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SERVING THE MINING INDUSTRY SINCE 1908
VOLUME 106/2 – FEBRUARY 2014
www.miningaustralia.com.au
NO.1 FOR MINING TECHNOLOGY AND EQUIPMENT Vehicles
LATEST TRUCKS Surface and underground
P.10
Personnel
EDUCATION Training your miners
P.14
Processing
Print Post Approved PP100008185
In-pit
Crushing and Conveying The alternative to trucks
NEW ALTERNATIVES? Pricing and processing
P.24
Prospect Awards
2014 LAUNCH Nominate today
P.32
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AM0214_003.pdf
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COMMENT
Mining The State of safety Australian
Cirrus Media Manufacturing & Electronics Group: Associate Publisher – Martin Sinclair Email: martin.sinclair@cirrusmedia.com.au Editor – Cole Latimer Tel: (02) 8484 0652 Email: ozmining@cirrusmedia.com.au Journalists – Vicky Validakis Tel: (02) 8484 0964 Email: vicky.validakis@cirrusmedia.com.au Brent Balinski Tel: (02) 8484 0680 Email: brent.balinski@cirrusmedia.com.au Alex Heber Tel: (02) 8484 0884 Email: alexandra.heber@cirrusmedia.com.au Group Sales Manager – Tim Richards Tel: (02) 8484 0829 Mob: 0420 550 799 Email: tim.richards@cirrusmedia.com.au QLD and SA Sales Manager – Sharon Amos Tel: (07) 3261 8857 Fax: (07) 3261 8347 Mob: 0417 072 625 Email: sharon.amos@cirrusmedia.com.au WA Representative – Jamie Wade Mob: 0435 945 868 Email: jamie@wadebusiness.com.au South Africa – Bob Stephen Stephen Marketing PO Box 75, Tarlton, Gauteng 1749, South Africa Tel: 27(011) 952 1721 Fax: 27(011) 952 1607 USA – Jonathan Sismey Cirrus Media 24th Floor, 125 Park Avenue, New York, NY 10017 Tel: (1) 212 370 7445 Fax: (1) 212 370 7441 Email: jsismey@ix.netcom.com Larry Arthur Cirrus Media Suite 203, 3700 Campus Drive, Newport Beach, CA 92660 Tel: (1) 949 756 1057 Fax: (1) 949 756 2514 Email: lharthur@ix.netcom.com Graphic Designer – Dave Ashley Production Co-ordinator – Tracy Engle Tel: (02) 8484 0707 Fax: (02) 8484 0966 Subscription Rates – Australia (surface mail) $140.00 (incl GST) New Zealand A$148.00 Overseas A$156.00 Reader Services – 1300 360 126
What else is there to say.
I
often this part difficult, sitting here, mulling over what to write month after month. But for this edition, it’s not surprising that I’ve got a topic; what else can I write about but safety on site following the series of accidents we’ve seen lately. In the last six months there has been a spate of fatalities and injuries, it’s true. However, this won’t be a typical demonisation, not in the slightest. Yes, there have been accidents, and it has the nation looking at the industry, but it is because so many serious accidents in such a short time is completely atypical. Mining, when it is done to the standards that the Australian industry holds itself to, is not risk free but it Cirrus Media is fairly safe. Tower 2, Level 3, 475 Victoria Avenue, Chatswood, No industry that deals NSW 2067 Australia Locked Bag 4700, Chatswood Delivery Centre, with the levels of heavy NSW 2067, Australia Tel: (02) 8484 0888 Fax: (02) 8484 0633 equipment constantly on the ABN 80 132 719 861 ISSN 0004-976X move like mining does has www.cirrusmedia.com.au © Copyright Cirrus Media, 2014 similar safety records. All rights reserved. No part of the publication may be In 2012 there was not reproduced or copied in any form or by any means without the written permission of the publisher. a single fatality in Western Australia. This is how it should be. Mines operating to the Average Net Distribution right standards, and balancPeriod ending Sep 2013 8,031 ing safety with production. Printed by Bluestar Print 83 Derby Street, Silverwater, NSW 2128 (And keep in mind that Tel: (02) 9748 3411 2012 was when there was a Published 12 issues a year huge boom in construction right across mining, at least A M 0 2 1 4 _ 0 0 0 _ K I N in -the first 1 0 half 2 0of1 the 3 - year.) 1 2 - 1 And to be frank, this is
www.miningaustralia.com.au
Comment Cole Latimer ozmining@cirrusmedia.com.au how a lot of mines around the country are. The right risk management and safety procedures are ensuring that these workers have the safest shifts they can. But again, management only plays so large a part. Some accidents are avoidable and rules have been put in place to stop actions from being carried out on site, such as having mo-
bile phones in haul trucks, yet some operators still do. These are accidents just waiting to happen because someone decided the rules did not apply to them. Others are just tragic accidents: someone pulls out on to a haul road in their LV, doesn’t look properly and is hit by a haul truck that doesn’t have time to stop. And yes, some are just
mismanagement from the top down but not every accident is. Australia is a nation that others look to for safety benchmark. We lead the world, and hold ourselves to a higher standard. Which is partly why any death, let alone a spate of them in a relatively short time period, causes such shock in the industry. This is a new year and while some incidents have occurred the industry will, without a doubt, work to make it a safer year. And that’s all I can hope for. Well, that and a reversal on pricing trends.
FRONT COVER
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ON the front cover of this edition we’ve featured the in-pit crushing and conveying system Metso recently installed at Boral’s Peppertree quarry. The automated system is the largest in the Southern Hemisphere and was installed as an alternative to trucking the aggregate out.
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AM0214_004.pdf
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Contents The quarry of the future?
Februar y 2014 issue
The scoop on underground mining
New hard rock LHDs….p12
Reaching Generation Y
How mobile in-pit crushing and conveying will change quarrying....p16-22
The gamification of training….p14
Features MINESITE VEHICLES Top of the bell curve The latest articulated trucks ........................ p10 MINERALS PROCESSING Going for gold Greener ways to process and recover gold ... p24 The scale of the problem Automated processing plant pipe maintenance ................................................ p26 Indonesia bans export for processing How will Indonesia’s foreign processing ban affect the region? .................................. p27 4
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VICTORIAN SPOTLIGHT Victoria cuts red tape Is it too late for Victoria’s own mining boom? ......................................................... p28 MOTORS & DRIVES How to choose between synchronous and induction motors Which is the right motor for your operation? ................................................... p30 PROSPECT AWARDS LAUNCH The 11th Annual Australian Mining Prospect Awards Be a part of it today .................................... p32
EXHIBITIONS A trifecta of mining trade shows Exhibitions booming in Central Queensland ................................................. p37
Regulars INDUSTRY COMMENT ................................. p6 NEWS ........................................................... p8 PRODUCT SHOWCASE .........................p34-35 JOBS ........................................................... p36 EVENTS ...................................................... p38 www.miningaustralia.com.au
AM0214_000_ATL
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The New Scooptram ST18 Enjoy the ride!
The greatest ride in the mine The all new Scooptram ST18 is smart, hard working and easy to like. By combining advanced technology and smart features – the Scooptram ST18 means a big move for safety, maneuverability, comfort and productivity in underground operations. It’s the greatest ride in the mine. Enjoy the ride! Design your own Scooptram ST18 on StyleMyST18.com Atlas Copco Mining and Rock Excavation Australia Freecall: 1300 366 880 www.atlascopco.com.au
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INDUSTRY COMMENT
Has Fair Work Commission
“METH’D” UP? A
recent ruling by the Fair Work CommisDrug testing on site isn’t just about sion has banned the you, but the safety of the use of urine tests for the detection of drugs and alcopeople around you too. hol for workers at the NSW The Dirt writes. Government-owned electricity network company Endeavour Energy. The commission labelled the use of urine tests “unjust and unreasonable” in a case which could have wider implications for a range of industries, including mining. The Electrical Trades Union said the decision confirmed two previous court rulings that found the use of urine test was unfair because it could detect drug use from days earlier, rather than more recent use that could lead to impairment at work. ETU NSW deputy secretary Neville Betts said the decision highlighted that the role of drug and alcohol testing in the workplace should be impaired in their abilities, But is what workers do be about identifying potential urine tests unfairly moni- on while they’re not workimpairment, rather than dis- tor workers’ private lives by ing really just their own busiciplining staff for private ac- potentially showing a posi- ness? tions taken in their own time. tive result even where a subMine sites are dangerous “While oral testing accu- stance may have been used places to work at the best of rately identifies recent drug many days prior, in a private times, with heavy machinery M0 2 1 4 _ 0 0 0 _ B O C 1 2 0 1 4 - 0 1 - 2 0 T1 3 : 5 1 : 0 4 + 1 1 : 0 0 use,A where an individual may capacity.” and equipment a staple in
any project – do we really want people with drugs in their systems on Australian mine sites? Some argue that what people do on their days off is their business and if they want to smoke a cone or take
a hit of meth they should be able to do so as long as their actions do not affect their ability to work safely once back on the job. We say bollocks to that. In a society where having a job is a privilege and not a right, the timeline around when a person took something and whether it is still showing up their system even though they are not still directly impaired is of little consequence. Don’t know about you but I wouldn’t want to work with someone who had a bender at the weekend and then turned up to work feeling ‘fine’. Isn’t this just like getting behind the wheel after a few drinks feeling OK but being pulled over and blowing 0.07? While we don’t suggest urine tests should be used as a tool of control – we do think that if you have residual drugs tracing through your blood you should not be allowed to work on a mine site, ever. For your sake, and the sake of people around you.
A Member of The Linde Group
BOC is your leading partner in mining At BOC, we understand the knowledge, expertise and process needed to succeed in the mining industry, and we’re proud to play an important role. Whether you’re talking about oxygen, nitrogen, specialist gases or LPG and LNG in bulk, onsite or compressed supply; patented gas processes designed to enhance extraction, production as well as reduce the use of reagents; or welding and safety equipment and training programs — we’re there. You can count on our reputation and commitment to service and safety because your business is important to both of us. To find out more, call 131 262, visit your local Gas & Gear® retail outlet or boc.com.au
BOC Limited, Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia contact@boc.com | boc.com.au | 131 262 BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2014. MP13-0351-1|ML|AM|0214
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facebook.com/bocsouthpacific
www.miningaustralia.com.au
AM0114_005_SAN
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DRIVING TECHNOLOGY. DELIVERING PRODUCTIVITY. THIS WAY! Deep down it’s all about power, performance and productivity. And this is exactly what Sandvik’s new generation of underground trucks is designed to deliver. With the new TH551 and TH663 you can now transport more tonnes than ever before – faster, safer and at less cost. Innovative technology is the driving force behind every feature and the result is probably the safest, most reliable and most intelligent hard-rock hauling truck ever made. Join the movement toward The Future of Mining. It’s This Way: sandvik.com/th551 • sandvik.com/th663 SANDVIK MINING Part Sales 1800 1 7263845 | General Enquiries 1300 1 7263845 info.smc-au@sandvik.com | www.mining.sandvik.com/au
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AM0214_008.pdf
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HEADLINES
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. Roy Hill workforce doubles
manufacturer POSCO announced it will offer up its 12.5 per cent share in Roy Hill Holdings as collateral for the massive Pilbara iron project in a deal worth 1.49 trillion won ($1.4 billion). While in December the Korea ExportImport Bank agreed to offer up $1.12 billion for the mine’s development. The US government owned ExportImport Bank also gave approval for $US694m ($737m) in financing for the project. The Roy Hill project has awarded $3 billion worth of contracts for the development of the mine as it pushes to commence production in September 2015.
with the Rural Fire Service. In statement the corporation said “the increased fire risk posed by a large group of people in the forest and obstruction of forest roads required for emergency access” was the reason for the closure. “The fire hazard in the area is particularly concerning as a result of low rainfall and high temperatures recently leaving the forests very dry. We can’t take risks when it comes to safety,” it said. “Signs have been erected and people occupying the site were informed of the closure yesterday and asked to leave the forest area.” Front Line Action on Coal have set up a camp in the area for more than 500 days in protest of Whitehaven Coals Maules Creek mine project.
It is estimated 1700 people are now working on Gina Rinehart’s Roy Hill project as the next phase of construction ramps up ahead of debt package deals. Equity partners of the project have approved the go-ahead of the next stage of works which has seen an influx of construction workers descend on the site. Samsung and major subcontractors including John Holland, BGC Contracting, Forge Group and NRW Holdings have been notified of Australian Mining gets the the plan to forge ahead with the latest news every day, providing construction of the mine. mining professionals with the The news comes as the project Protesters force closure up to the minute information continues to seek loans and finance of forest over fire safety on safety, news and technology agreements from major partners as The Leard state forest has been for the Australian mining and it tries to raise $4 billion in funding closed by the Forestry Corporation resources industry. from export credit agencies and an of NSW amid risks posed by the BGC wins $100m iron ore additional $3 billion from commercial Maules Creek mine protesters in the decided to close the forest until the contract banks. end of March after receiving a letter case of a fire. A M0 2 1 4 _ 0 0 2 _ R E E _ R 1 2 0 1 4 - 0 1 - 2 9 T 0 9 : 2 7 : 0 7 + 1 1 : 0Mining 0 and civil contracting firm BGC In November Korean steel from NSW police and holding talks The Forestry Corporation of NSW has been awarded a $100 million
contract to restart operations at Arrium Mining’s South Australian Iron Knob mine. The four year contract to kick start operations at the Whyalla site will include the development of two new pits, Princess East and Princess West, as well as the reopening the established Monarch pit. The company said it will also complete initial cutbacks at each of the pits. Arrium Mining recently undertook the first blast in the area in more than 15 years. Both Arrium and BGC have worked together for over a year at the miner’s South Middleback operations where the contractor provided mining plant and maintenance services, ore excavation and haulage. BGC Contracting’s chief executive Greg Heylen said the Iron Knob contract represents a substantial addition to the company’s existing contract with Arrium.
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Take Advantage of Bendigo’s Engineering and Design Capability in Mining
Bendigo Manufacturing & Mining Equipment Group
Customer focused solutions provider. Supplying the Mining Industry
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To find out more, visit www.bendigomme.com Supported by
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MINESITE VEHICLES
Top of the BELL
CURVE
The first in a new series of articulated trucks is hitting Australia.
The trucks are designed with hill start assist and vertical tip angle safety monitoring, Hitachi says.
A
s the cost of fuel rises, and the rebate tax scheme fails to support the growing demand of many operations, operators are look to more fuel efficiency from their vehicles, without sacrificing payload. One Australian quarry, EB Mawson & Sons’ Lake Boga Quarry, has looked to Hitachi’s new Bell B30E articulated dump trucks to address these concerns. The operation is the first in Australia to receive the trucks, according to Hitachi. Jim Gardner, Hitachi Construction Machinery Australia’s national product manager – articulated dump trucks said the “new B30E is a showcase of Bell’s approach to design, [as] demand for trucks that are more fuel efficient, yet haul higher payloads, continues to drive product advancement in the ADT markets”. The trucks were initially launched in to Australia late last year, with a new design and features advanced emissions technology for rapid engine response and better cold-start performance, faster haul cycles, and most importantly better fuel efficiency. Purpose built for harsh conditions found on mine sites, the E-Series incorporates central oscillation, 10
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high suspension travel on all axles, and a balanced weight distribution which provides greater agility across uneven mine surfaces. Gardner added that “safety is always a priority for quarry operators and the new B30E is no exception”. “Incorporating hill start assist and vertical tip angle safety monitoring, the new trucks are also equipped with onboard load weighing and
keyless start as standard.” EB Mawsons & Sons’ Lake Boga Quarry manager Darren Colville added that “safety is our number one priority, and the Bell truck delivers when it comes to safety features, with everything from reverse cameras and mirror packages to onboard inclinometer and weighing systems”. It has dual engine braking coupled with automated transmission re-
The trucks are designed to be more fuel efficient as well as able to haul a larger payload.
tardation which contributes to greater retarding power an in turn reduced brake wear. The retarder power can be adjusted to ensure a controlled descent in most conditions. The articulation joints are reinforced while the chassis is built from high-strength welded alloy steel, which provides greater overall durability while lowering machine mass and reducing powertrain and structural stress. Colville explained that its articulation was a major factor as “at Lake Boga we prefer to operate articulated trucks due to bench width requirements”. “These trucks allow us to extract more from the quarry; Bell’s new design makes it easy for our operators when manoeuvering in and out of the pit. “They also enjoy the cabin and the smoother ride.” The cabin comes with sound suppression, ergonomic controls, and a greater operator visibility. The B30E is driven by a Mercedes Benz OM 926LA engine which gives 240kW of gross power and has a bin volume of 17.5 cubic metres with a rated payload of 28 000 kilograms. www.miningaustralia.com.au
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Tough, Reliable, Hardworking… That’s the Difference
At Texcom, we’re a close knit team. We rely on each other to get the job done on time and on budget. It doesn’t matter if we’re working on mining or civil projects, the goal is the same. That’s why we trust BKT Tyres. Just like the rest of us, they’re tough, hard working and really perform when the pressure is on. We have fitted them to our 40 tonne articulated dump trucks and wheel loader and haven’t looked back. They deliver good wear rates, low cost per hour, low cost per millimetre and great performance in a variety of conditions. Add to that great aftersales support from the team at TFI Earthmover and you’ll start to understand why BKT has quickly become a valued member of our team. Michael Rose, Maintenance Planner, TEXCOM
For further information on BKT contact TFI Earthmover on 1300 916 556 or visit tfiearthmover.com.au
NCATF/048
We Go The Distance
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MINESITE VEHICLES
MINE
SPEC VEHICLES To drive your dollar further
The scoop on underground mining Atlas Copco has launched a new LHD.
A
Call us on 13 27 27 today Budget has a wide range of mine-spec vehicles available in all of Australia’s major mining regions. To discuss your mine-spec fleet requirements, please call your nearest Budget location on 13 27 27 today. Plus earn Qantas Points or flybuys points on eligible rentals.ˆ
^Membership and points are subject to the terms and conditions of the Qantas Frequent Flyer program. A joining fee may apply. For more information about earning Qantas points on car hire see qantas.com.au. Standard flybuys terms and conditions apply and are available at flybuys.com.au BUDG1248MM
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s grades decline and open cut mining becomes more intensive, a greater number fo operations are looking to make the shift underground whilst at the same time keeping their scale. Looking to fill this gorwing demand Atlas Copco has launched a new 18 tonne underground loader for larger operations. According to the company its new Scooptram ST18 has been created for development work and production mining and “completes Atlas Copco’s range of underground loaders in this segment”. Atlas Copco explained that the LHD has been designed to work in conjunction with Atlas’ 60 tonne capacity mine truck MT6020. Ben Thompson, Atlas Copco’s product manager, stated that “the optimised bucket means better muck pile penetration, faster acceleration, and faster dumping”. “The result is a better load factor on the truck and, in the end, a higher tonnage per month.” Additionally the Scooptram ST18 and the MT6020 mining truck share common parts and control system components, cutting down the costs of ownership and parts storage. Its bucket and boom design combined with variable displacement pumps provide safer and efficient operations. This, in addition to an in-built Atlas Rig Control System, results “in superior muck pile penetration, less wear and tear on the machine, and an overall faster and more productive loading cycle” the company said. Its cabin is FOPS and ROPS ap-
AustralianMining
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proved with extra leg room, whilst its control layout has been ergonomically optimised. Visiblity has been raised for the operator, with abetter line of sight even in the rear thanks to a sloping design and shorter power frame structure. The Scooptram ST18 is designed with a number of safety features such as automatic brake testing, protection guards, redundant steering systems, fire suppression, and is equipped to run semi-autonomously or via remote control. Atlas went on to say that “the new loader [also] offers many sustainable solutions that contribute to maximised uptime and a longer service life”. “For example, automatic ride control and automatic declutch to increase the lifespan of the equipment and to reduce spillage from the bucket. “Automatic traction control reduces tyre wear and fuel consumption and the addition of soft stops on the boom, bucket and steering which reduces wear and tear on the machine.” The ST18 also comes with additional service products such as RigScan, an advanced audit service product, that provides operators a realtime, non-instrusive overview of the machinery’s running condition and performance, while a remote monitoring system presents production and maintenance data through a user-friendly web app. This web app allows off-site personnel to measure the performance of vehicles and monitor operations at the site. www.miningaustralia.com.au
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TM
LOAD VOLUME SCANNERS
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PERSONNEL
Reaching Generation Y New training techniques are helping to train new miners in a more cost effective way. Geirean Marcroft* writes.
T
he Australian resources industry continues to be troubled by low productivity, skills shortages and the loss of valuable company knowledge through retiring employees and the high churn of contractors. In this fast changing and technology driven industry, the demand for a highly specialised workforce has amplified, sending a wave of urgency through the industry. Leading resources players are now looking to “gamification” one tool in their arsenal to satisfy skilled labour demands in an interactive, cost-effective and accessible way.
Gamification defined
Gamification – applying game elements and game design techniques to solve business problems – is a relatively new trend that many organisations are yet to realise. Methodically, it extracts the essence of what makes games so alluring (e.g. a shared sense of purpose, challenge and reward), decodes the mechanics that make them work (e.g. personalisation, rankings and leader boards) and then applies these processes in a multitude of imaginative initiatives for retaining and encouraging talent. The revolutionary potential of gamification has become more obvious after the convergence of two major trends: the coming of age of Generation Y and the increased competition for talent among industry players. In the mining industry, gamification has the potential to deliver business objectives in two main ways. The first uses gaming strategies and mechanics to drive specific behavioural change, 14
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such as collaboration or safety-related habits. The second uses “serious games”, such as immersive 3D simulations, to develop critical skills and capabilities by giving participants the opportunity to learn through experience within a safe environment. Gamification in itself is a flexible strategy that can be tailored and applied to many areas of an organisation. It should be thought of as an “accelerator” to an existing talent and change management program.
Achieving an agile business structure and knowledge capital
Gamification encourages a culture of flexibility and responsiveness by driving behavioural change for adoption of new systems or more streamlined business processes. Mining companies are already implementing gamification in processes like security, by using games to help people learn security behaviours and their relevance; and travel by providing metrics around the travel behaviours of employees and contractors to reduce costs and streamline bookings. Gamification can also support the adoption of health and safety initiatives at mine sites to reduce onsite injury and improve working relations with suppliers, logistics teams and other members of the mining supply chain. In addition to compliance with operational change, gamification drives adoption of existing knowledge management tools and processes, as well as promoting the exchange of knowledge and ideas. As a way to combat the transient nature of the mining workforce, the use of
gaming principles encourages contribution, discussion and innovative thinking to capture critical operational knowledge and change the common behaviour of keeping knowledge to oneself, whilst rewarding those who share and support colleagues.
Attracting and retaining
The Australian resources industry is being challenged by a serious skills shortage and difficulty attracting and retaining talent. By using games and Gamification as part of development and education programs mining companies can showcase these with prospective candidates as part of the requirement process which appeals especially to Generation X and Y, who are quickly becoming a larger and more significant portion of the mining workforce. Successful gamification programs have also been observed to significantly improve graduate program outcomes and are recognised for presenting an innovative perspective to employee development which is an important differentiator in a cluttered market.
Executing a gamification strategy
Gamification is not a silver
bullet and should not be approached in a silo. Rather, gamification should be an evolution of the current governance models of learning and training departments that exist in mining companies today. Gamification requires a long term ‘business as usual’ mindset to achieve sustained results. Successful implementations leverage existing governance structures involving business operations, HR and health and safety departments. There are five key steps that mining companies should take to implement and harness gamification strategy: • Define business objectives and outcomes – determine the business problem you are trying to solve and the results you are you looking to achieve and their related metrics to measure outcomes. • Understand your audience – understand what motivates them and therefore what approaches will be most effective while taking into account existing incentive structures. • Define a gamification strategy – Determine what kind of gamification you will use and how this will be
integrated into the business. • Design and build – create your game design, mechanics and user experience with supporting programs such as onsite and offsite promotion, incentive and reward programs and necessary technology. • Pilot, deploy and operate – use a pilot to test and gather data so you can optimise the design and then rapidly scale the deployment with ongoing improvements for sustained behaviour change among staff and contractors. Gamification is fast becoming an important tool to manage today’s low productivity and high churn issues in the Australian resources industry. For a competitive industry heavily reliant on improving these factors, gamification incentivises more frequent coaching and supports organisational change towards critical behaviours that lead to improved proficiency and knowledge retention for today’s workforce. *Geirean Marcroft is Accenture’s Managing Director of Management Consulting, Talent and Organisation responsible for Accenture’s Talent Development and Learning offerings. www.miningaustralia.com.au
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australian owned
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QUARRYING, CRUSHING & SCREENING
The quarry of the
future? New mobile in-pit crushing systems are making a mark in Australian quarries.
A
s the price of fuel rises and automation becomes more of a fixture on every site across Australia, the case for in-pit crushing and conveying The Australian quarry industry’s 16
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demands for greater efficiencies as well as higher standards of safety and sustainability are driving a move towards in-pit crushing. Following an extensive design consultation process for its Pep-
pertree Quarry, Australia’s largest building and construction materials supplier, Boral, is now taking a lead in in-pit crushing. It has implemented a in-pit crushing solution at its new Pep-
pertree quarry, situated at Marulan South in the NSW Southern Tablelands. Due to become fully operational Continued on page 18 www.miningaustralia.com.au
AM0214_000_MIN
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MINPROVISE R E D U C I N G
PRECISION LASER
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T H E
ALIGNMENT
R I S K S
CLEANERS
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in 2014, the new quarry will supply the Sydney metropolitan area and greater NSW building and construction industries, with up to 3.5 million tonnes of aggregate products per annum. The Peppertree quarry is part of Boral’s Sydney Aggregates Project, which will address the anticipated depletion of raw material reserves at the one hundred year old Penrith Lakes Scheme in Sydney, of which Boral are a major shareholder. Peppertree will ensure that Boral maintains its competitive position as a leading supplier of quarry products for many years to come. Sydney Aggregates Project executive manager David Bolton, explained the significance of the new development. “We have over 80 million tonnes of proved resource at Peppertree and over 1.8 billion tonnes of inferred resource on land owned by Boral in the Peppertree area. This puts us in a great position for sustainable long term supply of high quality construction materials into Sydney and the surrounding areas,” he said. In addition to the Peppertree quarry, M Athe 0 2$200 1 4 _million 0 1 2 Sydney _ G R AAg-gregates Project includes new rail in-
frastructure in and around the quarry, a new manufactured sand plant at Boral Cement in South Marulan and a new rail transfer terminal at the Boral Maldon Cement Works near Picton NSW.
Why mobile in-pit crushing?
Construction of the new facilities at Peppertree started in July 2011 after more than a decade of planning. A risk assessment of the crushing process led to the selection of in-pit crushing as the safest and most efficient option for the new plant. Boral site manager, Steve Parsons said that the use of in-pit crushing for quarry applications has been a trend in Europe for some time but is relatively new in Australia, wiht a few mines such as Rio Tinto’s Clermont already running a system. “Boral is now looking to optimise its quarrying process and get away from the traditional load and haul methodology where you have a large number of trucks and people moving between the blast site and the fixed crushing plant.” The mobile crushing solution implemented at Peppertree has allowed Boral to significantly reduce its mobile fleet with its associated fuel consumption, 1 2 0 1 4 - 0 1 -safety 1 6 Trisks 1 0 : and 0 8 : 4 9 + 1 1 : 0 0 maintenance requirements.
The IPCC system is a growing alternative to trucking the aggregate out.
Boral Sydney Aggregates Project’s senior OHS adviser, Natalie Constantine, said the mobile crushing solution suits Boral on a number of fronts. “One is the safety aspect – it reduces our mobile fleet so we’ve got less traffic movements on the site, which is much safer,” she explained. “From an environmental perspective, it reduces fuel consumption and the environmental impact of dust emissions. From a health and safety as well as an environmental perspective, but most importantly, from an operational perspective it does everything we need it to do.” It scoured the market for a crusher that could handle the planned production volume at the Peppertree plant, and eventually selected Metso’s Lokotrack LT160 along with its Lokolink mobile conveyor system.
Intensive design consultation process
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tres in length, the Lokotrack LT160 at Peppertree is the largest mobile crusher in the southern hemisphere. Its development required extensive design consultation between Boral’s technical staff and Metso’s design team prior to design finalisation, and its manufacture has “produced the most sophisticated machine of its kind, with a number of innovations not seen on a mobile machine before,” according to Metso. From the outset, Boral was determined to ensure its new facilities incorporated world’s best standards in safety, sustainability and efficiency. One of the major challenges was to customise the LT160 to meet Boral’s strict safety requirements, which are even more stringent than either Australian or European standards. To achieve this, Boral put together a team of designers, engineers, operators and OHS personnel to review the LT160 design and to Continued on page 20 www.miningaustralia.com.au
AM0513_000_MMD
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Innovation
through experience Established in 1978, MMD designed and patented the Twin Shaft Mineral Sizer. To complement the robust Twin Shaft Sizer, MMD has also designed and developed a range of heavy duty Apron Plate Feeders, to be used in conjunction with sizers on both static and mobile Installations.
An independent company that focuses on Sizing and developing IPCC sizing solutions, MMD works with customers to develop systems adapted to their needs and has an unmatched record for the development and supply of effective trend setting static, semi and fully mobile sizing systems for mining a wide range of minerals around the world.
An exemplary track record of ‘Innovation through experience’ has led MMD to being an integral part of the global mining industry and a byword for productivity and reliability.
MMD Australia Pty. Ltd. Brisbane Mackay Singleton
sizers@mmdaus.com.au
THE MMD GROUP OF COMPANIES WWW.MMD SI Z E R S. C OM
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QUARRYING, CRUSHING & SCREENING
LEVEL TRACKING SYSTEM SDS 6110
A VERSATILE, SELF-CONTAINED, RELIABLE SOLUTION FOR REMOTE TANK LEVEL MEASUREMENT The machine was built using noise impacts from the site to meet Peppertree’s operational noise criteria. Continued from page 18
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identify any potential hazards and improvements before accepting the final design. This was a new approach for Boral. “We generally buy off-theshelf plant and subsequently modify it on site,” Boral project manager Kai Kane explained. “We spent a number of days with Metso’s designers in the UK then another two or three days with the designers in Finland to get the process underway. Subsequent to that, there were a number of video conferences that delivered the machine that we have today.” Regular video conferencing between the Boral and Metso teams was carried out over a six month period and allowed various improvements to be made, with about 50 safety related and general design changes compared to the machine’s previous design. 3-D models were used to conduct a virtual “walk through” of the plant. Risk assessments were carried out at each design stage. As part of the selection and design process, the Boral team also reviewed an LT160 that has been operating at Swindon in the UK for around 10 years. As well as ensuring that the crusher conformed to Boral’s safety requirements and was easy to operate and maintain, minimising noise was also an important outcome. “At Peppertree we have to meet certain noise criteria,”
Boral’s environmental adviser Sharon Makin said. “We modelled the noise impact using real time data from a similar operating crusher to make sure that the new machine and its controls would work for us.”
Design solutions
As a result of the design consultation process, the LT160 at Peppertree has a number of features which make the machine unique with regard to current safety practices. Some of the solutions, such as guarding and using stairs rather than ladders for maintenance access, are Australian standards requirements whereas others are unique requirements that arose during the design consultation phase including shrouds around the crusher to reduce both dust and noise; rubber wear liners on the hopper to reduce noise; a service crane installed for jaw liner changes to eliminate the need for a mobile crane; and walkways that extend the full length of the Lokolink conveyors on both sides (rather than just one side). Some of the solutions are extremely simple but very effective. For example the exterior lights on the crusher have magnetic mounts so operators can move them around to ensure the best lighting of their work areas at night. “Another thing that’s really interesting is the segregation of the electrical switch room,” Constantine said.
“It appears to be all one structure but, when you put the crusher in-situ, the electrical switch room has its own legs that jack up to slightly separate it from the rest of the structure so it isn’t affected by vibration when the equipment is operating. That’s a very neat solution and will reduce maintenance resulting from wear and tear on that part of the building.” Ensuring that the machine fully met Australian standards as well as Boral’s requirements before delivery, brought the company significant cost savings by avoiding the need for site rework and retrofits along with associated loss of production.
Anatomy of a truckless system
In a conventional crushing plant, a drill and blast team blast the shot and develop a muck pile. A front end loader at the muck pile loads haul trucks which transport the rock to a fixed primary crusher. With the in-put crushing solution at Peppertree, an excavator located on the muck pile loads material directly into the Lokotrack’s hopper. The rock moves along a grizzly feeder that passes undersized rock directly onto the machine’s outbound conveyor. Only the large rock that needs to be crushed passes through the jaw crusher, which is capable of processing rocks up to one metre in size. Continued on page 22 www.miningaustralia.com.au
AM0214_000_VEY
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THE PEOPLE WHO MAKE THE BEST CONVEYOR BELTS NOW ALSO
SERVICE THEM. Whether your mining operation is surface or underground, Veyance now offers a complete range of service, repairs and maintenance for all types of conveyor belts. • Belt installation • Splicing • Scanning • Belt repairs • Pulley lagging • Condition monitoring Because we’re a total service provider, Veyance will also deliver full certified trained technicians. We believe prevention is the key to lowest cost per tonne conveying, which is why we offer regular maintenance checks to help keep you running in peak condition. Our Veyance Services network is now operational in Mackay and Karratha and will soon to be up and running in the Hunter Valley. Learn how to speak the language of the belts at: www.goodyearep.com Mackay 0408 292 538
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In this way, energy isn’t wasted on passing small material through the crusher. Crushed rock is then transported to the fixed, in-pit belt conveyor via two mobile Lokolink conveyors. The fixed conveyor carries crushed rock from the Lokotrack to the fixed plant for further processing. A patented swivel mechanism on the Lokolinks ensures crushed material flows freely at all conveyor angles. The Lokotrack LT160 can crush 1150 tonnes of rock per hour and needs to be relocated every few hours – a process which can be done in minutes by an operator via a remote console worn around the operator’s waist. The Lokotrack is moved to the next loading position and the unique technology of the Lokolink conveyors allows them to simply follow. When blasting is performed, the Lokotrack and Lokolink conveyors move to a safe distance around 70 metres away. After the blast, a wheel loader cleans the quarry floor and the crusher moves to the new muck pile, resuming oepration with minimal production downtime. When the time comes to move to a different pit location, the Lokolink conveyors are disconnected from the field hopper using hydraulic actuators. The Lokotrack and Lokolinks can also move from one level to another along a normal ramp. The LT160 is a fully self-contained electrical machine. The track mounted drive of the machine is hydraulic while the grizzly feeder and the 200kW crusher motor are driven electrically so there is no environmental impact from diesel fumes. However, in case electrical power is unavailable the machine has a reliable, on-board CAT diesel generator which can be used to run the Lokotrack®’s hydraulic system and Lokolink conveyors.
The mobile crushing system is the largest one in operation in the Southern Hemisphere
interface, which is also connected to the control system via CAN bus. If any of the process parameters, such as pressure or temperature, move beyond their range limit, a warning or alarm is given at the display. The IC900 is connected via the Metso Gateway to Boral’s Distributed Control System (DCS) and SCADA system so that all operation can be monitored remotely. The Modbus-based Gateway interface on the LT160 is connected wirelessly to an Ethernet port on the field hopper and then cabled to the site’s control room. Feed rate control to the crusher is a crucial parameter for process optimisation. Operating in automatic mode, the IC900 system can make adjustments to the feed rate or if necessary, stop the feed altogether. As well as showing on the IC900’s display, process parameters are sent
wirelessly to a human-machine interface panel located in the operator’s cabin of the Hitachi EX1200 excavator. Cameras on the LT160 show the excavator’s operator what is happening within the feed process on the Lokotrack. If necessary, the operator can take over to fine tune the feed rate via the human-machine interface panel in his cabin. A belt weigher incorporated in the first Lokolink continuously monitors product output which is displayed by the IC900 display on the LT160. A separate, specific belt weigher display is located in the excavator next to the human-machine interface panel. The automation system controls the entire crusher start up process. The operator only has to start the LT160 then press the process start up button and the IC900 sequentially starts the entire system beginning upstream with the field
System automation and control
The Lokotrack’s start up and crushing process is automated by a Metso IC900 PLC-based system designed to protect, control and operate the machine. Hydraulic oil pressure and temperature sensors as well as conveyor and feeder speed sensors are located around the machine and wired to decentralised I/O modules that are connected back to the IC900 system via CAN bus. Critical machine parameters provided by the sensors can be monitored at the user 22
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Its built-in automation system can control the entire machine’s operation.
hopper pan feeder, the Lokolink conveyors, additional devices (water spray system), the Lokotrack’s main conveyor, the crusher, the grizzly feeder and then the LT160 pan feeder.
“The perfect template for a project”
After the machine was delivered to the Peppertree site in late 2012, the LT160 went through a three stage commissioning process (static, dry and wet) and achieved practical completion in the middle of August this year. According to Bolton: “We believe that the outcome of the design process will result in overall lower costs of operation.” “One of the key learning’s for Boral from this project is that when importing plant and equipment there are a number of opportunities to adjust the design and capability of the equipment. These opportunities are rarely taken up by Australian industry. We’ve found that the need to partner with offshore suppliers is critical – and it’s achievable.” While there were challenges with adapting the LT160 to Boral’s standards, Parsons said the project ran extremely well due to Metso’s commitment as well as the trust and rapport between the Metso and Boral teams. “The whole thing worked very well. It was the understanding of what was required and the ability of both teams to communicate seamlessly that delivered the result. It’s the perfect template for a project.” www.miningaustralia.com.au
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MT235a Australian Mining Full Page Screens Advertisement October 2011.indd 1
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MINERALS PROCESSING
Going for
GOLD
Two new, greener methods of processing and recovering gold may help miners become more sustainable, Cole Latimer writes.
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old is predicted to have an extremely rough year in 2014. Some pundits are even forecasting a return to the lows the metal saw in the early 1980s. If it doesn’t utilise technology as best it can then many in the industry will be hard pressed to survive through this current trough of high cost extraction for relatively low returns. One of the major areas in which operators can not only become more efficient, but also cut energy and production costs , is in the processing of the gold. Importantly, unlike coal processing, gold processing currently involves the use of environmentally hazardous cyanide, adding a raft of legal and regulatory burdens to operating. In this climate the industry also now has to treat more complex ores as the easier to process gold ores are now all mined. Many of these complex ores contain high levels of
soluble copper, which consume the cyanide used to process the gold requiring larger amounts of the toxic chemical which increases the environmental risk. However there are currently two innovative and greener methods currently being developed in Australia and the US which have the potential to change the way the industry processes gold. Scientists at the CSIRO and the North Western University in Illinois are researching two different methods, thiosulfate and alpha-cyclodextrin (a substance commonly extracted from corn starch) respectively, to process and recover gold. Thiosulfate and bromide are used to leach the gold, in a similar way to cyanide, whilst the alpha-cyclodextrin is used in a similar fashion to carbon to recover the gold. Speaking to Paul Breuer at the CSIRO, he told Australian Mining that research is currently developing gold processes using thiosulfate as an alternative lixiviant to
Substances derived from corn starch could help with gold recovery.
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cyanide and have made some major breakthroughs. “Gold only forms complexes with certain agents, and thiosulfate is one of the best lixiviants apart from cyanide,” he explained. “While thiosulfate has been investigated as a potential alternative for decades, having first been looked at for gold processing back in the 1970s, it has challenges in terms of thiosulfate consumption and recovery of the gold thiosulfate complex. “The gold thiosulfate complex cannot be recovered using carbon, which however is advantageous in treating carbonaceous containing gold ores.” The CSIRO has developed an elution process for removing gold from strong base ion exchange resin used to recover gold thiosulfates, with Breuer explaining that prior to the development there remained the challenge of effectively getting the gold thiosulfate off the resin. “The breakthrough was the use of sulfite in the solution used to recover remove the gold thiosulfate from the resin, which has now opened up a new area of recovery potential applications of thiosulfate with ion exchange resin for gold recovery,” he said.
Thiosulfate was chosen for in-situ or in-place leaching of gold as it is more environmentally friendly than cyanide, however its stability and rate of gold recovery is typically not as good as cyanide. But “when it is used with copper-ammonia as an oxidant for treating gravity concentrates, the gold leach rate can be higher than cyanide, though thiosulfate consumption in the process can also be high,” Breuer explained. Breuer went on to tell Australian Mining that more than one Australian miner is already going down this track and investigating thiosulfate for in-situ treatment of gold ores. However he stated that for the time being thiosulfate process development is fairly ‘niche focused’ as the CSIRO team is looking at its use for in-situ leaching and treatment of gold concentrates and that “in the short term it is not developing a complete replacement for cyanide, instead it is about building confidence and establishing the economics in the process in niche areas”. Scientists at the North Western University in Illinois are using alpha-cyclodextrin, a substance commonly ex-
tracted from corn starch, to recover gold. Zhichang Liu, at the University of Illinois, has discovered another green method of gold processing. His team has uncovered an environmentally friendly replacement for activated carbon – alpha-cyclodextrin, a material commonly composed of units derived from corn starch. “We mixed nitric acid and hydrobromic acid, then we dissolved gold in the solution to extract it from the ore,” he told Australian Mining. By using this method Liu explained that the leach rate is much faster and operators don’t need to use strong acids and cyanide as “we can use bromide instead, and this solution is neutral, so we can add the alpha-cyclodextrin to this solution to aid in isolating gold”. Fraser Stoddart, the chemistry professor leading Liu’s research team, said “alpha-cyclodextrin is the gold medal winner” for processing. “We have replaced nasty reagents with a cheap, biologically friendly material derived from cornstarch.” Liu added that the process can also extract gold from consumer e-waste. www.miningaustralia.com.au
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MINERALS PROCESSING
The scale of the problem A new automated system is tackling the continuing cost of scale build-up.
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ne of the major problems in minerals processing is the constant maintenance and flow-on cost to production. Which is why the industry has looked to automated solutions to fix problems such as scale build up to reduce not only the cost and time eaten during maintenance, but also its impact on to the mine’s production. A new, Australian first integrated scale control and management program implemented at Newmont’s Boddington gold mine’s processing plant is helping the miner address costs and increase production. The miner has worked with Nalco, which designed and installed the automated scale control system which includes site specific anti-scalant (which was developed after a series of water quality tests), a regulated dosing point and a remote deposit monitoring (RDM) control centre, which is cross-linked to Boddington mine’s processing circuit distributed control system (DCS). Described as a step change in scale control, the RDM technology measures scale formation rates in real time in a process side stream. This technology also provides 24 hour remote monitoring for both the BodA M 1 1metallurgical 1 3 _ 0 0 0 _team QUI dington and the system supplier to
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The system combines site specific anti-scalant dosing points with remote controlled monitoring.
actively monitor the system and keep track of is current operational state, allowing for a quick response to any adverse scale events without any delay. This ability to react quickly cuts down the potential for production interruptions or possible plant shut downs in a worst case scenario. - Nalco 1 stated 2 0 1 that 3 - 1the 0 sys- 0 9 tem can also be configured
to measure temperature, pH, and the conductivity of the process water to build a wider picture of scale formation and the chemical drivers that cause it. Paul Petrucci, the senior metallurgist at Boddington, said the integrated system – the first of its kind in Australia – has meant a tangible reduction in the frequency of T 1 4 and : 2 its 0 : impact. 1 4 + 1 1 : 0 0 scale, “[The RDM system] has
been a good solution to the scale problem,” Petrucci stated. He explained that prior to the RDM commissioning Boddington was inadvertently dosing excess lime into the process water system during short, unplanned outages, causing a scale build-up. “As a result of the data from the RDM we can identify this previously misun-
derstood scaling event and alter the control scheme to prevent its occurrence. “The data the system is providing means we can be more aggressive with optimising our anti-scalant dose rates and critically, match the required dose to the quality of the feed water. “This is saving us money by reducing anti-scalant purchases and improving the operation of the process circuit” while also cutting down the frequency of scheduled maintenance. The new pro-active treatment of scale problems has also aided the process water itself, improving the availability of the water within the plant. “The RDM system is giving us a total understanding of the scale process and, ultimately, improving process water quality,” Petrucci stated. According to Nalco, the scale control program at the Boddington process plant is, in common with scale control in any mineral processing plant, a dynamic process. It went on to say that systems such as the one at Boddington are likely to become more common for Australian mines as “water quality and consumption rates will impact on the frequency and intensity of scale events and require an equally flexible management system”.
www.miningaustralia.com.au
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MINERALS PROCESSING
Indonesia bans export for processing Indonesia has finally brought in its ban on certain mineral and metal exports, so how will this affect Australia?
I
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A M0 2 1 4 _ 0 0 0 _ P R I 1 2 0 1 4 - 0 1 - 2 3 T1 8 : 5 4 : 2 9 + 1 1 : 0 0 Indonesia has banned export of unrefined nickel, although it will still allow gold and copper concentrate to be exported.
demand for nickel for the development of stainless steel continues, even though it has stockpiles large enough to take it through to the end of the first quarter, according to Bloomberg. Australian nickel producers have been hit hard by the fluctuations in nickel prices since a massive spike in 2007. However the market has predicted the sector will grow again, with the Indonesian ban only likely to strengthen this belief. Western Areas CFO Joe Belladonna explained that this is mostly likely due to the forecast squeeze on global nickel supplies, particularly as the higher grade, easier to process nickel sulphide supply swindles. “Nickel laterites and nickel pig iron are not capable of filling this sulphide void at a time [when] the metal is increasingly being recognised and sought for its strategic application in stainless steel and other products with extraordinary performance characteristics,” Belladonna said. Due to this “industry performance is expected to improve during the five years through to 2017-18, with revenue rising at an annualised rate of 5.2 per cent to total $3.13 billion in 2017-18,” IBISWorld stated.
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ndonesia’s implementation of its long discussed ban on mineral exports to support domestic processing will see fortunes rise for nickel miners. In 2012 the Indonesian Government introduced new laws to curb foreign ownership and ban the export of raw materials, worth around US$2 billion annually. The laws were originally due to be brought in by 2014 to stop foreign companies exploiting the resources and to bring processing in country. True to its timeframe, Indonesia brought the export law into effect on Sunday, heralding what could be the largest shake-up of the nickel industry in years. Indonesia is the world’s largest producer of the metal and the legislative changes were receiving much opposition from miners – objections which appear to have been heard by the Indonesian Government. The laws passed this month by President Susilo Bambang Yudhoyono were a watered down version of the drafted regulations. The nation was previously planning to also halt the export of unprocessed copper, iron ore, lead, and zinc, however it granted a reprieve for these metals allowing them to continue to be exported as concentrate until 2017, although it did not do the same for bauxite. “Minerals that have to be refined before export are bauxite, nickel, tin, chromium, gold and silver because they don’t have intermediate products,” Sukhyar, director general of coal and minerals at the ministry, told Reuters. The changes means a number of mining companies, including US based Freeport McMoRan which is the biggest operating miner in the country, can continue to export for now. Banning the export of unprocessed mineral ore was originally tabled in a bid to create more jobs and keep profits within Indonesia, forcing miners to develop smelting capacity by 2017. The policy has been slammed as “nationalistic” by many mining companies but altering the laws may also spell good news for Australia and the Philippines. The Philippines is predicting an increase in sales of nickel as Chinese
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VICTORIA SPOTLIGHT
Keep it Safe, Keep it Clean Clean, Safe Bulk Materials Handling relies on the continued performance of efficient equipment. Without maintenance, all equipment fails to perform effectively, no matter what equipment is being used and failed equipment around conveyors ultimately results in lost production time, unsafe work areas and environmental contamination.
Victoria cuts ESS provides competency based technicians to specifically to monitor and maintain Conveyor Belt Cleaning, Sealing and Support systems. ESS Techs are able to inspect conditions and produce a condition report and maintenance plan that can be actioned by Owners, Contracting companies or ESS Technicians in a manner that prioritises the maintenance based on risk analysis. ESS offers a range of flexible maintenance and monitoring services to ensure optimum performance from the plants conveying systems. We tailor our services to your requirements.
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RED TAPE Victoria is pushing through new reforms to encourage investment in the state.
T
he Victorian government has announced a number of reforms that it says will cut red tape and boost productivity and investment in the state’s mining sector. While the first mining boom started in Victorian with the gold rush, mining in the state has since lagged behind other regions. New South Wales and Queensland with their massive coalfields and copper gold deposits, Western Australia with a large chunk of the world’s iron ore, and South Australia and the Northern Territory with their uranium deposits as well as high copper levels. Even Tasmania, Australia’s greenest state, has been seen as more favourable to mining in recent years than Victoria. In 2012 Victoria was ranked the worst for all Australian states by the global Fraser Institute survey in terms of how miners rated the government regulation and ease of doing business. But the Victorian Government is determined to change this, announcing it will spend spend $31.7 million over the next four years on programs designed to build and sustain its mining industry. Acting Premier and Minister for State Development Peter Ryan along with Treasurer Michael O’Brien announced 36 red tape reforms, cutting costs, streamlining the mining application process and offering up crown land for rehabilitation purposes.
Red Tape reforms:
• Crown land used for vegetation rehabilitation Currently native vegetation offsets
for private land clearing can only be sourced on private land, with offsets on crown land limited. This reform will mean miners can develop rehabilitation programs on public land, making it cheaper and easier for companies to meet rehabilitation standards. • Bonds for land rehabilitation by installment Current bond requirements for miners requires 100 per cent of the money upfront, meaning costs can run into the millions of dollars. This reform will slash the rehabilitation bond by up to 50 per cent during the start-up phase of new mining and quarrying projects where the risk of default is low. In addition the government also plans to introduce a cash bond for individual bonds up to $100,000 as an alternative to bank guarantees. • Return of bonds for land rehabilitation The government says the current process for the return of the rehabilitation bond is protracted and will streamline the return process to mining operators to ensure the money is repaid as soon as possible following the successful completion of landowner consultation. • Mining information online After more than 150 years, the Victorian Government will do away with paper and move the mining exploration licence system online. O’Brien said the red tape reforms would translate to a saving of more than $715 million for businesses in the sector. www.miningaustralia.com.au
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MOTORS & DRIVES
How to choose between synchronous and INDUCTION MOTORS Each motor type offers unique advantages and it is important to understand the design, fabrication, installation, operation and maintenance of both solutions, writes Amin Almasi.
T
he usual technology for electric motor driver uses an LCI (Load Commutated Inverter) converter associated with a synchronous two-pole electric motor. However, the VSI (Voltage Source Inverter) technology and the induction motors are becoming popular option. Two technical solutions, the LCI (synchronous motor) technology and the VSI (induction motor) technology for the electric motor driver are compared. It is important to consider the footprint, the torque pulsations on train shaft, harmonics and initial price. In addition lessons learned from design, fabrication, installation, operation bothM A 1 and 0 1 3maintenance _ 0 1 6 _ Gof RA solutions are presented.
Because of the reactive power consumption of its thyristor bridge, an LCI system cannot naturally power an induction motor. If this is the case, the forced commutation circuits would have to be added, resulting in a very complex, costly and less reliable solution.
Different topologies
The VSI stands for “Voltage Source Inverter” using a capacitive DC link with self-commutation semiconductors. It can supply a lagging and leading power factor load. A VSI can power both the induction motors and the synchronous motors. At present, the VSI systems are 1 available 2 0 1 3 - with 0 9 -different 2 3 T 1 topolo1 : 0 8 gies (2, 3, 4, 5, etc levels) and dif-
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A variable speed drive panel for a large VSD electric motor.
ferent electronic power components (GCT, IGBT, and others). They can feed medium and large voltage electric motors for power ratings up to around 50 MW (higher power levels are under study). A well-known VSI arrangement is a 12-pulse VSI with two network serial bridges associated with a 3-level PWM (Pulse Width Modulation) motor inverter. For comparing the Load Commutated : 4 5 + 1 Inverters 0 : 0 0 (LCI) vs. the Voltage Source Inverters (VSI), the following factors should be considered: 1. The LCIs have been used for more than 30 years (since the early 80s) for high-power synchronous motors. On the other hand, the VSIs are more recent and they have been used (mainly up to 30 MW, with some isolated cases above 30 MW) for around 15 years. 2. The LCI technology generates torque pulsations. A harmonic filter is generally required. Because of the speed excursion of the variable speed drive application, it is mandatory to implement a comprehensive torsional study (the torque analysis) of the complete train. 3. Because of multiple pulse rectifier configurations, The VSI network diode bridges reduce the harmonic current level emission. Depending on the network short circuit level, using a 12, 18 or 24 pulse rectifier topology can result in the elimination of harmonic filter(s) in practice. The induction motor (using VSI technology) provides the robustness and the simplicity. There is a very low harmonic content on the motor torque (using a modern fast switching device), an appropriate PWM (Pulse Width Modulation) and a sinusoidal output filter. There is a constant “Power Factor” (PF) on
the network side >0.95 with no need for an additional power factor compensation system. There is a very low harmonic content, particularly when using 24-pulse arrangement on the network side.
Lowest cost
There is also a smaller footprint, mainly due to the absence of the harmonic filter. Typically the VSI solution requires only 70 percent of the footprint compared to a LCI option with the same rating. The VSI solution also offers the lowest cost. An induction motor is cheaper compared to a synchronous motor for the same application. There are few references in the operation of induction motors with powers higher than 30 MW. There are few references in operation of PWM-VSI technology with power level more than 30 MW as well. The choice of the induction motor (VSI) solution is recommended for the application range that at least one successful reference is available, but with a proper de-risking plan. A de-risking plan should be carefully implemented. The main factor is a full-load test of the induction motor with its VSI. A string test of the complete machinery train should also be considered. All these tests should be specified in the specification and need to be insisted in the “call for tender” and the “bid clarification”. The induction motors are simpler to fabricate and install (compared to the synchronous motors). They are also simpler for the “performance test”, the “start-up” and the “operation”. To sum-up it is difficult to give a general rule for the selection between the LCI and the VSI options. The selection strongly depends on the application. www.miningaustralia.com.au
AD_AMTOSFEB_13.pdf
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AM0214_032.pdf
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2014 PROSPECT AWARDS
The 2014 Australian Mining
PROSPECT AWARDS C
elebrating more than a decade of recognising and rewarding excellence in the Australian mining industry, the Prospect Awards are launching once more in 2014. Highlighting all aspects of mining, from the technology, the nitty gritty, the work at the front lines, through to those doing innovative and inspiring work in the community, the Prospect Awards focuses on the good work that our mining industry does on a daily basis. These awards help the industry stop once a year, and reflect on the positive impact it is making, not only on production, but on Australia as a whole. Last year saw a strong showing from Glencore, who
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The awards run across 15 categories and recognise excellence in the mining industry.
had finalists and winners in a number of categories ranging from Australian Mine of the Year to its employees taking out both the Mining’s Woman of the Year and Contribution to Mining awards, while
Anglo American won both Minerals Processing and Coal Mine of the year. Unsurprisingly Sandfire Resources won the Hard Rock Mine of the Year award for its sterling per-
formance of going from discovery to operation in three years. An ability to make hard work look like good luck saw Sheffield Resources win Explorer of the Yea, whilst
an interesting approach to dust management won DuPont and NCIG the Excellence in Environmental Management award. The main theme that ran throughout the awards, which last year were held at the Ivy Ballroom in Sydney, was innovation. And 2014 year is no different. We expect to see innovation again, in every category. Running across 15 categories, this year’s awards will be a chance for mining to highlight the ingenious nature of the industry and those people who are making a difference. So nominate your company or someone you know today and be a part of the celebrations.
www.miningaustralia.com.au
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PRODUCT SHOWCASE
Protective coatings
Mobile boring rig
ATLAS Copco is set to launch a new mobile rig for boring “opening holes” in mines which it says will TROPICAL carnivorous plants have inspired be capable of developing both box hole boring and protective industrial coatings. down-reaming without any site preparation. Scientists at Harvard University have used the Called ‘Easer’ the rig can produce opening holes same principles found in the pitcher plant’s with a maximum diameter of 750 mm and a hole coatings, which are near frictionless surfaces with depth of up to 60 m. It uses standard 200 mm (8 unique self-healing properties to develop the new in) boring rods with a 228 mm (9 in) pilot drill bit. coatings. With the exception of the rods, and the setup Scientists have been able to mimic the pitcher procedure, all the necessary operating equipment plant’s inner skin design to produce a transparent is part of the carrier, and the setup procedure does coating that can be economically applied to not require any site preparation. almost any object – both large and small. Atlas Copco said the increased demand for a highly The multi-stage coating process involves mobile and versatile rigs specifically designed to attaching a thin, but rough layer of porous silica create opening holes safely and efficiently led to particles which are used to lock-in a lubricating the development of the new rig. layer onto the surface to be protected. “Our mission in developing the Easer has been to Designed for both box hole and down-reaming boring. The coating reached the finals of this year’s speed up the operation,” product manager Johnny Chemical Engineering (IChemE) Awards. Lyly said. IChemE chief David Brown stated that “some “The timeframe for drilling a 40 meter opening hole, from setup to take down is less than 30 existing coatings have limitations including hours, and set up/take down is done in less than one hour.” contamination and degradation by contaminants, The Easer offers the same drilling modes as traditional raiseboring rigs: box hole boring, lack of self-healing capabilities, and damage down-reaming and conventional raiseboring. tolerance”. To switch from box hole boring to down-reaming, the gearbox is rotated 180 degrees – an “By mimicking the pitcher plant’s skin structure, operation that can be carried out in an underground workshop. Harvard University’s new coating self-heals In raiseboring mode, the Easer can drill up to 1200 mm. almost instantly, even if scrapped with a knife or Atlas Copco said name Easer is derived from the expression “ease off”, meaning to take off blade. or release pressure, which is used in reference to the blast hole into which rock expands “It is capable or operating in extreme during blasting. temperatures and high pressure, and can be The Easer is scheduled for launch during 2014. applied to surfaces ranging from metals and • Atlas Copco semiconductors A M 0 6 1 3 to _ paper 0 0 0and _ cotton F L Efabric.” 1 2 0 1 3 - 0www.atlascopco.com 5 - 2 7 T1 1 : 1 2 : 2 7 + 1 0 : 0 0 BB-0696 FillDense_Layout 1 5/13/13 10:35 AM Page 1
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www.miningaustralia.com.au
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PRODUCT SHOWCASE
Longlife survival packages
Portable marking machine
THE Survival Storehouse has released Mainstay’s latest range of longlife survival food. According to the company it has developed the food specifically for individuals or groups have been cut off from support services and must rely on themselves and the materials around them until help arrives, and have been designed with mining in mind. There are food ration bars and pre-packaged water. “These rations and water packages are designed to be put in underground refuge chambers and the like and essentially left there until they need to be used, as they have a shelf life of five years,” the company told Australian Mining. “The food ration bars are packaged in meal-sized portions and require no preparation, are non-thirst provoking, and are of shortbread-like consistency,” Survival Storehouse says. The ration sizes come in a 3600 calorie (15 000 kJ) three day pack, a 2400 calorie (10 000 kJ) two day ration pack, or Aids in traceability. a single day 1200 calorie (5000) ration pack. The ration packs have been designed to withstand temperatures up to 148 degrees Celsius and have no peanuts or peanut oils in them, whilst the 125 mL water packs have a five year shelf life and been designed to withstand temperatures of close to 100 degrees Celsius. Its Ark III personal-sized survival package can support a person for up to three days, and includes a ‘space blanket’ as well. • Survival Storehouse 0418425731 www.survivalstorehouse.com A M0 2 1 4 _ 0 0 0 _ L I Q _ R 1 2 0 1 4 - 0 1 - 2 9 T0 9 : 1 8 : 2 5 + 1 1 : 0 0
THE XM700 micro-percussion portable marking machine is designed to meet identification and traceabilty requirements. It facilitates the easy identification of machinery, assets, tooling, construction equipment, and metal structures. The unit produces deep identification marks on the hardest surfaces. Fully portable, it is powered by battery or mains. It doesn’t need to be plugged in and requires no PC, no control unit, and no keyboard. It has an ergonomic design and is easy to use on vertical or inclined surfaces. It offers flexible connectivity for easy data exchange with a PC, a code reader or a USB key. It includes an intuitive touch-screen interface which can even be used while wearing a glove and features large navigation icons to provide direct access to desired functions with a finger or a stylus. The user can mark each item individually with references, serial numbers, batch numbers, date, 2D codes. The marking machine comes with a range of accessories, including a support column, a side handle (right or left-handing), a barcode reader, and a water-proof suitcase on wheels. • Gravotech 02 9684 2400 www.gravotech.com
SALE
By order of our Client
HIGH VALUE MATERIAL HANDLING EQUIPMENT Immediately Available – Offers Invited LOCATION: Gladstone, QLD Australia
For further information, please contact:
GRAYE ROTH Mobile: +61 (0) 427 903 097
Email: Graye.Roth@liquidityservices.com www.miningaustralia.com.au
FEATURING:
• Fixed aggregate transfer conveyor radial stack system • 2x Crawler Conveyors - Hitachi • 6x Concrete Booms – Putzmeister • 6x Diversion Valves - Putzmeister • 3x Concrete Pumps - Putzmeister
To view and bid on the lots, please visit:
http://tiny.cc/go-dove_18258i AustralianMining
February 2014
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AM0214_036.pdf
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MINING JOBS
To advertise a new job contact Hussein Azzan at 02 8484 0852
To see the latest jobs available visit www.miningaustralia.com.au, which is updated daily. OHS ADVISOR SALES ENGINEER Fenner Dunlop is one of the largest engineered conveyor solutions provider The role of Sales Engineer (Western and Metro Victoria and South in the world. With a team exceeding 800 and sites throughout Australia that Australia) is a full-time position within the multi-disciplinary Sales include manufacturing plants and an extensive service branch network we and Engineering Team. The Team is responsible for business growth have built our success on a strong TEAM culture and commitment to safety. primarily through customer relationship development, as well as new We require a dedicated OHS Advisor who has great enthusiasm with customer acquisition and prospecting activities. the ability to utilise their skills to take on this dynamic role. Fenner Benefits of the role is an opportunity to work in an expanding and Dunlop’s priority is to source the best talent in the market and to build a reputable company at the forefront of materials handling productivity workforce of OHS professionals to work in the Conveyor Solutions industry. improvements; an established customer base with respected and proven Reporting to the Senior OHS Advisor, you will be responsible for driving high performance product range; a sales role with technical solutionsOHS best practice in the Queensland region by reporting, analysing and based focus; extensive travel throughout Australia recommending improvements to help framework zero injuries and harm. The key responsibilities include setting appointments and arranging Critical to this is the introduction of strategic objectives around safety and customer sales trips, conducting site technical audits and providing building of relationships with key stakeholders within our branches and recommendations for upgrades. mine sites. Targeting a broad range of industry sectors, including but not limited to This role will require extensive travelling to other sites and service branches the quarrying and mining sectors, the role requires a consultative sales which may require travel outside of normal working hours (Mondayprocess with the preparation of sales quotations and the contribution Friday). The OHS Advisor will be responsible for Townsville, Mt Isa, Cairns, to tenders. Gladstone and Brisbane service branches. You will be the first point of contact for any client enquiries. Key responsibilities include promoting safety initiatives to ensure safe and You will be required to be present and manage Kinder & Co stands at effective work environments; provide specialist OHS advice, guidance and targeted tradeshows, as well as contribute technical content for white coaching to all staff on effective OHS; consultation with Fenner Dunlop paper articles for publication in trade journals and presentation at employees, safety representatives and contractors regarding safety issues; industry events. determining safety procedures and ensuring best practice is followed; The candidate should take ownership of the entire sales process and participate in inspections, investigations, auditing and compliance would be expected to contribute ideas and strategies to improve and reporting; record findings of all audits, enter actions and report to line grow the company’s capability and capacity to increase sales. leadership; actively participate in risk assessments for the site; develop The ideal candidate will have a proven track record of solutions-based content for weekly safety meetings and complete projects in allocated selling demonstrating excellent customer relationship development. timeframes; liaise directly, as required, with relevant client and regulatory Therefore a minimum of 12 months experience in a similar sales authority representatives; and proactively develop an OHS culture of environment is a requirement You should also be a tertiary qualified continuous improvement Mechanical Engineer or have suitable trade experience. To be successful in this role you will have proven knowledge of AS/NZ You should have excellent written and verbal communication skills 4801, AS/NZ 14001 and ISO 31000 along with the QLD Work Health and and be able to liaise with customer maintenance, engineering and Safety Act and Regulations; Cert IV Training/Diploma in Occupational Health purchasing teams. & Safety; a trade background and/or previous experience in mining or other Being driven by achieving targets, you should also be a team player with heavy industries will be highly regarded; pivotal to your success will be your an attention to detail. Experience in SAP Business One is an advantage interpersonal, communication and engagement skills around stakeholder but similar experience in management information systems would be management and customer service; experience of OHS Management desirable. Systems and behavioural-based safety systems are essential; the ability Candidates must be Australian residents with valid work permits; also to work unsupervised and to identify and plan own work, and you must candidates must hold a current Australian Driver’s Licence. have ability to travel to various company office and project site locations To apply email applications to careers@kinder.com.au If you wish (Australian drivers license is essential) and must hold or be eligible to hold to A discuss in more detail the Sales Engineer role prior to your M0 2 1 4 _ 0 0 0 _ S U L 1 2 0 1 4 - 0a Maritime 1 - 1 Security 5 T 1 Identification 0 : 2 7 Card. : 1 6 + 1 1 : 0 0 application, call Charles Pratt on 03 9587 9244. This is an excellent opportunity to expand on your current OH&S skills.
Fenner Dunlop is a growing and dynamic company offering great staff benefits, personal growth and development opportunities. If you feel you qualify for this role please apply now or call 1800 689 629. TALENT ACQUISITION OFFICER Due to continuing growth in our business a new position is currently available in our HR team for a truly unique candidate. Focusing primarily on recruiting blue and white collar roles to support our WA and NT operations what we need is someone who is passionate about end to end recruitment, and committed to providing a high level of candidate care during the recruitment process that provides a positive experience for all our candidates. And that partners with, and builds strong relationships with our internal customers. We need someone who is passionate, a strong coordinator that is able to meet tight deadlines and work under pressure, delivers and improves process and ensures exceptional service is provided both to the business and candidates. Key responsibilities include liaising with internal management on white and blue collar recruitment requirements; providing stakeholder support, advice and coaching in relation to the company recruitment processes and policies; job ad creation & advertising vacant positions; managing and screening candidates; scheduling and conducting interviews; background and reference checking; developing ‘talent pools’ for future recruitment requirements. To be successful in this role you will have had experience in a similar role, with exposure to mining industry (preferred) in a fast paced multisite environment; a high degree of commitment to excellent service to both internal stakeholders and candidates; an eye for talent and previous experience in managing and growing candidate talent pools; advanced computer literacy (Word, Excel, PowerPoint), candidate database management; analytical and influencing skills with great communication skills with the ability to adjust communication style according to the audience; an ability to work under pressure, manage multiple tasks and prioritise to meet tight deadlines; ability to work autonomously and high attention to detail. To be successful you will have a minimum of 5 years recruitment experience in a fast paced environment. You will be confident and enthusiastic; a results driven and self-motivated individual who can build relationships and communicate with people at all levels of an organisation. If this sounds like you and the type of role that you can thrive in, then we want to hear from you today! For more information please call 1800 689 629.
Sulzer – A Company with Proven Expertise
Sulzer‘s expertise is based on understanding of our customers’ needs. We work closely with our customers to develop products that suit their processes in the best possible way. We know what is required of pumps operating in abrasive and corrosive conditions. Apart from the
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material and construction chacteristics, the products in our extensive portfolio demonstrate the highest attainable efficiency level in the market, offering the most eco-efficient product solutions. If pumping and mixing are key factors in your production process, just contact us.
Sulzer Pumps (ANZ) Pty Ltd Phone +61 (0)3 8581 3753 jonathan.fullford@sulzer.com www.sulzer.com
www.miningaustralia.com.au
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EXHIBITIONS
A trifecta of mining TRADE SHOWS for Central Queensland M
ining growth areas in Cen- nomic centres for business and intral Queensland are gearing dustry in Queensland. up to host three industry “Townsville is the transport and and resource events as Rockhampton, economic hub for North Queensland Townsville, and Toowoomba go on with direct air and sea links to Asia show for the value they can add to and the Pacific, including PNG,” Carslowing players in the sector. roll said. “It’s a dynamic and abundant Australian Events will bring the region with over $50 billion in mining Central Queensland Industry and and construction projects in the pipeSix weeks later the trifecta wraps Resources Expo [CQ Expo] back to line, so we’re very excited to bring the up in the Surat Basin, an area that Rockhampton Showgrounds for its first event of its kind to the area. continues to flourish with a new airthird year from March 19-20, and the “Similarly, Rockhampton’s prox- port under construction, and an ininaugural North Queensland Industry imity to Gladstone, as well as the land rail link now a reality. and Resources Expo [NQ Expo] to coal rich southern Bowen and GaliSpeaking to Australian Mining, Townsville Entertainment and Con- lee Basin highlight the importance of Carroll said that after a horror 2013, vention Centre from March 27-28. providing a platform for exhibitors business confidence had been restored The third event is the Surat Ba- to reach Central Queensland’s rap- in mining, with indicators pointing to sin Energy and Mining Expo which idly developing resource industry. a more resilient sector that just wantwill return for its fourth consecutive Carroll said running the NQ and ed to get on with the job of mining. year to the Toowoomba Showground CQ events back to back will give And to boost this further, Carfrom June 18-19. businesses the unique opportunity roll says the trade shows will feature Australian Events director Bob to showcase themselves and connect a range of visitors and exhibitors to Carroll designed M A 1 said 0 1 the 3 _ events 0 4 2 _are GR A 1 with 2 0industry 1 3 - 0 in 9 two - 2 3close-by T 1 1 : boom 0 8 : 0 ensure 9 + 1 0people : 0 0 are being put in touch to showcase the three leading eco- regions within 10 days. with the contacts they need.
Despite mining apparently down, exhibitions haven’t. Displays will be presented by suppliers, service providers, HR companies, government agencies, and manufacturers within the industry to provide an opportunity for exhibitors to showcase innovation as well as providing a platform to network with industry heavyweights and suppliers to ensure they get the best gear at the best price. “Everyone is trying to save money with better systems, more efficient transport and better logistics and these events will showcase products that are of interest to all businesses,” he said.
Send your part, see the mark Scan barcode to see video demonstration www.miningaustralia.com.au
AustralianMining
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AM0214_038.pdf
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Conferences, seminars & workshops Event submissions can be emailed to editor@miningaustralia.com.au Central Queensland Industry & Resources Expo 19-20 March, 2014 Rockhampton, QLD CQEXPO is now in its third year and is firmly placed as a key trade event for Rockhampton and Central Queensland. This event is designed to support the industry and resource sectors of Rockhampton, Gladstone and the Southern Bowen and Galilee Basins, with exhibits by suppliers, service providers, government agencies and manufacturers. A new Chamber of Commerce in Rockhampton, exciting developments in the mining sector in Central Queensland, the promise of a new industry supportive Federal Government and an increased demand for energy through the Port of Gladstone are all helping to set the scene for a renewed boom time in Rockhampton, and across Central Queensland. The CQEXPO will be the meeting place for those already active across the region and for those wanting to be a part of the action. • CQ Expo www.cqexpo.com.au
WA Major Projects Conference 26 March, 2014 Wheelers Hill, VIC This Conference continues to be the largest major projects and infrastructure conference in the state, attracting over 350 delegates annually. The event will feature the latest updates on infrastructure, housing and development happening in Western Australia. With more than $280 billion worth of projects in the pipeline for Western Australia, investment in infrastructure is crucial for the state’s growth and development. This two day Conference creates a platform where senior executives from government, construction and mining will gather to network, learn and participate in discussions about the current and future projects happening in Western Australia. • Expotrade www.waconference.com.au
North Queensland Industry & Resources Expo 27-28 March, 2014 Townsville, QLD The inaugural North Queensland Industry and Resources Expo is the third leg of the essential Industry and Resources trifecta of events in Queensland. Townsville is the economic hub and powerhouse for North Queensland, with direct air and sea
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links to Asia and the Pacific including PNG. It has brilliant rail and road transport access with plans in place for future expansion of these facilities is a dedicated trade event designed to support the industry and resource sectors of North Queensland. NQ Expo will be the showcase for this dynamic and abundant region. It will be a targeted and cost effective opportunity to network, market and generate sales, leads and industry contacts. • NQ Expo www.nqexpo.com.au
Construction Risk Management Summit 1-2 April, 2014 Wheelers Hill, VIC This timely Summit will bring together an expected 150 delegates from the construction, risk management and insurance industry. Allowing opportunities to learn, discuss, network, challenge and collaborate under one roof. Hear how the use of technology will improve your risk management processes. All elements of risk will be discussed; contractual risk, project risk and financial risks. Covering project delivery delays, managing what happens on the construction site as well as OH&S issues. • Expotrade www.constructionrisksummit.com.au
Mining World Moscow 9-11 April, 2014 Moscow, Russia MiningWorld Russia 2014 is the 18th international exhibition and conference for mining and processing metals and minerals in Russia. Last year more then 430 companies from 32 countries, including Australia, exhibited at the event, with the Australian ambassador speaking at the opening. Russia is currently one of the world’s largest emerging markets, and represents a significant opportunity for Australian mining equipment and services companies to garner new work as the Australian market slows down. According to Austrade there are a number of opportunties for Australian METS companies that include mining software and systems development;investment, including joint ventures; integrated project management; contract mining; supply (including leasing and acquisition) of mining plant and equipment; technology transfer and consultancy expertise. • MiningWorld Russia www.miningworld-russia.primexpo.ru/en/ www.miningaustralia.com.au
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// B E C A U S E Y O U D O N ’ T D O T H I N G S B Y H A LV E S
Hitachi AC Drive dump trucks. Built to match Hitachi excavators. Our trucks and excavators are brothers. They’re designed by the same engineers, assembled in the same factories, and built to the same quality. If you’re running a Hitachi excavator, then you’ve already experienced half of the Hitachi advantage. Now it’s time to see what a fleet can do.