issues and expanding on technological innovations. AccessEAP and Beyondblue will expand on how to create mentally and physically healthy workplaces and why workplace wellness is good for a business’ bottom line. There will be seminars on highperformance thinking strategies to

achieve a zero harm, positive safety culture; how to manage and improve work safety with software tools; how companies are using in-vehicle monitoring systems to improve driver safety in Australia; and on contractor safety management and compliance. There will also be a time dedicated to the latest innovative developments in the sector, with presentations from those at the forefront of concepts such as virtual reality, 3D printing, and the future of workplace health and safety. The event will also host a panel discussion tackling the question ‘Is workplace psychological health and safety being undermined and trivialised by unsystematic “quick fixes” approaches?’ The panel members include SafeWork NSW psychosocial inspector Alexis Wray and Master Builders Association of NSW executive officer, safety, David Solomon. “Mentally healthy workplaces are as important to Australian employees as physically safe workplaces; however workplaces are not meeting their expectations. Three quarters of Australian employees expect mental health support in the workplace environment, but many may not be aware of, or are unable to access appropriate resources,” Nick Arvanitis, head of workplace research and resources at Beyondblue, said. THE LATEST SAFETY TECHNOLOGY AND EQUIPMENT WILL ALSO BE ON SHOW

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Belt cleaner systems from ESS make conveyor systems cleaner, safer and more productive PROBLEM: Carryback is material that sticks to the belt past the discharge point and then drops off along the conveyor’s return run. Without belt cleaners, prevalent carryback causes material build up on rolling components leading to seized idlers, wandering belts and increased power consumption. In the mining industry, up to one in three FIFO workers reportedly experience mental health difficulties, with an R U OK? campaign launched earlier this year encouraging workers to support one another before they “hit rock bottom”. R U OK? CEO Brendan Maher encouraged employers to do more to foster workplace cultures that encourage discussions about wellbeing. “Working away from family and friends inevitably takes a toll on people; especially if they’re dealing with issues at home. We need to remind workmates to watch out for the subtle changes that suggest someone isn’t coping so well,” he said. Running parallel to Safety in Action will be the SIA’s National Convention, a two day conference featuring global and Australian safety leaders to challenge employers to change their thinking about safety. The leaders will address the theme of “Disruptive Safety” which has a range of meanings including

SOLVED: With belt cleaners, minimalized carryback results in… • Improved maintenance planning and conveyor availability as emergency outages, unscheduled downtime and “hurry-up” repairs are reduced. • Reduced maintenance expenses by lower labor costs for fewer and faster service procedures. Improved manpower utilization by fewer belt tracking and material cleanup chores. • Maximized equipment life by fewer replacements of prematurely worn components damaged by fugitive material and buildup. • Improved working conditions and plant safety and morale by better housekeeping. • Improved community relations and regulatory compliance by reducing environmental pollution.

disruptive change, which tackles positively disrupting the status quo in workplace health and safety; the disruptive environment, which questions how health and safety officers, managers, and executives can work together to withstand changes in their businesses; and working in challenging fields, questioning whether anything can be learnt from industries with high health and safety risks and how these can be translated throughout the business. The convention also includes the SIA Annual General Meeting, OHS education awards, OHS leaders and CEO’s breakfast, and a women in leadership forum. Australia’s largest cleaning and hygiene show CleanScene, will also be co-located at Safety in Action, presented by the National Cleaning Suppliers Association (NCSA). It will feature exhibitors catering for cleaners, commercial, industrial and facility managers, government agencies and purchasing officers. AM AUSTRALIANMINING

www.esseng.com.au

SEPTEMBER 2016

1800 074 446

SAFETY

SAFETY IN ACTION: EXHIBITORS & MAP EXHIBITOR

Stand No.

EXHIBITOR

Stand No.

EXHIBITOR

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EXHIBITOR

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3G SAFETY WATCH

E12

CORPORATE BODIES INTERNATIONAL

I19

INX SOFTWARE (SAFETY SOFTWARE)

I12

PREMIUM HEALTH

ACCIDENTAL HEALTH AND SAFETY

G17

DATA STATION

IOAC OPTICAL PTY LTD

J17

PROSPECTA SOFTWARE AUSTRALIA

QUICKALLY SCAFFOLDING AND ACCESS SOLUTIONS

I10

REHAB OPTIONS INJURY MANAGEMENT

RISK MANAGEMENT TRAINING ORGANISATION

E26

RISKWARE

ALCOLIZER TECHNOLOGY

I13

DEB AUSTRALIA

JIAYU KAIER GARMENTS CO.?LTD.

ASSURA SOFTWARE

K16

DONESAFE

KAIFENG GROUP CO., LTD

ATOM

ELIDE FIRE BALL &BETTER-AIR AUSTRALIA

KEMTEK IMAGING SYSTEMS

AUSTRALIAN SAFETY WHOLESALERS

EMONA INSTRUMENTS

F11

KM WORKWEAR PTY LTD

AUSTRALIAN SECURITY TECHNOLOGY PTY LTD

G19

FERNO AUSTRALIA

KOCKUMS BULK SYSTEMS PTY LTD

F25

BAMBACH SADDLE SEAT

J10

FUSHI PROTECTIVE PRODUCTS CO,.LTD

LABOURHEALTH

F23

BARRINGTON GROUP AUSTRALIA

BASTION PACIFIC PTY LTD

L11

beyondblue

G10

BLACK DOG INSTITUTE

BRADLEY AUSTRALIA

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GENCOM WIRELESS SOLUTIONS

LEDIFIED

K10

GENIEGRIPS

LEXISNEXIS

I18

GET HEALTHY AT WORK

LINYI KINGSTAR CAPS&SHOES CO.,LTD

E28

GREATGUARD SAFETY PTY LTD

MAYO HARDWARE

E10

GUARDIAN FIRE AND SAFETY SOLUTIONS

MCM ELECTRONICS

I14

HAIGH AUSTRALIA

MEDIFLEX INDUSTRIES

C13

BREATHALYSER SALES & SERVICE

BTW COMMUNICATIONS

J13

BUREAU VERITAS CERTIFICATION

CANBERRA INSTITUTE OF TECHNOLOGY

J11

HANGZHOU ZHANGSHITONGHE SHOES CO.,LTD

NCC APPAREL

CAREMONKEY

HR3

I15

NSW ELECTRICAL TEST & TAG/ ZEDFLO

CHEMALERT

F20

IMS STRATUS

NTT DATA FIGTREE SYSTEMS PTY LTD

J27

TODH.ZHOU

D11

HAMMERTECH

MIX TELEMATICS

MYOSH

G7 K15

CHEMICAL SAFETY INTERNATIONAL

INBODY BODY COMPOSITION ANALYSERS

E14

OCO EYE SAFETY

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CHEMICALS OF SECURITY CONCERN

INTEGRITY SAMPLING PTY LTD

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OZHELP- KPI FOR LIFE

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CIRLOCK

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INVENTIS GREGORY

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PELICAN PRODUCTS AUSTRALIA

COOL

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G18 G19

K11K15

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I10 I11 I17

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J2 J26

J1 J27

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O10 011

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ROOFEXTENDA

K18

ROYAL LIFE SAVING

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SAFE FLOORS AUSTRALIA

K11

SAFE WORK LABORATORIES

SAFEQUIP

L30

SAFETY INSTITUTE OF AUSTRALIA

G11

SAFETY SOLUTIONS MAGAZINE

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SAFEWORK NSW

SAI GLOBAL

SCRIM SAFETY FIRST

D12

SHANDONG BEST SERVE SAFETY SHOE LTD

SHE SOFTWARE

J18

SHIRLEY SUN

SKIN PATROL

SKYTRUST INTELLIGENCE SYSTEM

J20

STAPLES AUSTRALIA PTY LTD

J21

SUPER SPILL SOLUTIONS

SUZHOU FRONTIER WORKWEAR CO.LTD

SUZHOU VISION CLOTHING CO.,LTD

SYDNEY SAFETY TRAINING

L14

THE BRIGHT GROUP

L26

THE GLOVE COMPANY PTY LTD

ULTIMATE LED

L10

UNEEDIT SUPPLIES

L12

UNIMAX MEDICAL PRODUCTS CO.,LTD.

L25

UNIVERSITY OF NEWCASTLE

K20

VelocityEHS

VIZWELL INTERNATIONAL INC.

J15

WHS MONITOR

F27

WRIGHTWAY PRODUCTS

WUHAN HENYI TEXTILE CO.,LTD.

WUHAN KINGLONG PROTECTIVE PRODUCTS CO.,LTD

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Safety In Action Sydney 2016 sydney melbourne brisbane

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account: Carly designer: Casey revision by: KD

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venue: Sydney Showgrounds, Halls 5 & 6 date: 6 - 8 September 2016 code: SAFENV6

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XIAMEN PROBTAIN NONWOVEN INC.

ZHEJIANG LANBEI INDUSTRY&TRADE CO.,LTD

ZHEJIANG LEIMA SHOES IND.CO.LTD.

K17

ZHEJIANG SHUNFA REFLECTIVE CLOTHING CO.,LTD

F30

ZHX GLOVES

SAFETY

OLIVER RELEASES NEW RANGE OF SAFETY FOOTWEAR Oliver Footwear has announced a new AT 55 Series of safety footwear with ten styles including two that incorporate metatarsal foot protection. The series is the company’s lightest ever AT 55 footwear release and is suitable for worksite conditions where lightweight comfort with heavyweight safety protection is required. The new deeper tread profile and self-cleaning design creates stronger grip and durability in harsh terrain. The AT 55 Dual Density Polyurethane and Rubber sole combines a shock absorbing low density polyurethane midsole with the hard wearing rubber outer sole. Now, the softer midsole core extends into the cleat providing cushioning that absorbs the shock of rough workplaces. The sole is also heat resistant to 300°C and exceeds all non-slip resistant requirements under AS/NZS and international standards. Premium wearer comfort features included in the new range include the COOLstep moisture wicking lining that absorbs and disperses moisture across the boot for quicker drying. This lining is also treated with a natural anti-microbial

solution that controls bacteria that create odour, stains and product deterioration for the life of the product. The COMFORTcushion Impact Absorption System offers a combination of cellular urethane and PORON performance cushioning to protect the heel and ball of the foot by superior cushioning and shock absorption. This results in reduced foot, leg, and lower back fatigue. The SOFTstride comfort system works to soften and absorb the impact on the foot after each stride. A layer of open cell low density urethane foam built into the insole contours to the individual foot shape for the ultimate in comfort and support, especially where long hours on the job may be common. The NANOliteTechnology has a gently raised surface of the insole that massages your feet as you walk, promoting greater blood flow to help reduce fatigue. The perforated foam air control layer also enhances air circulation. With the NATUREform steel toe cap – with its wider shape and padded latex liner – toe comfort is assured without them being in contact with the cap. All styles with these caps are licensed to

WELDING RESPIRATOR SYSTEM The SR 900 respirator system allows users to customise the product based on site requirements. It can be easily configured for filters, powered air purifying respirators (PAPR), supplied air, as well as a remote filter holder mounted on the waist belt. It features the mask body of TPE (thermoplastic elastomer), a deep chin cup and broad nose rim, two exhalation valves, and new valve caps with air diffusion that eliminate clogging during spray jobs. It has a continuous head strap or cradle harness, accepts all Sundström filters and compressed air attachments, and has a detachable filter holder which allows direct hose attachment. Users can also choose between single or twin breathing hose. The system comes in Small/Medium, Medium/Large and Large/Extra Large sizes, and can also be fitted with an optional SmallTalk microphone and loudspeaker. By removing the filter attachment on the mask and attaching the breathing hose and remote filter holder, users can wear the filter behind their back. The filter sits on a waist belt and can be moved to any position. In turn, the mask itself is given a very shallow profile, making it suitable for welding as it easily fits inside a welding shield or visor. An additional benefit is that the filter is mounted well away from any welding hazards, such as sparks, heat and metal fumes. • Safety Equipment Australia 02 9910 7500 www.sea.com.au

THE SOLE IS HEAT RESISTANT TO 300°C AND EXCEEDS ALL NON-SLIP RESISTANT REQUIREMENTS UNDER AS/NZS AND INTERNATIONAL STANDARDS

all AS/NZS and International safety standards. Oliver’s new HEELguard is designed with padded comfort to aid stability and protect against impact and roll over hazards. While the TECtuff toe bumper features in all styles to protect against scuffing the front end of the boots. Three AT style choices, AT 55-332Z, AT 55 345Z and AT 55-385, also offer quick release zippers for ease of donning and doffing. All AT 55 styles use water resistant nubuck and full grain leather uppers, while stitching is enhanced with Kevlar thread on critical wear seams for maximum abrasion and chemical resistance.

The two AT 55-336 and AT 55- 346 styles with metatarsal protection use the PORON XRD that is comfortable, flexible and lightweight without rigid, bulky or constricting padding. As a high performance molecular protection, it is also a unique protective shield that absorbs up to 90 per cent of the most intense force. Both AT55 Metatarsal styles also feature Q-Flex non-metallic insole protection against penetration by sharps over the entire foot surface while ensuring flexibility and comfort. • Oliver Footwear 03 53 200 200 info@oliver.com.au www.oliver.com.au

HEAVY DUTY HOSE REELS Tecpro Australia has released the new Mine Spec range of heavy duty hose reels. The reels include a spring rewind mechanism to make it easy for operators to retract the hose after use. It also ensures the hose can be stored safely to prevent it from becoming a potential trip hazard. The reels are suitable for hoses from 6mm – 3cm diameter and can accommodate hose lengths from 15m – 100m (depending on hose diameter). Designed and manufactured in Europe using 50 per cent thicker st a i n le s s st e el t h a n standard hose reels, they can withstand the rigor of harsh environments. They are available for low or high pressure applications and can withstand 400 Bar operating pressure, with a 600 Bar model available on request. As well as the regular AISI 304 stainless steel models, the reels are available in 316 stainless steel, powder coated steel, and cataphoric treated steel. In all, there are 12 different versions of the reels available in each material in the range. They are suitable for use in refuelling stations, AUSTRALIANMINING

SEPTEMBER 2016

lubrication bays in maintenance workshops and heavy vehicle wash bays as well as other areas requiring wash-down in the mining and heavy industrial sectors. • Tecpro Australia 02 9634 3370 www.tecpro.com.au

MINESITE CONSTRUCTION

A NEW FACE FOR MINING CONSTRUCTION AS THE CONSTRUCTION WORKFORCE AGES, NEW TECHNOLOGIES ARE SET TO REVOLUTIONISE THE SECTOR. DATA61 RESEARCH SCIENTIST GEORGE QUEZADA WRITES.

y 2034/35, almost 20 per cent of Australians (6.2 million) are projected to be aged 65 or over. One sector already feeling the impact of the ageing population is construction. In Queensland, the number of construction workers aged 55 and over increased from 8 per cent of full-time workers in 1992 to 14.2 per cent in 2014. An ageing workforce is likely to increase the need for less physically demanding jobs or maybe technology might address this issue. Task automation and the industry’s innovation culture are two of the greatest areas of uncertainty for the construction industry. A new study that developed evidence based scenarios for 2036, depicts how automation and manufacturing could grow in the construction sector, creating more knowledge intensive jobs as a result. The study explores future technology that eliminates dangerous and difficult tasks, particularly in light of the ageing workforce. Experts in the industry were asked the extent to which technology would progress and how many or which tasks could be automated. There was no consensus on this and the other point of contention between the interviewees was how bold the industry would be in its pursuit of new solutions. The research did suggest the construction workforce will

need a broad understanding of digital applications, in addition to traditional project management and communication skills.

Construction jobs of the future

The trends analysis and scenario development in the report produced some examples of possible construction industry jobs in the year 2036, including: Building assembly technician: Someone who oversees robotic systems and examines data feeds throughout the life of a project. This worker would optimise workflows and make adjustments on real time feedback from clients about design or changes to materials. Virtual/augmented reality trainers: Breakthroughs in virtual and augmented reality technology could provide low-cost immersive environments where apprentices and trainers can meet virtually in any training situation, such as worksite, factory, design studio – the possibilities are endless. Building drone operators: These professionals would control and program drones to carry out complex tasks such as site inspections, deliveries and maintenance. Robot resource manager: Robots in the workplace will need someone to take care of commissioning, software programming, maintenance and repurposing or recycling of robotic parts. Keeping track of this exploding field of technology will be a key challenge for the role.

AUSTRALIANMINING

Other opportunities

The Australian construction industry is changing with the introduction of digital collaboration platforms, like Building Information Modelling (BIM), robot machine prototypes such as the Fastbrick robot and rapid progress in 3D printing capabilities. These innovations will need more people skilled in the use of software programs and less people for labour-intensive jobs such as bricklaying or paving. BIM is software that creates a 3D visualisation of a building. However, it extends beyond 3D imaging to show scheduling, cost control, facility management and energy performance monitoring. The UK government has mandated that all centrally funded work is to be undertaken using BIM by April 2016 and the Queensland government

SEPTEMBER 2016

has stated that it will progressively implement the use of BIM into all major state infrastructure projects by 2023. As workers’ skills in BIM increase in Australia, the improved cost and time saving will drive customers to demand that projects are managed in this way. Already, in the Netherlands, the company MX3D is using 6-axis industrial robots to print a fully functional steel bridge. Contour Crafting technology, a process invented at the University of Southern California, has great potential for automating the construction of whole structures as well as sub-components and a company in China is using 3D printing to build houses. The manufacturing part of the construction industry is expected to grow at 5per cent per annum out to 2023, compared to a growth rate of 2.3per cent for the industry as a whole. While the current prefabricated building market in Australia is still comparatively small, with only A$4.5 billion of the total A$150 billion construction industry, it is expected to contribute to more affordable housing stock and to take a much greater share of creating multi-storey buildings. The nature of construction work is set for a step change over the next 20 years and careful strategic thinking is needed to navigate the changes. The changes will require humans to exercise judgement and decisionmaking that reflects human values and aspirations; a task that is well beyond the most advanced artificial intelligence systems. AM This article was originally published on The Conversation.

INNOVATION

EMBRACE INNOVATION OR PERISH MINING IS AT A CROSSROADS, AND IT HAS A CHOICE: TO INNOVATE AND COLLABORATE, OR FALL BY THE WAYSIDE. COLE LATIMER WRITES.

iners can no longer go it alone. The mining industry has undergone one of the most rapid changes in decades, and the old ways of doing business no longer suffice. We have entered an age of collaboration, where companies must be willing to innovate, or suffer the consequences of poor productivity. According to a new Deloitte report, Innovation in Mining – Australia 2016, “The Australian mining industry is going through one of the most intense

periods of change we have ever seen, and the ability to innovate – to evolve, adapt, and improve – is indispensable.” Cost cutting and incremental improvements aren’t enough to lift mining, and the industry must embrace innovation or else. “Innovation is not only key to protect the future of the mining sector,” Deloitte said, “but that of the entire mining system, from the country in which the resources are harnessed to the people in its workforce, government, and the broader mining community.” Nicki Ivory, Deloitte’s Australian national mining leader, explained that AUSTRALIANMINING

the industry has endured a difficult market marked by commodity price volatility, diminished Chinese demand tied to a slowdown in the country’s economic growth, capital and investment access issues, and ongoing environmental issues. “However to remain globally competitive, Australian miners must decide if they are willing to go beyond the basics and incorporate a structured approach to innovation,’’ Ivory said. In the study, Australia ranked ahead of Canadian and African mining companies and service providers as more innovative, edging

SEPTEMBER 2016

towards an ‘advanced’ level, which demonstrated systematised efforts and clear innovation strategies which are emerging and defined innovation systems. When it came to how Australia’s mining industry saw itself, junior miners emerged as the most innovative, followed closely by service providers, however the major miners saw themselves as relatively low on the innovation scale, where fragmented efforts are being made, there is an unwillingness to make ‘the big leap’, one major miner clarified by stating: “We want to be first to be second.”

INNOVATION

With attitudes such as this still prevalent in the industry, there is still plenty of ground to cover. It is time for an ‘intelligent mining’ revolution; one that embraces innovation and prepares itself for a new era of mining. But, has the industry left it too late to make real change, having focused on cost cutting measures instead of new ways of doing business? In its report, Deloitte found that “while companies have generally succeeded in creating more efficient operations, the law of diminishing returns is now setting in”. “During the upturn, a huge amount of inefficient practices became embedded in many organisations, leading them to be arguably more dysfunctional than they’ve ever been, impacting severely on productivity,” VCI chief executive Graeme Stanway explained. “As an industry, we’re now undergoing the process of unpicking a lot of that. In hindsight, we didn’t build enough agility into our organisations, looking all the way back to the 90s and the focus on lean businesses. “We focused too much on lean, rather than developing agile businesses that would have thrived through expansion without locking inefficiencies into the core structure. “The challenge is the mining cycles occur over a very long period of time; by the time the next one comes around, we’ll have forgotten a lot of these lessons from this current cycle once again. The good companies will find a way to overcome this.” So what lies ahead for the mining industry?

Understanding Innovation

While the word gets tossed around frequently, what is innovation in its application to mining? “Through overuse, misuse, hype and enthusiasm, the word innovation has lost its meaning,” Deloitte said. This is little surprise for many in the industry; in the report one major miner is quoted as saying, “Focus is not really on innovation but on reducing costs, cost reductions have brought minor innovations but no big revelations.” “While the desire or imperative to innovate is as old as business itself, innovation is too often asked to solve the problem du jour, and every other problem at hand. However, asking so much of innovation can dilute an enterprise’s capacity to use innovation to its greatest advantage.” So what exactly is innovation? Austmine chair Christine Gibbs Stewart explained: “When we refer to innovation, we’re not simply referring to the next big invention, we are also

encompassing incremental innovation, or a re-thinking of how we use equipment, technology or processes that we already have in place.” Deloitte added that it is less a case of misunderstanding innovation holistically, rather it is major mining companies implementing a narrow view of its implementation. “Mining companies understand that innovation is the path to long term sustainability, but most of their attention is still centred upon innovating to drive short-term performance,” Deloitte said. “Mining companies will need to push beyond the current focus on product innovation and expand their view of where and how they can innovate. “In order to outperform the competition and drive higher levels of productivity and growth, mining companies must mobilise their innovation efforts beyond the technical R&D groups and into the wider organisation.” It noted there were four major innovation building blocks: Approach – how they build a methodology for the work to be done in generation innovations, and how they manage their innovation efforts; Organisation – how the company engages with innovation, mechanisms in place for identifying and leveraging external capabilities and partnerships, as well as clear outlines on governance e.g. how and by whom; Resources & Competencies – how they acquire and nurture the people who carry out innovative practices, the financial resources devoted to it, and specialised protocols developed for different aspects of innovation; and finally Metrics & Incentives – the targets developed to guide performance as well as measures created to then evaluate progress as well as the incentives to drive supporting behaviours. Deloitte then broke down innovation implementation into three facets; Core: innovations that optimise existing assets, products and services; Adjacent: innovations that help to incrementally expand existing businesses into ‘new to the company’ business; and Transformational: innovations that are breakthroughs and inventions that are new to the industry or the world. Research shows that the most successful innovators manage their innovation efforts and investments as a portfolio of activities balanced across the three aforementioned ambition levels. However, miners are mainly focusing on Core innovations, using technological solutions to optimise existing techniques, rather than pushing towards true Transformational change. AUSTRALIANMINING

What innovation?

Participants of the study stated that they mainly used innovation to develop technology and efficiency measures to reduce costs; find better ways to increase production; improve mineral recovery; and remove more waste material early in the process, from which Deloitte went on to break down its implementation into ten different types of innovation and their perceived importance versus companies’ effectiveness in its application. Deloitte found that while the majority of companies are focused on continuous improvements and operational excellence, the industry understands it needs to focus on next level Adjacent and Transformational innovation to truly evolve. “For all intents and purposes, we see little true innovation. While being innovative is something we will seek out, our primary focus is on continuous improvement and a better bottom line, without compromise, quality, production, and the service we provide,” one major miner is quoted as saying. Unsurprisingly, with this attitude, Product Performance – optimising the extraction of core products more effectively – was identified as the type of innovation that was most crucial to continuing competitiveness.

SEPTEMBER 2016

METS COMPANIES ARE LEADING AUSTRALIA’S INNOVATION CHARGE, ACCORDING TO DELOITTE

The second most important application of innovation was in the Profit Model field – the way in which companies make money – followed by Product Performance and Service. One of the largest gaps between the perceived importance and actual effectiveness was in Product Systems – the use of by-products – which Deloitte believes “points to an opportunity; with companies generally rating this type of innovation as critical to their competitiveness, it seems they could benefit greatly from identifying why their efforts in this area are not coming to fruition”. Innovation in their Network rated as the lowest in importance. Not every company viewed innovation in the same way, the report found, rating each type of innovation differently according to their role within the industry. “Service providers, for instance, rated Stakeholder & Customer Engagement higher than other groups,” Deloitte said. Across almost all types of innovation, majors and service providers are generally more focused

INNOVATION

INNOVATIVE PRACTICES, SUCH IN-PIT CRUSHING AND CONVEYING, ARE BEING IMPLEMENTED TO LIFT PRODUCTIVITY

than juniors are; however juniors did outscore the majors in Structure (the alignment of their talent and assets), Process (signature or superior methods for work outside operations), and Product Systems. While the majors have a way to go yet – and understand this gap between target and application – Deloitte stated that service providers, and operators on the ground, are making real strides forward.

Innovation at the ground level

Despite the fact many major miners aren’t as innovative as they believe they should be they know change needs to come, so how can the change to remain ahead of the curve? “The situation is such that mining companies can no longer afford to go it alone,” Deloitte said. Collaboration appears to be key. “Leaders need to be collaboratively oriented, not just functionally-focused, if they are to drive innovation most effectively [however] this orientation rarely happens on its own: innovation leaders need to be developed alongside innovation capabilities.” Gibbs Stewart explained, “Innovation is currently the buzzword in the mining industry, and the focus is on new collaborative ways of working together to solve some of today’s biggest mining challenges.”

“Things like open innovation, hackathons, new operating models and technology partnerships between mining equipment, technology and services companies are being used to change the paradigm of how the mining industry operates,” she said. “Innovative METS are characterised by visionary leadership, world-leading products and services, international focus and a high level of connectivity. This includes having a strong network both in Australia and abroad, as well as learning from, networking with, and leveraging those connections for commercial opportunities.” Speaking to Ausdrill COO Andrew Broad at Diggers and Dealers, he told Australian Mining being a contractor in this current age of mining is all about being innovative, flexible, and collaborative in the way you work with clients. This was echoed by Barminco CEO Peter Stokes. “It’s about working together, it’s not a ‘them and us’ mentality with contractors; by working together collaboratively you can bring a new level of productivity,” Stokes told Australian Mining. One service provider was quoted in the Deloitte report as saying, “When our clients don’t communicate well and involve us AUSTRALIANMINING

in their operations and planning we can’t be effective in our innovation capabilities to assist them”. Broad went on to say contractors are also evolving in their offering to work more collaboratively with miners, a key point in the report when it comes to remaining innovative. “There needs to be flexibility in contractor offerings [if the contractors are to stand out],” Broad said. “For instance we are working with junior miners, and instead of the traditional pay structure we have been drilling for equity in the eventual project…it’s about being innovative.” An unnamed service provider is also quoted in Deloitte’s report espousing the importance of this approach. “Innovation is an embedded key element of our culture, with formalised processes around idea generation, review committees, inhouse engineering capability, project implementation teams, and feedback loops,” the company stated. Cormack agreed, “It’s the service providers where we are seeing much of the industry’s innovation, such as software companies who are providing cutting edge technology.” He explained that it was the “agile, smaller companies with flatter organisational structures that are more innovative”.

SEPTEMBER 2016

These smaller companies are more able to institute more collaborative processes and smarter ways of doing of business. “A culture of open innovation has emerged within this group, and out of necessity, they have become adept at leveraging external partnerships to find solutions to complex problems. However, the report noted that “for many mining companies, collaboration – both internally and externally – appears to be sporadic at best”. This is exacerbated by a lack of open process systems and interoperability between OEM system and “fears of jeopardising the security of intellectual property”, which all remain a challenge to “the fluid exchange of ideas across internal silos as well as external ecosystems participants”. Yet these factors shouldn’t dissuade miners. “Collaboration is the real enabler of innovation,” Cormack told Australian Mining, “and this is being driven by [miners] networking with direct suppliers, as well as CRCs and universities.” Other groups, such as Unearthed Solutions and its nation-wide resources focused hackathon, are also creating new innovation streams. This group alone, through its hackathons, online challenges, and technology accelerator is focused on

improving efficiency and industry competitiveness. Unearthed Solutions’ Mikey Kailis, told Australian Mining that it is important in the years ahead that the industry learns to work together, and events like the hackathons are opening miners up to the world of the more agile start-up scene, and to new opportunities. “It’s important the industry learns to be become more collaborative,” he said. “If companies can become more open to innovation they’ll be more able to adapt to the changes ahead. “We’re teaching that methodology, nurturing start-ups and entrepreneurs to take on the industry’s challenges…to help change the industry’s mindset.” “Diversity of thinking will be essential to creating the steady stream of innovations needed not only to deliver the next wave of growth and productivity, but also to build sustainable business models over the long run,” Deloitte added. This mindset change is crucial. As the bad habits caused by the boom have become more prolific, adopting these new ways of doing business is the only way forward. Deloitte’s own study found that the industry has taken this on board, and is on track to becoming more proficient at innovating,

and ultimately at generating more bottom-line value. It called on majors to first articulate an innovation strategy, and think beyond technology for innovation as it is not just the equipment but also a shift in mindset. “Innovation needs to be driven from the top and shouldn’t be an unstructured effort from middlemanagement,” Deloitte said. Collaboration, such as that elaborated upon by Ausdrill and Barminco, is crucial for major miners if they want to mature their innovation capabilities. “[Miners need to] think beyond just R&D – assess how you collaborate on common issues with a wider set of partners, including service companies and even competitors. “Collaborate with (other) juniors and work with (other) service companies who are struggling with many of the same issues,” Deloitte urged. “If you’re a junior, work with service companies; if you’re a service company, work with other service companies.” Cormack added: “Innovation isn’t rocket science.” “There’s a recipe for success. “Any miner can improve their innovation maturity.” And now is the time miners must choose to innovate, or choose to be left behind. AM

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AUSTRALIANMINING

SEPTEMBER 2016

EARTHMOVING EQUIPMENT

RAISING THE GRADE CATERPILLAR HAS LAUNCHED ITS NEW MOTOR GRADERS WITH LARGER ENGINES.

aterpillar has unveiled its new 14M3 motor grader, which builds on its predecessor models. According to the company, the new machine is designed with a larger engine, increased fuel efficiency, improved machine balance, enhanced transmission performance, advanced electro-hydraulic steering, more powerful telematics, and added operator-safety/convenience features. An easily maintained drawbar-circlemoldboard assembly is designed for productive performance in a range of applications, and long-term durability of major structures combines with low operating costs and serviceability to provide optimum value. The Cat C13 ACERT engine replaces the C11 engine in predecessor models and features an ECO mode that boosts fuel economy by limiting the engine’s high-idle speed to 1,750 rpm in working gears, while maintaining machine power. ECO-mode savings are especially significant when working at high idle in light to moderate applications in gears 3R to 5F. The grader’s lift arm and centre shift assembly use a single, heavy duty steel casting designed to dissipate working forces, and the rear frame features two bumper castings and thick hitch plates. A series of easily installed “top-adjust” metallic or nonmetallic wear strips and wear inserts ensure that drawbar-circlemoldboard components maintain a “factory-tight” condition that promotes high quality work and reduces operating costs. An adjustable circle drive also assists in reducing service time and costs. The standard Variable Horsepower system is designed to closely match power requirements in all gears, and the Consistent-Power-To-Ground feature automatically changes engine power levels to compensate for coolingfan losses, resulting in consistent power delivery in all ambient temperatures and working conditions. The C13 ACERT engine is available in three versions to suit emissions standards in the area of use. All emissions solutions are transparent to the operator and do not interrupt working cycles. The grader’s 8F/6R power-shift transmission has a wide operating range for application flexibility and maximum productivity. The Cat Advanced Productivity Electronic Control System (APECS) enhances gear-to-

gear shifting by maintaining consistent torque flow and smoothing shift points. The Shuttle-Shift feature enables directional shifts without slowing engine speed or using the inching pedal, and an available Autoshift system allows programming shift points to best match requirements of specific applications. An engine-over-speed-protection system prevents downshifting at excessive ground speeds, and the standard automatic differential lock disengages during turns and re-engages during straight travel, simplifying operation and protecting the power train. For added braking capability, hydraulically actuated, oil-cooled, disc brakes at each tandem wheel feature

the toe of the blade can follow a hard surface, while the remaining cylinder is controlled manually. A 4.3m moldboard comes as standard; with a 4.9m version as an option. A range of cutting edges and bits are available, as are a three-shank ripper, and scarifier. A fully scalable, factory integrated Cat GRADE with Cross Slope system allows operators to maintain desired cross slope by automatically controlling one side of the blade. In addition, newly patented Stable Grade and Auto Articulation technologies improve operator performance and productivity. The Stable Grade detects and reduces machine bounce during operation while Auto Articulation

grader replace the multiple levers and steering wheel of conventional motor graders, reducing hand and arm movement by up to 78 per cent for less operator fatigue. The logical control pattern allows any operator to quickly become productive. Steering is speedsensitive, becoming less sensitive at higher speeds, and a secondary steering system engages automatically if required. Selectable blade-lift modes— fine, normal, and coarse—match blade control to the application, and the “Return-to-Center” system automatically restores straight-frame travel from any articulation angle. The grader’s large windows provide all-around visibility, and the optional rearview camera enhances sight lines

larger brake discs and piston areas. Also, separate oil supplies for braking and implement systems eliminate cross-contamination, reduce heat, and extend system-component life. An available compression brake enhances the 14M3’s overall stopping power. The 14M3’s load-sensing hydraulic system incorporates advanced electrohydraulic operation for precise, responsive implement control. Proportional Priority PressureCompensating valves provide different flow rates for the head and rod ends of the cylinders, further ensuring consistent, predictable control. Balanced, proportional hydraulic flow enables all implements to operate simultaneously with consistent speed. Blade-float features allow the entire blade to follow ground contour, or

improves manoeuverability and performance in tight working spaces and enhances operator comfort. Cat Advanced Control Joysticks are optional with Cat GRADE with Cross Slope, and they also allow precise operation with AccuGrade . The joysticks allow the operator to configure auxiliary hydraulic functions safely and effectively without removing either hand from the controls, which results in decreased operator fatigue and increased productivity. More effective fleet management is placed in the machine owner’s hands with the Cat Product Link telematics system which allows remote monitoring of machine location, fuel usage, machine performance and fault codes via the VisionLink user interface. Intuitive joystick controllers in the

to the rear. The standard suspension seat features side bolsters for comfortable side-slope operation, and heated/ventilated seats are available. The high-capacity HVAC system pressurises and dehumidifies the cab for year-round comfort. In terms of maintenance, service intervals for the 14M3 have been extended, including 500-hour engineoil changes and 2,000-hour transmission and differential oil changes. Most routine maintenance points are accessible from ground level, LED lights are available for the engine compartment, and wear indicators allow brake wear to be measured during routine service without removing brake pods. Oil-sampling taps are easily accessed, as are pressure taps for various systems. AM

AUSTRALIANMINING

SEPTEMBER 2016

EARTHMOVING EQUIPMENT

KOMATSU RELEASES NEW MINING SHOVEL SHOVELS UNVEILED EARLIER THIS YEAR ARE NOW READY TO HIT THE MINE.

omatsu has released its ‘next gen’ mining shovel, the 700 tonne PC7000. Available in face shovel and backhoe configurations, and is matched to plus-200 tonne trucks such as Komatsu’s 830E, 860E, and 930E haul trucks. The machine is powered by two Tier 2-rated Komatsu SSDA16V159E-2 engines, which are rated at 2500 kW. The crawler assembly overall length 10.5 metres, while it has a track pad width of 1500/1900 mm. According to Komatsu, the PC7000 has a maximum travel speed of 2.5 km/h, and bucket capacity (for both backhoe and front shovel configurations) of 36 cubic metres at 1.8 tonnes per cubic metre material density. The machine has backhoe bucket breakout force of 1671 kN; a front shovel bucket breakout force of1994 kN; and an overall operating weight of 682 tonnes in the backhoe configuration and 674 tonnes for the face shovel configuration. According to Komatsu Australia national product manager Michael Hall, the shovel “represents the latest in mining technology, and was developed as a result of close collaboration with our mining industry partners from around the world; with mining becoming ever more challenging, we opted for a truly customer-oriented approach”. “As part of this process, our longterm mining partners were asked to define their requirements for the next generation of shovels. “They identified safety, productivity, maintainability and performance as key drivers – and all were taken into consideration by our design and development engineers.” The PC7000’s design was also strongly influenced by industry groups such as the Earth Moving Equipment Safety Round Table (EMESRT). Hall said the PC7000 had the highest engine power and breakout force in its class, providing fast cycle times. “This, combined with an easy-fill bucket design, meant in less time at the face to fill the bucket, along with reduced fuel consumption per BCM,” he said. “At the same time, our Komatsu Hydropilot system prioritises

hydraulic flow, ensuring smooth hydraulic response, with simple system layout and a reduced number of components. Maintenance-related downtime has also been significantly reduced, with the machine design providing easy access to major components, centralised service points and improved maintenance access through the location and increased width of walkways. Customers can constantly check the machine’s operating status of their machine through KOMTRAX Plus, which is standard on the PC7000, said Hall. “And for Australian, New Zealand and New Caledonia customers, all machine operational

AUSTRALIANMINING

data is constantly monitored and checked in our INSITE Fleet Management Centre at our Fairfield headquarters,” Hall said. “Our INSITE centre constantly monitors data covering key machine, fleet, production and industry parameters across all Komatsu mining, construction and utility machines operating throughout our region, ensuring we harness the latest ICT (information communications technology) to derive maximum benefits for our customers.” Additional production enhancing technology on the PC7000 is available through Modular Mining’s ProVision system, which provides bi-directional data transfer from

SEPTEMBER 2016

mine planning to the machine and from the machine to mine planning; improved bench level adherence to plan; delineation of blocks and polygons to enable selective mining and ore grade consistency, minimising material waste and improving production efficiency; and enhanced safety via hazard alerts, restricted area identification and proximity warnings. “With backhoe, front shovel, diesel and electric drive configurations already sold around the world, our new PC7000 is rapidly obtaining market acceptance among major mining companies,” Hall explained. The shovel was first shown at Bauma, in Germany, earlier this year. AM

EARTHMOVING EQUIPMENT

THE FIRST HARD ROCK CONTINUOUS MINER CATERPILLAR HAS DEVELOPED NEW TECHNOLOGY TO REVOLUTIONISE HARD ROCK MINING.

at has released the new Rock Straight System, the HRM220, a fully mechanised longwall system for continuous mining of flat and tabular deposits of hard rock minerals. It features a hard rock shearer that uses Cat Activated Undercutting Technology. A low-profile hard rock chain conveyor and hard rock hydraulic roof supports complete the system, which delivers simultaneous cutting, loading and hauling. The technology is the first commercial continuous mining and hauling system for underground hard rock applications. It replaces conventional drilland-blast operations in low heights, ranging from 1.3 to 2.0 metres and in bedded deposits such as platinum, copper, and gold. It follows the seam and increases the ore mined while minimising dilution. It also reduces health and safety risks as fewer people are needed underground. The electrically powered rock cutter and hard rock conveyor have no exhaust emissions, and there is no need for explosives use in the production cycle. According to Cat, its Cat Activated Undercutting Technology is the key to the success of the cutting machine, the HRM220. The design of the two cutting heads enables the picks to attack the rock from a suitable angle. The activation movement enhances velocity, momentum and

impact of each pickâ&#x20AC;&#x201D;while moving the pick away quickly to minimise wear and heating. This results in reduced energy consumption and replacement cost of cutting tools. Each of the cutting units is powered by a 132-kW motor and can cut rock exceeding 120 MPa uniaxial compressive strength. The haulage speed can be up to

AUSTRALIANMINING

six metres per minute, depending on the rock, and, in combination with a cutting depth of 100 mm, can deliver high production rates of approximately 160 tonnes per hour. The cutting units can be positioned at different heights to increase the productivity of a single cutting sequence. The HRM220 incorporates electronic modules that enable control, monitoring and protection of the miner. Remote operation and diagnosis of major components can be done from the operator cabin via on-screen information and data can be transferred to a surface location for analysis when needed. The mainframe protects electrical equipment and hydraulics from cutting and haulage forces, enhancing reliability and the systemâ&#x20AC;&#x2122;s life. The cutting system has a total weight of 41.0 tonnes. The HRC30 Hard Rock Conveyor is designed to transport rock in low

cutting heights. A single flight bar chain moves the apron pans across the length of the cutting face as they ride on the line pans. The apron pan system ensures reduced wear when moving abrasive rock. The number of line pans can be varied to suit different face lengths up to 100m. The conveyor uses high-strength steel for long service life and reliable operation. The HRS1220 Hard Rock Roof Support is specifically designed for the Rock Straight System. The two-legged shield incorporates a solid base connected with an advancing mechanism on each side of the base. The supports feature a working range of 1060 to 2155mm with a yield load of up to 2599 kN. The Cat PMC-R electro-hydraulic control system provides roof support automation, providing equipment monitoring and remote diagnostics and increasing productivity. AM

IT CAN DELIVER HIGH PRODUCTION RATES OF APPROXIMATELY 160 TONNES PER HOUR IN LOW CUTTING AREAS

SEPTEMBER 2016

EARTHMOVING EQUIPMENT

HITACHI LAUNCH NEW EXCAVATORS HITACHI HAS DEVELOPED A NEW SERIES OF EXCAVATORS WITH TRIAS SYSTEMS.

itachi Construction Machinery has released the new ZAXIS-5 series excavators into Australia. The new ZX-5 range comprises a series of 13 excavator variants in total, designed to maximise performance, operator comfort, efficiency, reliability and overall productivity. The machines range from the smaller ZX130 with an engine rating of 73.4kW and operating weight of up to 14,500kg, to the higher end of the scale with the giant ZX890 model, which has an engine rating of 377kW and operating weight of 85,100kg. Additional models include the ZX140W and ZX170W wheeled and ZH210LC hybrid excavators. “Equipped with the innovative TRIAS or redesigned HIOS III hydraulic systems, the ZX-5 series will provide higher yields with better fuel consumption compared to the previous model. The result is simply lower fuel costs, with no compromise on productivity, which over time makes a big difference to total cost of ownership,” Frank Gili, HCA general manager of sales (Construction & Forestry), said. “In developing the innovative TRIAS system our engineers, based on feedback from our customers, fully understood the importance of improved efficiency without compromising productivity. This is where the new TRIAS 3-pump 3-valve hydraulic system comes into its own.

“Engineers put additional emphasis into the chassis design, including reinforcing it with strengthening brackets to ensure these are the most durable series yet,“ he said. “As far as maintenance goes, all areas for inspection and service are now more accessible than before, which is just clever thinking.”

Operator comfort has also been improved across the series. “The seat and console can now slide further back, offering expanded leg space and a more comfortable working environment for the operator,“ Gili said. “The console on the right side has been ergonomically redesigned. The new heated air suspension

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DEALING WITH WAGES AND EMPLOYMENT IN A FLUCTUATING MARKET DESPITE LOW COMMODITY PRICES, EMPLOYMENT IN THE RESOURCES SECTOR LOOKS POISED TO INCREASE, ALTHOUGH THAT MAY NOT BE THE CASE FOR SALARIES.

hile commodities such as gold and zinc have rallied this year, BHP’s massive $6.2 billion loss - a more than 400 per cent loss from its position last year - has added yet another peg in a string of declines in the resources sector. The miner signalled a 31 per cent year on year revenue drop to US$30.9 billion, with petroleum and coal accounting for most of the damage. Glencore also suffered a decline this year, recording an EBIT of US$875 million for the first half of 2016 compared to US$1.4 billion in last year’s corresponding period. This, coupled with commodity prices still at the lower end of the scale, may have hit the industry hard, but with emerging markets such as lithium and uranium, and zinc’s return, there are still some positive signs in terms of employment. Research from the latest Hays Salary Guide - a survey of nearly 2800 organisations comprising more than 2.6 million employees across a range of sectors throughout Australia - has identified the uranium market as a key area of employment for those in the mining industry. “While controversial, uranium

is touted as a major opportunity for Australian miners and with improved waste management and disposal and a growing risk appetite from state governments (with the exception of Queensland) we expect to see jobs growth in this space in 2017,” the report said. The Environmental Protection Authority (EPA) has already recommended the approval of two uranium mines in WA, Vimy Resources’ Mulga Rock project and Toro Energy’s Wiluna operations, and with South Australia potentially becoming the nation’s hub for nuclear power, employment looks to be on the rise. Employment prospects for geoscientists are starting to see signs of improvement, with research from the Australian Institute of Geoscientists (AIG) showing the unemployment rate has improved in the June quarter. It highlighted a 15.9 per cent unemployment rate and a 20.2 per cent underemployment rate, compared to March figures of 19.5 per cent and 23.4 per cent respectively. It is the first sign of improvement in the sector for two years. Nonetheless, unemployment rates still remain high and long term unemployment is a major area of concern amongst geoscientists.

AUSTRALIANMINING

The AIG research identifying the proportion of those without work for more than 12 months increased from 49 per cent to almost 60 per cent. Although AIG president Mike Erceg said the positivity in the employment prospects was welcome news, prolonged improvement is still necessary. “We need, to see improvement in the unemployment and underemployment rates over more than a single quarter before becoming too excited by the prospect of a turnaround in geoscientist employment opportunities,” he said. Western Australia’s Goldfields has created the majority of employment opportunities in the state, with several operations increasing both production and exploration. However, particular jobs, though much needed, are not high-paying, as the report states, “West Australian-based Geologists, Field and Lab Technicians are in demand but employers are not paying a premium for their skills. Employment is often offered on a short-term trial basis”. While this, again, highlights the difficulty geoscientists have in finding and retaining a job, it also points to further belt-tightening when it comes to salaries. The report stated 16 per cent of employers did not offer salary increases during the 2015/16 financial year. Those who did receive an increased salary, however, were barely given a significant sum – the majority receiving less than a three per cent increase – with the mining and resources sector listed among the least generous of all Australian industries. It went on to suggest that the sector is facing a salary decline as well. The guide identified different salaries earned in various roles in the mining industry, highlighting significant discrepancies from state to state. For example, the report indicates graduate mining engineers in South Australia earn between $55 – 75,000, compared to those in Western Australia receiving up to $100,000, while underground/

SEPTEMBER 2016

quarry managers in Queensland’s coal industry earn more than those in neighbouring NSW; earning up to $200,000 compared to $160,000. These figures could be distorted, however, by the increased use of contractors rather than permanent workers. The report revealed a 21 per cent increase in employers’ use of temporary or contract staff, reflecting Rio Tinto’s recent move to only hire contractors for their iron ore operations as part of a new recruitment protocol, [see pages 12 – 13 for more]. It is understood that under the new scheme, all external hires will be filled by Cat 1 contractors – with the exception of manager, superintendent and frontline supervisory roles – through the contract service providers Skilled, DT Workforce, and Workpace. This was met with backlash from mining unions who said the contracting roles are an insecure form of employment that comes with lesser wages and conditions compared to permanent positions. The Hays report has also emphasised the importance of gaining further skills or qualifications to remain in a job over the long term. “Blue-collar candidates are being asked to maintain their own tickets and qualifications and in many cases take steps to be dual trade qualified or multiskilled in order to futureproof their roles. This is particularly evident in South Australia and New South Wales as they continue to lose talent to the larger resources states due to a lack of opportunity. “As a result, South Australia has a severe shortage of some niche skills such as Rubber Liners and Belt Splicers. Underground and Haul Truck Operators are also required in the mid-west of NSW.” Although the report indicated a negative economic outlook for the resources sector - 42 per cent of respondents envisioned decreased business activity - emerging markets, and the creation of more mines could change it. As for the salary, we’ll have to wait and see. AM

PERSONNEL

HAYS RESOURCES & MINING WAGES METALLIFEROUS MINING ENGINEERING

Registered Mine Manager

Underground/ Technical Quarry Manager Services Mgr

Senior Mining Engineer

Mining Engineer

Mill Superintendent

Shift Supervisor Mill Operator

Metallurgical Technician

Laboratory Technician

180 - 250

160 - 180

140 - 160

100 - 145

130 - 140

110 - 120

75 - 105

75 - 95

75 - 85

QLD - Hard Rock

190 - 250

160 - 190

170 - 190

150 - 170

110 - 140

QLD

140 - 160

95 - 120

80 - 100

70 - 85

QLD - Coal

220 - 250

170 - 200

180 - 210

140 - 175

110 - 145

NSW

130 - 155

85 - 105

65 - 80

60 - 70

NSW

160 - 220

140 - 160

180 - 210

130 - 160

90 - 130

VIC

120 - 140

90 - 120

80 - 100

60 - 70

50 - 70

VIC

180 - 220

100 - 150

170 - 200

140 - 160

100 - 130

120 - 150

80 - 100

70 - 90

55 - 75

150 - 180

130 - 160

160 - 180

140 - 170

90 - 120

TAS

110 - 140

75 - 90

65 - 80

55 - 70

50 - 70

110 - 165

90 - 140

70 - 100

70 - 85

FIXED PLANT MAINTENANCE

Maintenance Superintendent

Maintenance Planner

Maintenance Supervisor

Mechanical Eng Mid level 3-7yrs

Electrical Eng Mid level 3-7yrs

TAS

150 - 200

110 - 140

130 - 170

120 - 140

90 - 120

180 - 250

150 - 200

160 - 180

130 - 170

110 - 150

Chief Surveyor

Senior Surveyor

Mine Surveyor

Graduate Geotechnical Mining Engineer Engineer WA

80 - 100

120 - 160

165 - 200

140 - 170

110 - 150

170 - 210

150 - 180

140 - 170

120 - 150

QLD - Hard Rock

75 - 100

120 - 160

130 - 160

120 - 160

120 - 150

QLD

140 - 180

100 - 140

95 - 135

100 - 140

QLD - Coal

75 - 100

120 - 160

130 - 160

120 - 160

120 - 150

NSW

160 - 180

100 - 130

130 - 150

90 - 120

NSW

60 - 90

130 - 160

150 - 175

120 - 150

VIC

120 - 160

100 - 130

90 - 110

80 - 110

78 - 110

120 - 140

90 - 110

100 - 130

90 - 110

100 - 120

VIC

60 - 80

110 - 130

110 - 150

90 - 120

75 - 110

55 - 75

120 - 140

120 - 150

110 - 125

90 - 120

TAS

105 - 130

85 - 105

80 - 105

75 - 100

TAS

60 - 85

105 - 130

95 - 120

85 - 115

70 - 90

130 - 180

100 - 140

115 - 145

70 - 90

120 - 160

140 - 160

135 - 155

90 - 135

METALLIFEROUS GEOLOGY - MINING

Chief Geologist

Senior Mine Geologist

Mine Geologist

Graduate Geologist

Pit Technician/ Geological Technician

200 - 250

130 - 170

90 - 135

70 - 90

70 - 95

QLD - Hard Rock

170 - 200

140 - 170

90 - 120

60 - 90

65 - 80

QLD - Coal

160 - 200

130 - 170

90 - 130

60 - 90

65 - 80

NSW

180 - 220

120 - 160

90 - 120

60 - 80

70 - 90

VIC

150 - 180

120 - 150

100 - 120

65 - 75

50 - 80

120 - 140

100 - 120

90 - 120

45 - 50

55 - 60

TAS

120 - 160

95 - 115

80 - 100

55 - 70

160 - 200

120 - 170

90 - 130

80 - 95

METALLIFEROUS GEOLOGY - EXPLORATION

Exploration Manager

Senior Exploration Geologist

Exploration Geologist

Field Assistant

175 - 220

120 - 160

80 - 120

70 - 95

QLD - Hard Rock

175 - 210

120 - 160

80 - 110

65 - 80

QLD - Coal

170 - 200

130 - 170

100 - 120

65 - 85

NSW

180 - 220

120 - 160

80 - 110

50 - 70

VIC

150 - 180

130 - 160

100 - 125

60 - 80

130 - 150

120 - 160

90 - 120

50 - 70

TAS

120 - 150

95 - 130

80 - 100

55 - 70

150 - 205

120 - 165

100 - 130

70 - 95

MINERAL PROCESSING

Process Engineer Senior Process Manager - Mid level 3-7yrs Metallurgist

Metallurgist

Graduate Metallurgist

180 - 245

110 - 160

130 - 170

100 - 140

75 - 100

QLD

180 - 220

90 - 110

120 - 160

80 - 110

60 - 75

NSW

170 - 190

80 - 100

100 - 130

80 - 100

60 - 75

VIC

160 - 190

85 - 110

110 - 135

85 - 100

60 - 75

140 - 160

95 - 120

110 - 130

80 - 110

60 - 75

TAS

150 - 180

70 - 100

100 - 125

75 - 100

55 - 70

170 - 220

100 - 130

130 - 160

90 - 120

60 - 80

AUSTRALIANMINING

SEPTEMBER 2016

PERSONNEL

Underground Supervisor

Jumbo Operator

Bogger Operator

Service Crew

140 - 160

115 - 140

90 - 120

Leading Hand

Mechanical Fitter

Electrician

Boiler Maker/ Welder

Instrumentation Technician

140 - 160

120 - 145

120 - 140

120 - 145

140 - 160

QLD

100 - 115

95 - 115

100 - 120

90 - 115

90 - 120

QLD

130 - 160

110 - 130

100 - 120

NSW

100 - 125

90 - 115

90 - 120

75 - 90

80 - 110

NSW

130 - 150

110 - 130

110 - 135

90 - 110

VIC

90 - 110

80 - 100

80 - 120

80 - 100

VIC

105 - 145

130 - 150

110 - 130

85 - 105

95 - 110

75 - 90

90 - 120

75 - 90

85 - 110

100 - 140

100 - 120

80 - 100

90 - 110

TAS

80 - 95

70 - 85

75 - 85

TAS

90 - 110

85 - 110

80 - 105

60 - 75

95 - 115

100 - 120

90 - 120

130 - 160

135 - 170

110 - 140

90 - 120

MOBILE PLANT MAINTENANCE

Workshop Supervisor

HD Fitter

Auto Electrician

Boiler Maker/ Welder

Service Person

OHS & ENVIRONMENTAL

HSE Manager

OH&S Manager/ Superintendent

OH&S Coordinator

140 - 165

120 - 145

110 - 140

100 - 120

170 - 220

140 - 170

120 - 145

100 - 120

QLD

130 - 160

125 - 150

120 - 140

100 - 115

95 - 150

QLD

160 - 185

120 - 160

95 - 120

80 - 100

NSW

105 - 145

80 - 110

90 - 115

80 - 120

85 - 100

NSW

180 - 220

140 - 200

90 - 130

80 - 120

70 - 95

VIC

140 - 180

90 - 120

80 - 100

70 - 95

VIC

90 - 125

85 - 120

90 - 120

85 - 115

90 - 130

80 - 130

70 - 120

80 - 100

140 - 170

120 - 160

75 - 120

55 - 90

TAS

80 - 110

75 - 100

65 - 85

70 - 85

TAS

130 - 200

120 - 180

100 - 130

90 - 120

130 - 160

125 - 150

100 - 120

150 - 220

150 - 170

80 - 100

65 - 80

Open Pit Supervisor

Excavator Operator

Dump Truck Operator

Driller

All-Rounder

Environmental Superintendent

Environmental Coordinator

Environmental

Training Coordinator

150 - 170

125 - 150

100 - 120

105 - 125

120 - 145

140 - 160

90 - 150

70 - 90

110 - 140

QLD

140 - 160

100 - 120

100 - 125

110 - 130

QLD

125 - 155

90 - 130

75 - 90

80 - 90

NSW

110 - 140

90 - 120

75 - 110

75 - 115

80 - 120

NSW

140 - 170

110 - 140

90 - 120

100 - 120

VIC

105 - 140

90 - 115

70 - 110

75 - 120

80 - 115

VIC

90 - 120

65 - 85

60 - 75

110 - 140

100 - 140

85 - 100

75 - 120

85 - 120

120 - 140

80 - 100

65 - 90

80 - 100

TAS

90 - 110

70 - 90

60 - 85

70 - 95

65 - 85

TAS

100 - 150

100 - 130

65 - 90

65 - 110

100 - 160

100 - 130

100 - 120

110 - 130

90 - 120

80 - 90

75 - 90

90 - 120

AUSTRALIANMINING

SEPTEMBER 2016

PERSONNEL

GEOLOGISTS CONTINUE TO SEE LOW RATES OF EMPLOYMENT AND GENERAL UNDEREMPLOYMENT, DESPITE IMPROVING CONDITIONS

INDUSTRIAL DESIGN

Engineering Manager

Principal/ Lead Engineer

Project Manager

Senior Design Engineer

Senior Project Project Engineer Engineer (EPCM) (EPCM)

Design Manager/ Chief Drafter

Senior Design Piping Drafter Design Drafter Designer

100 - 120

80 - 100

120 - 150

90 - 110

70 - 95

90 - 100

QLD

120 - 170

90 - 120

120 - 150

85 - 120

65 - 100

80 - 110

NSW

130 - 160

80 - 120

100 - 130

80 - 100

70 - 90

80 - 100

VIC

110 - 150

80 - 120

110 - 150

100 - 130

70 - 100

80 - 110

120 - 160

80 - 110

100 - 130

85 - 120

60 - 90

85 - 120

TAS

90 - 120

80 - 110

110 - 160

80 - 140

70 - 100

80 - 140

120 - 170

90 - 140

115 - 170

75 - 130

70 - 100

100 - 120

INDUSTRIAL CONSTRUCTION

Project Manager

Construction Manager/ Senior Superintendent Estimator

Planning Manager

Contracts Manager

Project Engineer (Civil/Mech/ Elec)

180 - 200

170 - 220

120 - 170

95 - 120

QLD

180 - 220

170 - 200

160 - 200

155 - 200

160 - 200

130 - 150

NSW

140 - 180

125 - 160

120 - 170

130 - 180

100 - 120

VIC

180 - 220

180 - 200

120 - 150

140 - 170

150 - 180

90 - 135

140 - 200

130 - 180

130 - 150

120 - 180

140 - 180

110 - 140

TAS

120 - 160

100 - 130

110 - 130

80 - 110

160 - 240

140 - 200

155 - 200

140 - 200

120 - 170

Estimator

Contracts Administrator Planner

Site Supervisor

Site Engineer (Civil/Mech/ Elec) Safety Advisor

Design Engineer

200 - 220

130 - 150

200 - 220

110 - 130

100 - 120

80 - 120

80 - 110

110 - 140

95 - 120

80 - 100

QLD

200 - 220

165 - 200

180 - 220

130 - 170

85 - 120

QLD

100 - 150

100 - 140

90 - 140

100 - 140

90 - 130

NSW

150 - 220

140 - 170

130 - 150

100 - 130

80 - 110

NSW

75 - 125

90 - 120

100 - 130

90 - 120

90 - 140

VIC

180 - 220

150 - 180

150 - 220

100 - 150

70 - 110

VIC

110 - 130

80 - 120

110 - 140

80 - 110

80 - 120

80 - 110

140 - 170

120 - 130

120 - 140

110 - 140

90 - 130

90 - 120

80 - 120

100 - 130

100 - 140

75 - 115

90 - 100

TAS

150 - 190

110 - 140

90 - 110

80 - 100

TAS

80 - 120

80 - 110

80 - 115

80 - 100

200 - 250

165 - 210

180 - 250

120 - 170

85 - 120

100 - 150

95 - 140

90 - 140

110 - 150

100 - 140

110 - 130

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SEPTEMBER 2016

2/9/16 8:41 AM

TRUCKS & TRANSPORT

A NEW LEVEL OF UNDERGROUND HAULAGE ATLAS COPCO HAS UNVEILED ITS LATEST ADDITION TO ITS HAUL TRUCK RANGE.

tlas Copco has given Australian miners a sneak peek at its latest underground haul truck, the MT65, ahead of its official unveiling at

MINExpo. It showcased the machine – known as Julia – in a special event in East Perth. The machine has been developed to provide an extra five tonnes of capacity per load, and designed with a swathe of new and improved features. “The MT65 is based on years of knowledge from the successful MT6020,” Atlas Copco said. “The built in reliability combined with higher capacity and high ramp speed leads to dramatically increased productivity. “To improve energy efficiency we have reduced fuel consumption and decreased running costs. “It’s the strongest, smartest, and most productive truck we’ve ever put to use in operations.” The truck has been tested to its limits, undergoing field trials in Western Australia, at St Barbara’s Gwalia mine, which runs more than 1620 metres deep, or a ten kilometre haul distance. According to Atlas Copco, these load studies – carried out with contractor Byrnecut – have seen

a serious increase in productivity performance compared to the existing fleet of Atlas Copco MT6020 underground haul trucks over the three month, 2000 hour long trial, where tonnes per kilometre, speed on grades, and payload capacities were tested. Wayne Symes, the Atlas Copco business line manager for underground, said trials had recorded a 10 per cent increase in carrying capacity and lower fuel usage than the MT6020 Byrnecut operator Steve Nascivera, who had been testing one of the machines (dubbed Sofia), said he “found

AUSTRALIANMINING

it to be very user friendly, and very comfortable inside the cab [but] the biggest advantage is the sheer amount of dirt that we’re bringing up each run”. “Our average is between 63 and 65 tonne,” he said, with Atlas Copco stating it is able to dump these loads in around 13 seconds. The dump box has a maximum 65 tonne haulage capacity, and is engineered for high productivity and reliable performance, Atlas Copco said, adding it has optimised angles and wear resistant steel which enables longer operational life and easier release of material.

SEPTEMBER 2016

The load weighing system presents information directly to the operators on the filling process, and to the outside via status beacon lights, allowing operators to maximise filling and reduce overload. The MT65 is also ready for the next stage of mining, and has been built to be automation ready, utilising Atlas Copco’s Rig Control System (RCS), and its Certiq telematics solution, which provide machine data and information in an intuitive easy to use HMI. Safety has also been in focus, with an ISO ROPS and FOPS certified cabin that has sound levels below 80 decibels. Cameras are located on the front and the rear of the vehicle to increase visibility and safety of those around the vehicle. An improved front axle suspension increases driver comfort, and is reportedly even better than on the MT6020 model. Maintenance is a key component in its design. The truck has “best serviceability in the segment with easily accessible service points and features to ease operation,” Atlas Copco said, with all daily checks reached from ground level. It is also equipped with a new tyre monitoring system. “The main filters are collected and accessible in the smart service bay.” The truck weighs approximately 46.3 tonnes, and measures 2.785 metres in height, has a width of 3.5 metres, and is 11.021 metres long. It is driven by a Cummins QSK19 EPA Tier 2 engine, with a power rating of 567kW, and has a fuel tank capacity of 844 litres. According to Atlas Copco, orders were booked for the truck before it was even unveiled. AM

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The countdown to MINExpo 2016 is underway—and CatMiningExperience.com is the only place to get an inside look at our plans. Sign up for exclusive email updates. Hear from Caterpillar Group President and MINExpo 2016 Chair Denise Johnson. Meet the experts who’ll be sharing ideas and expertise to help you control costs, boost production and squeeze more life out of every investment, every day. And check back often for new content, including more videos, event schedules and a one-of-a-kind mining experience giveaway. Visit CatMiningExperience.com to see it first.

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POWER GENERATION & DISTRIBUTION

ATLAS COPCO RELEASES COMPACT INVERTER POWER GENERATORS NEW COMPACT GENERATORS ARE MAKING POWER MOBILE.

tlas Copco has unveiled two new inverter power (iP) generators. The two models, the P 2000i and P 3500i, are the latest in the range of portable generators. Atlas Copco’s inverters use advanced electronics and magnets to ensure efficiency. An inverter, in essence, first produces high voltage multi-phase AC power; the AC power is then converted to DC. Finally, the DC power is inverted back to clean AC predictable power at the required voltage and frequency. Designed for daily use, or for frequent single jobs, typically involving handheld power tools, the iP portable generators are easy to operate, with a recoil start function that ensures fast activation. Fuel consumption is low due to variable speed control that adapts

engine speed to load conditions. Additionally, the generators can be connected and used in parallel to increase the overall power capability without requiring a larger generator. Incorporating fuel tanks of four and 11 litres respectively, the P 2000i and P3500i can run for up to six hours before refuelling. Despite their large fuel capacity, the generators are compact and sufficiently lightweight - at 21kg and 45kg - to be easily moved around sites. The generators are also fitted with noise-reducing canopies to keep engine noise levels at a level of around 63dBA, which is comparable with an electric razor. Thermal protection enables the generators to operate efficiently even in extreme weather conditions, while automatic voltage control (AVR) ensures clean, consistent and reliable power where it is most needed. The iP generators, together with the previously launched P generators,

provide an easy-to-operate solution for contractors seeking efficiency and reliability at the click of a switch. These generators sit alongside Atlas Copco’s larger portable generators, including the QEP range. Designed for more intensive use, with higher power levels and extended features, the QEP model is designed for rental use or larger work sites where the power needs to be shared. The additional safety features found on the QEP R minimise the risk of damage to the generator through misuse, while the model’s on-board differential circuit breaker provides

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further safety assurance. The final model in the range, the QEP S, which features a noise suppression design, is ideally suited to urban environments where even lower noise levels are required for heavy construction activities. AM

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AUTOMATION & REMOTE CONTROL

THE PROTECTED MINING PLANT – USING AUTOMATION TO REDUCE RISK TO OPERATIONAL INTEGRITY IN THE SECOND OF A THREE-PART SERIES, SCHNEIDER ELECTRIC BDM PACIFIC SHANE AYERST EXPLORES HOW PROCESS AUTOMATION SYSTEMS CAN EVOLVE MINING PLANTS AND HELP ADDRESS THE PROCESS OPERATION CHALLENGES FACED BY MINING INDUSTRY TODAY.

lthough automation has enabled mining process operations to modernise, the sector still faces the challenge of increasingly complex threats to the integrity of systems, both internally and externally. More advanced process automation systems must be engineered with several layers of protection if a mining company is to ensure it has a truly ‘Protected Plant’. To ensure solid business continuity there must be a focus on the process-connection aspects of a system and how design elements can mitigate risks to operational integrity. Operational integrity can be defined as the capacity of the process system or plant to maintain its whole or unified state to ensure continuous production, business continuity, safety and security. Potential threats to a plant’s operational integrity that can affect the process system include: increasing speed of business, nonstrategic proliferation of big data, cyber terrorism or other attacks, natural disasters, industrial accidents, unmanaged implementation of new technology and poor planning. To address these threats it is possible to work backwards and recognise the characteristics of mining systems resilience. The system must have added reliability, protection from external forces and a means of fast, economical recovery if systems or sub-systems breakdown. Reducing risk to mining plant integrity involves eight key characteristics which provide protection to these automated systems.

1. High performance processors As Industrial Internet of Things (IIoT) technologies are adopted, the amount of raw site and supply chain data created grows exponentially. A modern process automation system must be designed to ensure that users have the processing power and communications bandwidth to

allow them to leverage big data as it begins to flood the enterprise. Mixing and matching capabilities preserves operational integrity by providing the flexibility to add processing power without needing to invest in a major system replacement. At the process layer, technology leaders in mining operations are already hitting the limitations of legacy process automation data processing throughput. Nevertheless, the problem for legacy processors is only going to increase as the proliferation of data producers below and data consumers above the automation system further increase the communications workload.

2. Multi-tiered historian

To realise the promise of big data in driving operational efficiency, all mining plants require a system to store and access historical data. For those operations with multiple locations, or plants running more than one brand of control system or historian, accessing all of this information places a strain on both information systems and operating personnel. A multi-tiered historian such as Wonderware Historian, can aggregate data from multiple historians up to a common parent. When such an historian is SQL Server-compatible, it can receive information from a wide variety of sources. Newer historians may support up to two million points in a single instance or even many more in the largest multiple configuration systems deployed by large mining operations.

3. Workstation level redundancy In traditional configurations, workstation users interact with data via a human machine interface (HMI), which sends requests to a server – and then fetches information from the controller to display for the user. With the advent of smart, connected cyber physical systems, it is increasingly the case that each workstation is configured to fetch at least some data AUSTRALIANMINING

SEPTEMBER 2016

AUTOMATION & REMOTE CONTROL

directly from the device or controller - if a workstation goes down, the user can still access needed data from another. This kind of agility drives resilience that is useful in many applications, ranging from immediate troubleshooting of process problems or disaster recovery, after issues that may have impacted workstations across a mine site.

4. Emergency shutdown level redundancy

Safety is always a top priority so safety systems require a high level of redundancy. Failure of a mining process automation system to properly

address safety is a resilient way that results in putting the people, the environment and the business at risk.

occur in a matter of minutes, allowing the plant to be back up and running with minimal service interruption.

cycle effects from conceptual design and development through to operation, maintenance and decommissioning.

5. System level redundancy

6. Cyber Hardening

7. Flexible system design elements

In state of the art systems, mirroring of operational control in remote backup locations provides end users with more capability to manage the availability of their applications, servers and equipment. In the instance of a natural disaster causing a system failure in one location of a mining site, such a system could fail over to a backup disaster recovery system mirrored on the other side of the world, or in the cloud. This can

With the increasing digitisation of mining operations, cyber security is a vital consideration and requirement which must be carefully considered over the entire lifecycle of mining assets. Mining operations must focus on resilience through the creation of multiple layered cyber security designs. These designs implement defence in depth and consider not only operational and network aspects but also human, physical and asset life

Proper system design from the commencement of a plant can have a major impact on the costs associated with engineering and implementation. Not only for the process control system itself, but also the development and rollout of high level mine management and optimisation systems that rely on process data. Flexible, open process control architectures that enable the managed flow of information increase the cohesion of process and supervisory control systems and decouple data flows between connected assets, process control and operational / enterprise level software. Such design has a major impact speeding up process engineering by eliminating a significant engineering bottleneck by reducing the co-dependence of instrument, process, SCADA, historian and MES engineering, testing and commissioning processes.

8. Controlled obsolescence

By managing and controlling obsolescence plans carefully, plant managers can expect to remove and replace aging and legacy operational assets near the end of their useful lives before they fail. Given the opportunity to replace and refit during off-hours, the benefits of business continuity far outweigh the costs of replacement. Developing a detailed asset lifecycle plan highlighting plant and equipment close to the end of its useful life gives mining plant managers the ability to maximise their return on investment for these assets while avoiding the consequences of aging systems. Automation system technologies cannot address every challenge overall faced by Australian mining but together they can help build a â&#x20AC;&#x2DC;protected plantâ&#x20AC;&#x2122; that allows those involved in the process-connected aspects of the system to their jobs in a more effective way. Advanced process automation offerings implement robust technology, wrapped in many layers of protection, which enables everyone in a plant to fulfil their roles more effectively. Advice and technologies from automation experts such as Schneider Electric help Australian mining companies every day to improve internal operations agility and efficiency â&#x20AC;&#x201C; increasingly important aspects in a volatile market beset by negative external factors. AM Keep an eye out for the next piece in the series: The Enlightened Plant and New Insights. AUSTRALIANMINING

SEPTEMBER 2016

LITHIUM

POWERING UP – IS A BOOM IN LITHIUM PRODUCTION AND DEMAND REALLY COMING? FACT OR FICTION – IS THE LITHIUM STORY ALL HYPE OR DOES THE INFORMATION SUPPORT IT BEING A COMMODITY THAT WILL, AFTER THE DUST SETTLES, CONTINUE TO ATTRACT ONGOING INVESTMENT AND DEVELOPMENT? DELOITTE’S TIM RICHARDS WRITES.

n a mining/energy and resources market where significant activity has been absent across most commodity players, in particular exploration and junior miners, the emergence of lithium has at least breathed life into this sector. For many, it is almost a moot point whether its potential is fact or fiction, as what it has done has re-ignited the entrepreneurial spirit that the commodities sector has been missing over the past few years. It has seen the badly needed injection of capital into the small to mid-end of the market that in turn creates new activity across the various market

participants and so the cycle starts and momentum gains. But the optimism is not just confined to the small to mid-end of the market. While some of the major global mining companies still consider the lithium market too small to arouse their interest, Rio Tinto has bucked that trend and recently said that its Jadar Lithium-Borate project in Serbia will be a strategically important project for its mineral business.

Overview of the current lithium market

As with any commodity, the facts about lithium centre on the economics of supply and demand. There has AUSTRALIANMINING

been much written recently about the factors impacting lithium demand. The major driver of the expected increase in demand is first the anticipated exponential growth in electric vehicles which use lithium-ion batteries and secondly (albeit at this stage to a much lesser extent) the use of lithium-ion technology for electrical energy storage systems. This can be attributed to one company - Tesla and the unprecedented demand for its electric vehicles and the promoting of the Tesla Powerwall. In the first week alone of the launch of its Model 3 electric vehicle on 31 March 2016, Tesla received more than 325,000 reservations. Reservations are now

SEPTEMBER 2016

nearing 400,000, even though first delivery is not expected until late 2017. There is of course more to it than the number of Tesla Model 3 reservations and Powerwall modules ordered. The last 10 to 15 years has already seen an increase in demand for lithium–ion batteries, with the ever-growing market for mobile phones, laptop computers, tablets and other rechargeable products. Interestingly though, even with this upsurge in electronic devices, the greatest usage of lithium today is still in ceramic and glass and other industrial products. To date the major suppliers have been able to readily deal with this increased demand.

LITHIUM

DEMAND FOR LITHIUM IS RISING RAPIDLY WORLDWIDE

the major producers who currently control, it is reported, 90 per cent of the market.

Size of the lithium market

While not knowing what the future will look like, at least understanding what it could look like will give some context to the lithium story. Of central importance is whether lithium-ion batteries will continue to be the preferred choice of ‘storage’ or be superseded by new and/or emerging alternatives. There is also the supply side and whether any barriers to entry will keep the supply of lithium firmly in the hands of

In 2015, the lithium market, using lithium carbonate equivalent (LCE) as a measure, was estimated to be approximately 170,000 tonnes. Of this, approximately 35per cent to 40per cent of lithium was used in lithium ion-batteries, with the balance being used in ceramic, glass and other industrial applications. There is a range of research forecasting growth in lithium demand to be between 270,000 to 340,000 tonnes LCE by 2020, with more than 50per cent being used in lithium ion-batteries. Looking further out to 2025, the research indicates the demand for LCE growing to between 500,000 to 600,000 tonnes, with demand for lithium-ion batteries accounting for 65per cent to 70per cent. It is not surprising, even when taking the lower end of the forecasts for LCE in 2020 and 2025, that this has created hype about the economics of lithium and whether supply will be able to match the ever-increasing demand. As the research suggests, the

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excitement around the lithium market is amplified when considering the impact on the demand for lithium if there is a significant take up in the use of electric vehicles and the continued successful development of electrical energy storage systems.

The electric vehicle

Understanding the impact of electric vehicles as a source of the increased demand for lithium is not straightforward. There are two categories of electric vehicles - the hybrid electric vehicle (HEV) and the fully electric vehicle (EV). The HEV uses an internal combustion engine as its main source of propulsion, whereas in an EV, the battery is responsible for all or most of the power consumption. While the HEV doesn’t provide any major anxiety for the driver, the EV historically does with anxiety over the amount of power and the distance range before charging is needed. Continued advancement in the technology is seeing this anxiety subside as the power and distance range is addressed. While increased uptake in HEVs will have a modest impact on the demand for lithium in the future, the real game changer for lithium is if there is a significant increase in the uptake of EVs in the future.

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This is because in an EV the power output from a lithium-ion battery needs to be significantly higher than a HEV (meaning it needs a bigger battery). This in turn means much higher lithium content in the battery and that content increasing as the power and range limitations are dealt with. On a relative comparison basis, there is approximately 10 times more lithium content in the battery of an EV than a HEV. Even though continued uptake in the use of HEVs will have an impact on the future demand for lithium, it is the prospect of the forecast uptake in EVs that is causing, by far, the biggest impact on the lithium market. While the take up of EVs has been modest, with 2015 production estimated to be 150,000 (which itself has nearly doubled since 2013), forecasts indicate that this uptake could increase to production of more than one million EVs in 2020. This level of production is estimated to require 75,000 tonnes of LCE (remembering that total lithium consumption across all applications in 2015 was estimated to be 170,000 tonnes LCE). Only time will tell whether the take up of the EV is more or less than forecast. The potential for ‘more’ is certainly creating high expectations. Again, while it remains uncertain, these

LITHIUM

expectations are not without some foundation as the world looks to the use of clean energy and governments around the globe continue to increase investment in both incentives and infrastructure to support the uptake in EVs. By way of example: • In late 2015 a requirement was set in China that all new residential buildings with parking spaces be outfitted with charging stations for electric vehicles and that at least 10per cent of large public buildings and parking lots also be fitted with charging stations. • There is continuing speculation in China that the government may introduce an air pollution levy in coming years to narrow the cost of ownership between EVs and traditional vehicles. • In June 2016, Norway proposed new laws to ban the sale of new petrol and diesel cars by 2025 and this is believed to extend to HEVs, which means only EVs will be able to be purchased from that time onwards. The major political parties who were previously unable to agree on this legislation have now reportedly reached an accord on these proposed laws and they are expected to be passed. • In April, the German government announced a €1.2b incentive program to boost the sale of electric vehicles, offering consumers as much as €4000 in rebates to help offset the higher price of

TALISON’S AUSTRALIAN GREENBUSHES MINE ACCOUNTS FOR A QUARTER OF THE WORLD’S LITHIUM SUPPLY

an electric vehicle. In making this announcement, the German Finance Minister said “the goal is to move as quickly as possible on electric vehicles”. The German government’s plan is to have more than one million electric vehicles on its streets by 2020. • The US government has rebate incentives of between US$7,500 and US$10,000 in place for the purchase of electric vehicles. This is to support President Obama’s objective for the US to also have more than one million electric vehicles on its streets by 2020.

Electrical energy storage

In looking at many of the lithium forecasts for 2020 and 2025, while electric vehicles have the single greatest impact, the next greatest impact (albeit far more modest), is attributed to the uptake in electrical energy storage systems. The use of lithium-ion batteries as the source of power across consumer electronics such as mobile phones, tablets, portable computers, power tools etc., has been generally well accepted. This has had and will continue to have an ever-increasing impact on the demand for lithium. But the real material upside for energy storage relates to grid scale storage and/or taking consumers off the energy grid. AUSTRALIANMINING

For the renewable energy sector, electrical energy storage has been the ‘holy grail’ and recent advancements and continuing research and development seem to be making this more attainable. Electrical energy storage potentially provides a solution, allowing renewable energy generators using sources such as solar and wind to continue to effectively supply power even when the sun is not shining or the wind not blowing. The impact this will have on the demand for lithium is still to be determined. While we see the advancements being made by companies such as Tesla and its Powerwall, (which uses lithium-ion battery technology), grid storage as an industry is still in its infancy. As such, the size of the potential impact lithium-ion technology will have in this market is predicted to be modest. While continued advancements in lithium technology will likely see it have a potentially significant role in the uptake of grid storage, the range of applications, conditions and other technical factors that exist suggest that other non-lithium technologies will also have a place in grid or large-scale storage. As an indicator of how electrical energy storage technology can disrupt traditional off the grid power supply, SA Power Networks announced in May 2016 that it would trial storage

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batteries in an effort to defer a $3m network upgrade. It plans to sell deeply discounted Tesla and Samsung home storage batteries (both of which use lithium-ion technology) to 100 households. As stated by SA Power Networks ”We have a looming network constraint. At some point we would have to upgrade the lines, so we are taking the opportunity to do this trial”. SA Power Networks will monitor the results of the trial to assess whether the use of storage batteries in residences will help deal with capacity constraints in the current grid network.

The supply side

Looking at the factors that will possibly impact future lithium demand is critical, but so is assessing the supply side. In 2015, the supply side was dominated by four major producers controlling more than 90 per cent of the market. Tianqi Lithium (the 51 per cent majority owner of the Talison Lithium mine at Greenbushes, which currently produces about a quarter of the world’s lithium supply) is the largest

LITHIUM

of the four producers. The other three producers are Albermarle (which by virtue of acquiring Rockwood holds the other 49 per cebt of the Talison Lithium mine at Greenbushes), SQM and FMC. Lithium can be sourced from brine - which is the dominant source in South America - and also from hard rock minerals. Brines are typically regarded as cheaper to extract, but can be more capital intensive and require greater lead times to production. Hard rock operations have higher operating costs, can be less capital intensive but - importantly - can have much shorter lead times to first production. Due to its much shorter lead time to production, it is considered that lithium sourced from hard rock mineral can respond more rapidly to price rises caused by increasing demand. It is commonly known that lithium is abundant and that there are fairly large numbers of both lithium mineral and brine deposits, although identifying deposits of sufficient grade and quantity has been a barrier to commercialising them, as have environmental

FULLY ELECTRIC VEHICLES – SUCH AS TESLA’S MODEL S – WILL ACCOUNT FOR THE MAJORITY OF LITHIUM CONSUMPTION

constraints, in particular with regard to brine deposits in South America. So while lithium is not resource constrained, the profitable extraction of lithium has been a challenge. However, technological advances are also playing a part in the potential supply of lithium. Traditionally, spodumene has been the dominant lithium-bearing mineral sought after and processed because of its higher lithium content. But advances in technology have the potential to significantly reduce the costs of processing and thereby potentially make other minerals with lower lithium content, such as lepidolite, more economic. How the supply side and both existing producers and new producers can respond to the expected increase in demand will go a long way to determining the future of many other emerging lithium producers. AUSTRALIANMINING

The emerging Australian producers

While we have mentioned the major players with varying degrees of capacity to increase supply, there are a number of other companies who have either started to produce lithium or will have by the end of 2016. This will ensure any continued upsurge in lithium demand will be met in the near term. Not far behind is another tier of companies that expect to begin producing in the next one to five years. Beyond this tier are a significant number of companies (including many junior explorers) joining the rush to be part of the lithium story. From an Australian perspective, the companies with Australian operations that fall into the more advanced categories include Galaxy Resources/ General Mining and its Mt Cattlin project and Neometals/Mineral Resources and its Mt Marion project. Both projects commenced mining in 2016. Pilbara Minerals’ Pilangoora project and Altura Minerals’ Pilangoora project

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followed. Both are at varying stages of completing a DFS. There are also many Australian companies in the initial stages of trying to identify lithium bearing-minerals and breathe life into their future aspirations of being a lithium mining company.

Fact or fiction (or both)

If the forecasts for the increase in the use of electric vehicles are correct, then it is quite realistic to expect a significant increase in the demand for lithium. This will only be enhanced if the demand for grid or electrical energy systems continues to gather momentum. The fiction or unknown side of this equation remains in the reality that only a very small percentage of those companies now claiming to be ‘in lithium’ will actually ever get to the stage of having something that represents a potential commercial lithium resource. That is not to say that most of them don’t have an important part to play in the lithium market because, as we know, without exploration, the next commercial resource will not be found. AM

DIGGERS & DEALERS

RISING GOLD, RISING MOODS AT DIGGERS A RESOURCES RECOVERY SAW ENCOURAGING MOODS AT THIS YEAR’S DIGGERS AND DEALERS

s Australia’s most successful mining event celebrated its 25th birthday, miners, brokers, explorers, services companies, and investors gathered from around the world to discuss the state of the industry, its future, and more importantly – make deals. The annual Diggers & Dealers event, held in Kalgoorlie, acts as a forum where the industry can come together to dissect the trends in mining, showcase their own developments and discoveries, and reveal how their company has performed over the last 12 months through a series of forums, as well as the large exhibition area. Unsurprisingly the event drew media from around the world, including German publications and tv stations, as well as CNBC. Gold was the rock star of this year’s Diggers & Dealers, at least according to Evolution Mining’s Jake Klein, but

nickel and lithium are the surprise winners of 2016. The majority of miners there were in the gold business, and nearly everyone at the event was convinced it demonstrated in part that the metal is edging its way back into a bull market. “There was a very clear message at Diggers & Dealers this year,” Far East Capital said, “the return of the bull market in gold is the strongest driving force in Australia’s mining sector at present…there were 43 presenters at the conference and 29 of them were gold companies.” It wasn’t just gold miners however, with the event also showcasing the Perth Mint’s Australia Kangaroo One Tonne gold coin, the world’s biggest and most costly, which contains about $60 million worth of gold. This year was much more positive than previous events; as has been well reported, Nick Giorgetta’s opening speech firmly stated mining is far from dead and buried, and even AUSTRALIANMINING

in the last few months has seen a strong resurgence. “It should be noted that there has been a reasonably strong upturn in most commodity prices since 1 July, and we can hope that this continues and provides the base for another year of strong performances from investing in resources companies,” he said. This positivity has been seen on the ground, with miners and suppliers demonstrating a renewed attitude towards the industry, with general consensus that the worst is over. One of the more interesting aspects was Rio Tinto’s presentation, on exploration, highlighting the changing focus in the industry away from that solely on production gains to the reemergence of exploration and early green-shoots for the next stage of the mining cycle. Rio Tinto’s group executive for growth and innovation, Stephen McIntosh, kicked off his presentation by stating Australia is long overdue for a new Tier 1 discovery, and while

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brownfields exploration has proven fruitful, new greenfield discoveries must be made. This was echoed by Giorgetta. “On the exploration front there have been many brownfield discoveries, and with companies committing more dollars to exploration, I am sure success will continue,” he said. However, “Greenfield exploration has suffered badly in the last few years and yet it is absolutely essential to the future of the resource sector.” McIntosh used his presentation to call on all miners at Diggers to come forward and talk to Rio Tinto on collaborating on the next Tier 1 discovery, repeating his line from last year: “We have our exploration cheque book ready for quality projects.” He also outlined new ways Rio Tinto is approaching exploration, and the new technologies it is trialling to ensure faster, more accurate exploration and surveying.

The event culminated in a gala dinner, along with a series of awards recognising those who excelled this year. The G.J. Stokes Memorial award went to Chris Bonwick, the man who helped lead Independence Group through its listing, the discovery of the Tropicana gold deposit and its eventual commissioning, and the takeover of Jabiru Metals. The Digger Award went to Fortescue Metals, after a stellar year where it rapidly drove down debt and its operational costs. This awarding was further justified later that month after FMG released its results, and was one of the few major miners to record an increase in revenues year on year, to the tune of 212 per cent. To date the miner has repaid around US$2.3 billion, with an existing net debt of $5.2 billion, and around $1.6 billion in cash on hand, FMG CEO Nev Power told Diggers & Dealers. However, it wasn’t just the financials where Fortescue was breaking ground. In terms of productivity, Power stated the miner has recorded positive results from its automated truck fleet, seeing a 20 per cent increase in efficiency compared to its manned fleets, adding they have moved around 200 million tonnes using its automated fleet of around 47 trucks at Solomon Hub. According to professor of mining engineering at the University of British Colombia, John Meech, this

rate is at the top level of automated truck productivity levels. When Australian Mining asked how they achieved these rates, when fellow iron ore miner Rio Tinto’s automated fleets are recording a 12 per cent production and efficiency increase over manned vehicles, Power said he did not know. “I’ve no idea,” he said. The Dealer of the Year award went to Evolution Mining, and was also further justified, as soon after Diggers & Dealers it revealed it was selling off the Pajingo gold mine, and had negotiated to receive 100 per cent of the gold produced from Glencore’s Ernest Henry mine, for $880 million. The Best Emerging Company award went to Pantoro for its Nicolsons gold mine, part of the miner’s wider Halls Creek project. Far East Capital said the project has gone from strength to strength, adding that geologists had in fact underestimated the site’s grade and are now recovering twice as much as they had originally expected. Further discoveries have taken its estimates to between 1200-1400 ounces per vertical metre. “It is a reaffirming coincidence that Pantoro was awarded the Digger’s Emerging Company of the Year award; all the boxes are being ticked.” Now the event has wrapped for the year, the industry once again prepares for the next Diggers & Dealers, and tries to forecast which metal will be the darling of 2017. AM

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Find out more at thermofisher.com.au Phone: 1300 735 295 Email: auinfo@thermofisher.com

THE EVENT HAS COME A LONG WAY SINCE THE 90S

AUSTRALIANMINING

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PRODUCTS

DOZERS EQUIPPED WITH REMOTE TECHNOLOGY RCT has successfully retrofitted a Caterpillar D8R with remote technology to adhere to new safety regulations. Alliance Resource Partners sought to make its dozers remote so as to comply with America’s new regulations on removing operators from dozers pushing coarse coal refuse into tailings ponds. While its Caterpillar D6T was a straight forward installation, its older model Caterpillar D8R was more complicated and deemed virtually impossible by other remote technology companies. However, RCT was able to install its ControlMaster Line-of-Sight Remote Dozer system (ATX2200). RCT Custom Projects manager John Androvich described the dozer installation as challenging. “It was a massive task as the D8R was about 15 years-old so it was all mechanically driven, whereas most new models we deal with today are now electric,” he said. The D8R needed extensive hardware to be fitted in order to achieve all functions remotely and the project required the company’s team to convert the machine to electric, before converting it to hydraulic, and then back to mechanical in some instances. The installation allows operators to remotely control the dozers; pushing slurry into the tailing pond from a safe distance, on stable ground, abiding by the new regulations. • Remote Control Technologies www.rct.net.au

THE INSTALLATION ALLOWS OPERATORS TO REMOTELY CONTROL THE DOZERS; PUSHING SLURRY INTO THE TAILING POND FROM A SAFE DISTANCE, ON STABLE GROUND, ABIDING BY THE NEW REGULATIONS

LUBER-FINER RELEASES ONLINE TRAINING PROGRAM Luber-finer has introduced Luberfiner University, an interactive online training program for distributors and point-of-sale associates in the heavy duty equipment industry. The comprehensive training tool, which can be accessed from any internet-connected device, educates users about the company’s filters and sheds light on the science

behind filtration technologies. Layne Gobrogge, director of Heavy Duty Marketing for Champion Laboratories, said, “In addition to providing users with a solid foundation about the basics of filtration, the training simplifies the more technical aspects of filtration technology.” Unlike traditional training programs that can be tedious and boring, the

program was designed to be approachable, engaging and interactive. The training modules educate users about heavy duty filtration and Luber-finer’s filtration solutions, debunks industry myths, and provides actionable sales tools; they feature interactive content presented in media-rich formats including videos, 3D product viewers, “click-to-flip”

presentations; and are organised in short 15-30 minute units, allowing users to pace their learning at a speed that works for them. More than 1000 people have already enrolled in Luber-finer University training since its launch in July. • Luber-Finer www.luber-finer.comNon nis am

DEWATERING PUMPS Atlas Copco has launched 18 new additions to its open frame dieseldriven centrifugal dewatering pump range. The expanded PAS range is suitable for multiple applications including dewatering on construction and mining sites, solids removal, drainage, and emergency situations involving flooding and shipping. The PAS open-frame system includes both wet and dry prime options, and the modular design allows many different configurations. The pumps provide a wide range of sizes, with performance levels from 105 m3/h to 630 m3/h, and discharge size ranging from 7cm to 20cm. The

PAS open-frame system comprises a centrifugal pump, semi-open impeller, and a large separator. This enables air to be separated from the liquid and sucked by the vacuum pump, allowing automatic priming. The dry prime variants offer rapid priming time and higher capacities, making them suitable for use over a longer period of time when there is a danger of running dry or experiencing an intermittent flow. Wet prime pumps are portable and cost-effective, suitable for applications with a consistent flow. The range benefits from mechanical shaft seals being set in an oil bath, which enables dry running capability AUSTRALIANMINING

without damage. A high efficiency hydraulic end lowers fuel consumption, while a high capacity diaphragm pump supports automatic priming. The semiopen impeller enables the pumps to handle solids of various sizes, without the risk of clogging. Additionally, all components are easy to access, allowing for simple servicing and maintenance. The wide range of sizes in the portfolio starts with the 6.4kW PAS3, a wet prime pump with a maximum flow capacity of 120m3/h, a discharge size of 7cm and a maximum head of 24.5m. It is able to handle solids of up to 40mm and benefits from an air cooling system and 4.5 hours of

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fuel autonomy. The dry-prime PAS8 operates at a head of up to 30m, offers a discharge size of 8ins and handles solids of up to 76mm with a maximum flow of 630m3/h. The PAS range has for several years been available in a dry prime, canopy version with 10cm, 15cm, and 20cm variations, handling flows up to 590 m3/h. The company also offers a range of portable, powerful and efficient electrical submersible pumps. The WEDA range can manage flows from 225 to 16.500 litres per minute with a maximum head of 85m. • Atlas Copco www.atlascopco.com

PRODUCTS

DOWN-THE-HOLE DRILL SYSTEM AUTOMATIC LUBRICATION DEVICE FOR BEARINGS

DELIVERS CROSSWISE FLUSHING THAT DOES NOT CREATE PRESSURE AGAINST THE GROUND

Sandvik ha s develop e d the Centrex Pro, a new down-the-hole drilling system designed with Spiral Flush to protect against the impacts of over-drilling. The Spiral Flush technology delivers crosswise flushing that does not create pressure against the ground, minimising overdrilling and risks of air escape. Less water is lifted to the surface

which helps alleviate the risk of disturbing marine deposits. The system’s back flush also reduces the risk of getting stuck in the hole. Spiral grooves prolong the drill’s service life, and an increased penetration rate improves flushing capabilities. Added to this is the Guide Center that decreases the risk of hole deviation through straight collaring. The system is suitable for drilled pile installation, slope drainage, anchoring, and stabilisation. • Sandvik www.sandvik.com

Schaeffler has released the latest series of Motion Guard automatic lubrication devices, an environmentally friendly method of keeping bearings adequately lubricated. The fully automatic series controls relubrication by continuously supplying a sufficient amount of fresh grease to prevent over-or-undersupply. It comes in single or multi-top versions, which can deliver grease to a specific location at intervals set by the user. It is also cost-effective as it replaces the need for an expensive central lubrication system •Schaeffler Australia www.schaeffler.com.au

VIBRATING SCREENS McLanahan has released the MD Vibratory Screen line of vibrating screens; compact, high capacity, dry screening unit for minerals. The screens handle larger capacities than traditional screens while occupying the same – or less – floor space. They can make multiple product sizes simultaneously as progressively smaller material sizes are separated from deck to deck. The screens are available in widths from 0.05m to 2m, with one to five screen decks depending on the application. They can handle feed sizes as large as 7.6cm and make size separations down to approximately 60 mesh.

Its design reduces the risk of pegging and blinding, while achieving high capacities due to its ability to make a separation at a given size using a mesh aperture of greater size. To provide a longer screen life, larger particles are removed by heavier, larger screens, while finer screens see only smaller particles and only a portion of the incoming feed. The line is efficient as it has a compact design, requires minimal maintenance, has low power requirements and processes product that is completely dust enclosed. • McLanahan www.mclanahan.com.au

BELT TRAINER FOR CONVEYOR TRACKING THE PIVOT AND TILT FEATURE ENSURES THAT THE BELT STAYS AWAY FROM THE STRUCTURE AND THE MATERIAL STAYS ON THE BELT WITHOUT THE USE OF SENSOR OR EDGE ROLLERS

AUSTRALIANMINING

Flexco has released the PTEZ Belt Trainer tracking idler for its line of belt trainers. Designed with the company’s “Pivot and Tilt” feature, it can be used in any application that requires tracking to prevent damage to the belt or conveyor structure, including singledirection and reversing belts. The Pivot and Tilt feature ensures that the belt stays away from the structure and the material stays on the belt without the use of sensor or edge rollers. The tapered ends on the roller drive the pivot and tilt mechanism, allowing the two forces to quickly move the belt back to centre. The belt trainer can be used on vulcanised or mechanically fastened belts in almost any medium-duty application, including wet and dry conditions, belts with edge damage or wear, and belts that are mistracking to one or both sides. Available for belt widths between 450 mm to 1200 mm, the belt trainer can be mounted as a standard “pull-up” mounting or on the clean side of the return side of a cupped belt. The adjustable mounting brackets ensure quick and accurate installation. The belt trainer also features a polyurethane roller cover, which ensures a lasting performance in even in tough conditions. • Flexco www.flexco.com.au

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PRODUCTS

HIGH REACH DEMOLITION MACHINE THE MACHINE HAS BOTH HIGH REACH AND DIGGING CAPABILITIES DUE TO THE PATENTED MODULAR BOOM SYSTEM.

Volvo Construction Equipment (CE) has launched its EC480E HR high reach demolition machine for heavy duty demolition. The machine has both high reach and digging capabilities due to the patented modular boom system. The system includes a hydraulic modular joint with hydraulic lock mechanism to release digging equipment and change from the high reach demolition boom to a standard configuration in a simple and swift operation. The new E-series machine increased better visibility, comfort and reach than its D-series predecessors. It has a maximum reach of 28m, and a maximum tool weight of 3.5tonnes. With the modular boom system, operators can fit a digging boom in

place of a high reach boom in under an hour, rather than taking a full day, maximising production time. Non-road diesel engines in construction and demolition machines are major contributors of PM 2.5 fine particles that may cause health problems such as heart and lung diseases, asthma attacks as well as other respiratory symptoms. As the machine is powered by a Volvo Tier 4 Final engine which meets the world´s most stringent emissions regulations – required for all Australian governmental jobs by 2018 – it is fully compliant. The machine has a hydraulic removable counterweight option, enabling easy detachment and installation of counterweights. A versatile undercarriage can be retracted for transportation or AUSTRALIANMINING

fully extended for ultimate stability. For dust suppression, four nozzles on the arm provide a fine mist that clears dust and cleans the machine. To achieve the correct flow and pressure for hydraulic attachments such as mowers, grinders, shears, crushers and tilt rotators, the machine can be factory-fitted with a variety of auxiliary hydraulics and drain lines. An attachment management system, controlled via a monitor, stores up to 20 different hydraulic attachment settings. In addition, Volvo CE offers a full range of quick couplers, including its dedicated S-type coupler, that are matched to Volvo’s bucket range to ensure high break-out forces at all times. It also picks up a variety of attachments from various manufacturers.

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The machine’s high visibility cab features a one-piece laminated front window, right hand window and LEXAN roof window to create a safe and protective operator environment. A frame-mounted falling object guard protects the operator and cab from falling debris, while doublethickness side doors on both sides of the superstructure protect coolers and pumps in the event of a side impact. Operators also benefit from the hands-on tilt function, allowing them to adjust the angle of their cab up to 30°. Two demolition arm mounted cameras display on an 8-inch monitor and provide further sight of the attachment. • Volvo Construction Equipment www.volvo.com

PRODUCTS

MINE SCHEDULING SOFTWARE

KINETIC ENERGY CONVEYOR BELTS Martin Engineering has introduced its new technology that uses kinetic energy from a moving conveyor belt to generate power to run electronic systems within a power station. The Martin Roll Gen System to create a self-contained mini power station that allows operators to run electrical monitoring systems and safety mechanisms. Operators are not required to maintain a special stock of conveyor rollers, since the generator can be employed on a variety of steel rollers. Intelligent monitoring systems for any conveyor system require power for extended operation. Due to the distances involved, cabled communication systems are not ideal, and therefore wireless communication systems are more advantageous. Options such as solar power are not well suited to the general conditions of a conveyor system, as monitoring devices are often required in an enclosed structure without access to sunlight, or for continuous operation during both day and night. “We found that we could draw energy from a moving belt by attaching an independent generator directly to one of the rollers,” said Paul Harrison, Global Engineering Manager. “This way, the conveyor could produce power without altering the structure of the system or affecting its physical configuration.” Being able to add a generator to a roller delivers the benefit of utilising the proven reliability of existing roller designs, while drawing power from the belt for a wide variety of electronic devices. Product engineers developed a design to accomplish this through the use of a magnetic coupling that attaches to the end of an existing roller. The outside diameter of the generator matches the diameter of the roll, but places the generator outside the material path to avoid the heavy loads and fugitive material that tends to damage existing design attempts. The roll generator is held in a fixed position by the roll support system, but is not normally required to bear any of the material load. In the new, patent-pending design, a “drive dog” is

attached to the end face of the roll that is resting on the generator, using magnets. The drive dog engages the generator through the outer housing’s machined drive tabs. The magnetic attachment ensures that electrical or mechanical overload does not force the roll to stop; instead the magnets will slip on the roll face. The conveyor roll loads are carried by the large support shaft in the generator, which does not rotate and is rigidly mounted to the idler support structure. The generator forms a lightweight driven unit that does not affect the existing roll in any way, except to be rotationally engaged via the magnets, and so draw a small amount of mechanical power in order to generate the electrical energy. The generator is sealed from fugitive material and forms an integral unit independent of the conveyor roll. The bearings of the generator are able to handle the conveyor belt load, as they are of similar size to the roller. • ESS Engineering www.esseng.com.au

IT CREATES A SELF-CONTAINED MINI POWER STATION THAT ALLOWS OPERATORS TO RUN ELECTRICAL MONITORING SYSTEMS AND SAFETY MECHANISMS

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Hexagon Mining has released improvements to its MineSight Schedule Optimiser (MSSO) in Version 9.6. MSSO is part of the MineSight Planning Suite and determines the most productive mining sequence to achieve the highest project profitability. The system satisfies a variety of project quality, quantity, market, and geotechnical constraints, as well as destination capacities, equipment resources, and economic parameters. Advanced integer programming engines are used to solve blending and scheduling problems. Version 9.6 supports stratigraphic models, also known as Gridded Seam Models (GSM), which are commonly used for flatlying deposits and metal vein deposits. Mining geometries (polygones or solids) can be imported into MSSO either from MineSight 3D viewer or from an existing MineSight Planner project. Through integration with MineSight Reserve, reserves associated with the geometries along with a list of mining seams available in the GSM are used for proper reserve allocation. The latest version introduces allows operators to define cashflow limits and enables customised benching with options for defining elevation range for polygonal geometries. It also features advanced constraints relaxation; fixed cost by phase and destination; has the ability to export cut geometry to MineSight 3D (MS3D) objects and MS3D End-of-Period tool; and can speed improvements for reserves calculation. • Hexagon Mining www.hexagonmining.com.au

PROSPECT AWARDS AWARDS PROSPECT

THE PROSPECT AWARDS AUSTRALIAN MINING PREPARES TO RECOGNISE INNOVATION AND EXCELLENCE IN MINING AGAIN.

he Australian Mining Prospect Awards are launching again, and this time it’s our ‘lucky’ 13th Annual night. Year after year Australian Mining seeks out the best technology, innovations, individuals and companies in the resources industry in an effort to recognise and reward their achievements over the last 12 months. Whether it is better production rates, higher efficiencies, clever design, smarter technology, or simply someone who comes in each and every day and gives 110 per cent, the Prospect Awards are a forum to highlight the achievements that have been made. And in the current mining and industrial climate, highlighting the successes being made across mining is crucial to demonstrate that it is still a sector which – despite the volatile commodities and high pressure markets – is still one that is forging ahead to become a better industry. At last year’s event, which saw protests outside from various environmental and activist groups, hundreds gathered to celebrate an industry which has been doing it tough. Innovation in safety; smarter ways of making mines more efficient and productive; and instituting better work processes

were all highlighted. Since our awards in October last year things have become even more stressed, meaning now, more than ever before, the industry needs to take a step back and celebrate their many achievements. With this in mind Australian Mining is opening nominations again for these awards. So nominate someone you know who is making mining a better industry, and recognise those innovators today. AM THE AWARDS RAN ACROSS 15 CATEGORIES

THE EVENING SAW HUNDREDS OF PEOPLE GATHER TO CELEBRATE MINING

UNIQUE TECHNOLOGY, INDIVIDUALS, AND MINING PROGRAMS WERE IN FOCUS ON THE NIGHT

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DON’T MISS YOUR CHANCE TO BE RECOGNISED AT MINING’S NIGHT OF NIGHTS - NOMINATE ONLINE TODAY!

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NOW OPEN

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For more information regarding nominations, please go to

www.prospectawards.com.au Platinum sponsor