Professional Documents
Culture Documents
www.im-mining.com
JANUARY 2016
SOUTH AFRICAN
TECHNOLOGY
CONSULTANTS
MAINTENANCE
PROCESS
MONITORING
& DESIGN
Support you
can trust.
For more than 40 years, miners have trusted JENNMAR to deliver superior
ground support products and innovative solutions to challenging strata
conditions. From bolts and beams to channels and trusses to resin and rebar,
were proud to make the products that make mining safer and more efficient.
At JENNMAR, were passionate about ground support and customer
support and well continue to earn your trust, everyday.
IM_Trust_1-2015.indd 1
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8 CONTENTS
JANUARY 2016
8
16
27
40 MAINTENANCE
Keeping equipment running properly with
the longest possible service intervals
requires the right approach to fluids and
lubricants and the right planning for
scheduled maintenance, reports Paul Moore
40
58 BLOCK CAVING
56
48
60 CONSULTANTS
Consultants often hold the expertise that
unlocks project value in the form of
exploration strategy, prefeasibility and
feasibility studies but also process and
mining method technical reviews, and into
production in areas such as tailings
management. Paul Moore contacted some
of the key players
60
www.im
-mining.
com
COVER: RIMEX
JANUAR
Y 2016
The cover this month shows the state of the art, 188,000 ft2 RIMEX manufacturing
facility in Agassiz. The company celebrates its 40th anniversary in 2016, having
started in 1976 when Founder Chris Weston began selling industrial wheels in British
Columbia, later to be succeeded by his son, current CEO Derek Weston. The
company has gone on to become a global leader in the supply of rims and wheels
to the mining industry; as well as leading supplier of tyre pressure monitoring
systems (TPMS) with its TyreSense system. Through the years key technology
advances have been made by RIMEX, such as with its MES (Machine Extreme
Service) and TSR (Taper Secure Radial) Series. These products stand out with
their true roundness, reinforced steel across the rims and robust specs that
meet the demands of modern mining tyres. www.rimex.com
3 The Leader
4 World Prospects
64 Forthcoming events
Informe
d and
in-dept
SOUTH
AF
TECHNO RICAN
LOGY
CONSUL
TANTS
MAINT
ENANCE
h editor
ial on
the wo
rld min
ing ind
ustry
PROC
MONIT ESS
ORING
& DESI
GN
FATIGU
E & AW
ARENES
OPERAT
S
IBC Classifieds
JANUARY 2016 | International Mining 1
THE LEADER
VO LU M E 1 2 N U M B E R 1
Ugandan safari
Founder and Publisher
John Chadwick B.Sc. Min Eng
Email: john@im-mining.com
Editor
Paul Moore B.Sc (Hons), M.Sc.
Email: paul@im-mining.com
Editorial Board
Professor Malcolm Scoble
Robert E. Hallbauer
Chair in Mining Engineering.,
University of BC, Vancouver
Peter Knights
BMA Chair & Prof. of Mining
Engineering University of Queensland
Stephen Stone
West One Management
Perth, Western Australia
Dr. Andrew M. Robertson
President, Robertson GeoConsultants
Vancouver, Canada.
Ed McCord
Project Consultant
Caterpillar Global Mining, USA
Jason Nitz
Fleet Management & Dispatch
Superintendent
Newmont Mining Corporation, USA
Dr Terry Mudder
Managing Director, TIMES Ltd, USA
Simon Tarbutt
Consultant, Santiago, Chile
Editorial Enquiries:
Tel: +44 (0)1442 870 829
Fax +44 (0)1442 870 617
Advertising Sales:
Phil Playle
Email: phil@im-mining.com
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Email: sheldonmann@gmail.com
Circulation Enquiries
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Website:
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Annual Subscription Enquiries:
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Email: emma@im-mining.com
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WORLD PROSPECTS
WORLD PROSPECTS
Kidde Sentinel
Standing Guard
Protect your operations from downtime and your critical assets from fire damage
install a Kidde Sentinel Vehicle system today.
OPERATION FOCUS
OPERATION FOCUS
Solvent extraction
The SX plants designed by MMI use its
SideFeed mixer-settler design; 28 SX plans
using this design have been constructed
worldwide since 2004. The total number of
SideFeed mixer-settlers designed is now 183
units.
The settlers have a full length adjustable weir
that allows millimetre setting of the
organic/aqueous interface level in the settler
body. This depth is critical in optimising the
settler performance especially with a layer of
crud present.
A recent innovation has been the development
of a piping arrangement that allows one unit to
INNOVATION
THROUGH
EXPERIENCE
For over 35 years, MMD have been at the forefront of Mineral
Sizing and In-Pit Sizing & Conveying solutions, providing
systems that maximise production, improve safety, and
increase efciencies.
The Twin Shaft Mineral Sizer handles over 75 different
minerals in more than 60 countries worldwide, with the ability
to process both wet sticky material or hard dry rock or a
combination of both through the same machine.
MMD remains a group of committed and experienced
individuals who have the skills and knowledge to provide
reliable solutions for their customers, with local after-sales
support and technical expertise when and where needed via a
global network of MMD ofces.
OPERATION FOCUS
be bypassed; or its duty changed. All this can be
accomplished without any changes except
opening and closing of valves.
Modelling of iron and manganese transfer has
shown that it is not always possible to achieve
an Fe:Mn ratio of > 10:1 in the electrolyte.
This ratio is needed to suppress the
manganese oxidation by ferric ferrous
couple within the EW cells. Often a less iron
selective reagent can be beneficial in managing
the Fe:Mn electrolyte ratio. If a wash stage is
used, low acid and low copper concentration are
needed to allow some of the chemically bound
Fe to be transferred to the electrolyte. If the
wash stage has a high advance water flow then
there is another driver for lower Cu:Fe selectivity
to keep the iron in electrolyte above 0.5 g/litre to
limit the spent electrolyte Eh.
The modelling of these conditions has shown
the synergy and interaction that exists between
the SX and EW plant operations. Upsets in one can
cause subsequent upsets in the other; that in turn
reinforce the original upset condition. The closed
loops can cause fast and
catastrophic collapse of the SX
operation in particular.
good understanding of
the requirements of a system
that can provide overwhelming
force to quickly extinguish any size of
fire. A conventional system of a sufficient size
On-line bypass arrangement for seven
SideFeed mixer-settlers
Electrowinning
The control of contaminants coming from SX has
been the subject of a number of papers by MMI
and its partners. The most critical are iron,
manganese and chloride. Particularly in Africa,
there is often nascent silica in the SX PLS, and
electrolyte manganese contamination can be
severe. However, with high concentrations of
cobalt in the leach solution, associated cobalt
carryover can provide the necessary Eh
protection that would otherwise be missing.
M
vis Co
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in st it t me
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Demand
reliability
OPERATION FOCUS
High quality cathode produced using
polyacrylamide grain modifier
Chloride levels in the spent electrolyte are then
monitored and the salt addition adjusted based
on the chloride analyses. In general, salt
addition varies between 200-500 g/h, depending
on the quality of the water being added and the
amount of water makeup.
In recent plant operations a non-ionic
polyacrylamide (flocculant) has been shown to
be superior to guar in creating flat dense
deposits with minimal nodulation in the lowest
third of the cathode. The typical guar is of
variable quality and can be difficult to source,
with demand from the food industry. The
polyacrylamide has consistent quality and has
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Nowadays it is almost
common to find many
different systems in a
plant for different
applications
(supervision,
maintenance and
production schedule
systems), all of which
rely on the same
information (eg a circuit
breaker position).
However, if all
applications rely on the
same information, one
of two scenarios could be playing out, neither of
which will lead to good plant management: the
same information is input several times into
these different systems, or the communication
between the systems is actually communication
between the people operating those systems.
ABB says that System 800xAs integrated
platform completely eliminates this problem.
Usually in industrial plants, management of
high- and medium-voltage substations is handled
by two completely different systems and teams.
By applying IEC 61850 to both levels, it is
possible to integrate all the substations into the
same System 800xA system, thereby simplifying
the operation and the communication between
high- and medium voltage switchgear, for
PROCESS MONITORING
RIEGL
VZ-4000
Very Long Range 3D Terrestrial
Laser Scanner with
Online Waveform Processing
RIEGL VZ-4000
3D Terrestrial Laser Scanner
With the RIEGL VZ-4000 Laser Scanner and
specifically designed software packages,
RIEGL provides a perfect solution for the
demanding fieldwork in open pit mining
and topography.
| up to 4,000 m range | eyesafe Laser Class 1 |
accuracy 15 mm, precision 10 mm | Laser Pulse
Repetition Rate up to 300 kHz (222,000 meas./sec)
| multiple target capability | multiple-time-around
(MTA) processing | full waveform export capability
(optional) | built-in camera, on-board inclination
sensors, GPS receiver and compass integrated,
external GNSS receiver (optional) | stand-alone
operation
www.riegl.com
RIEGL LMS GmbH, Austria RIEGL USA Inc. RIEGL Japan Ltd. RIEGL China Ltd.
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PROCESS MONITORING
locations; impact velocity on the lower chute and out-going conveyor;
presentation of coal on the out-going conveyor (side loading); and slip
velocity between the coal discharging the lower chute and out-going
conveyor ie to assess if the coal is softly loading the belt.
The data and observations from the EDEM BulkSim simulations were
utilised to commence re-designing the lower section of the chute. Several
design concepts were developed. To determine which design was optimal,
EDEM BulkSim simulations were conducted to evaluate the performance of
each design.
Improvements brought by the final design showed controlled flow in the
spoon chute; soft loading on out-going conveyor to reduce dust emissions;
an improved velocity profile on the out-going conveyor; and improved
central loading on the out-going conveyor.
In addition, a relative wear analysis was conducted in EDEM BulkSim to
examine the normal (impact wear) and tangential (abrasive wear) on the
new lower chute. This analysis assisted the Longking engineers to design
the wear liner package.
EDEM BulkSim told IM that its ability to accurately simulate the coal flow
through a crushing and screening station provided a number of benefits to
Longking. The client gained greater insight than using traditional design
methods; and the simulation provided confidence that the design would
perform well with low probability of blockages while reducing dust
emissions. In addition EDEM BulkSim visualisation helped Longking
demonstrate the design solution to the client and increase their confidence
that the solution would work to solve the issues.
EXPERIENCE
Shaft Sinking
Mine Development
Contract Mining
Raiseboring
Raise Mining
Underground Construction
Engineering & Technical Services
Specialty Services
Six TOMRA XRT sorters are in operation at the Karowe diamond mine
where they replaced dense media separation (DMS)
Consider it done.
redpathmining.com
Processing portability
Portability along with modularisation is a key
trend in the process industry as machines
become more efficient and with a smaller
footprint, enabling them to adapt to smaller
projects in remote regions. Metso in November
2015 received an order for a Metso NW220GPD
portable crushing and screening plant to be
delivered to Saburkhan Technologies in Aktas,
Cradle to cradle
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MINExpo is a selected participant in the U.S. Department of Commerces International Buyer Program (IBP). Through the IBP,
U.S. Embassies and Consulates around the world will promote and recruit buyer delegations to the event. If you are interested in
joining a U.S. Embassy led delegation, please contact the location nearest you (http://www.export.gov/worldwide_us/index.asp).
www.facebook.com/minexpo
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The CS logo is a registered trademark of the U.S. Department of Commerce, used with permission.
NMA-447_InternationalMining_General_FNL.indd 1
12/2/15 12:06 PM
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Booyco PDS vehicle
installations across
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2015/11/19 1:00 PM
Underground innovation
Last year JCHX Mining Management, one of the top
mining construction companies in China, received
high-fidelity, training simulators for its Atlas Copco
282 drill rig and Normet 1050 shotcrete sprayer
operators, at its training facility in Miyun County,
Beijing. The simulators are examples of
ThoroughTec Simulations latest CYBERMINE
system.
Larin Allison, Regional Vice President of Asia
Pacific at ThoroughTec explained: The two
simulators have been customised for JCHX to
include Mandarin language localisation.
We are committed to achieving our goal of zero
injuries in our operations and one of the ways to
achieve this is with highly trained personnel, says
100103 HitchcockMichalski
Language barriers.
9.8 million injury
free man-hours.
Minimal infrastructure.
Political instability.
A 7.2 Mtpa gold plant
delivered 3 months
ahead of schedule.
Impossible?
Not for DRA.
Kibali Gold in the DRC produces 600 000 oz of gold every year. Acknowledging the community,
4000 homes were saved and relocated. Started in 2012, completed in 2014, three months
ahead of schedule with exceptional safety statistics, under budget for our client.
DRAglobal.com
100103 HitchcockMichalski
Extraordinary Possibilities
Screening technology
As the demand for enhanced efficiencies and
throughput increases, the market is seeking out
solutions that have a proven track record, yet can
be customised to suit specific applications. The
screen panel is the most critical aspect of the
screening application as it defines
what the mining customer will receive
from the process.
According to Rhodes Nelson,
Managing Director of Multotec
Manufacturing, one of the driving
forces in screening at the moment is
the ability to determine wear of screen
panels and to plan for their
maintenance and replacement. By
being able to establish wear patterns
before they cause a shutdown,
process plants save substantial
amounts of labour and money on
downtime. As a result, we have seen
an increasing demand for our online monitoring
system Hawkeye as well as for enhancements in
recording processes.
Visual wear indicators is another technology
that is seeing an increased demand as it provides
a major advantage in terms of monitoring screen
panels. This is a system with a visual indicator that
shows the incremental wear rates that occur on
screening media. As the aperture wears, the visual
dots become clearly visible and the changeout
criteria cannot be misinterpreted. The end result is
far more accurate determination of screen panel
changeouts.
holes where a shaft is being sunk. The units make use of air-driven power
packs and can charge a development end faster than cartridges.
YEARS
GRINDEX
1 9 4 0
2 0 1 5
With all power for the mine coming from on-site generators, Gundersen
says that special attention has been paid to overall system efficiency and low
power consumption of the cooling system. This affects several design
parameters such as the number of tubes in the heat exchangers, water
flowrates in the two circuits and the size (and therefore thermal approach) of
www.grindex.com marketing@grindex.com
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Hillhead 2016
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Technical advancements
Project delivery company WorleyParsons states
that in the current climate it is focusing on
implementing technical solutions that will bring
projects to fruition quicker, with reduced costs to
the customer.
Henry Jonker, General Manager Minerals,
Metals & Chemicals for WorleyParsons RSA,
explains that the company is continuously
evolving with technology and that it is becoming
the norm for all new projects to utilise technical
advancements in order to work more efficiently
and cost effectively. We want to demonstrate to
our customers that we can add value by doing
things differently through technology, and we
encourage them to take a more of an intellectual
design view which will ensure that a project will be
executed in a more effective and quicker way. For
example, we are deploying integrated and
intelligent design engineering systems such as
SmartPlant on a number of projects, which uses
3D technology to gain intelligence that will
streamline efficiencies, explains Jonker.
Mushir Khan, Manager of Engineering at
WorleyParsons RSA, comments: There are very
few companies implementing the full intelligent
design suite and WorleyParsons is leading the
field in the mining industry with an integrated
application of this technology. Its power lies in the
fact that it delivers myriad downstream benefits,
including meeting budgets, coming in on
RESISTORS
ARE WHAT GRIDCOM DOES BEST!
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MAINTENANCE
Fluid maintenance
absence of deposits or
wear, demonstrating the great cleaning and
protective abilities of the oil.
Anderol Specialty Lubricants, a division of
Chemtura Corporation, has announced that the
ANDEROL 5000 PLUS EP Synthetic Gear Oil
product series, which is designed for gear
applications requiring high micro pitting
resistance and protection under extreme
conditions, is the first product to receive
approval from General Electric (GE) for use in
off-highway vehicle motorised wheel gearbox
applications under GEs new gear oil
specification D50E35. The approvals are for ISO
VG 220, 320, 460, and 680. The new
specification goes into effect on January 1, 2016
and requires high micro pitting resistance and
superior performance in other demanding bench
tests. The off-highway vehicle industry is a
growing market that includes heavy-duty
equipment such as mining haul trucks. These
gearboxes are subjected to high loads and low
speeds, which highly stress the lubricant. These
operating conditions can result in micro pitting
damage, a precursor to pitting and gear failure.
On January 1, the current GE OHV Gearbox oil
specification D50E27 will become obsolete, and
any future maintenance for existing and new
equipment under warranty must use the
lubricants approved under the new specification
D50E35, says Salvatore Rea, Chemtura OEM
Liaison. Were proud that ANDEROL 5000
PLUS EP meets the new, rigorous standards set
by GE and the growing performance demands of
all industrial gearbox manufacturers.
The PAO/ester-based ANDEROL 5000 PLUS
EP gear oils are formulated using a specific
balance of advanced synthetic base stocks and
additives to provide performance greatly
superior to conventional petroleum oils,
including significantly improved load carrying
ability, excellent wear and rust protection,
higher viscosity indices, higher flash points, low
pour points, cleaner running systems and
improved thermal and oxidative stability. This
helps promote higher gearbox reliability,
extended lubricant life and reduced
maintenance costs for the end user.
Being central to effective production in the
mining industry, crushers need to work 24/7
MAINTENANCE
MAINTENANCE
Shells new lubricant blending plant in
Indonesia is capable of producing
120,000 t (136 million litres) of finished
lubricants a year
Indonesias growing
demand for vehicle
motor oils and other
lubricants for
applications in sectors
like mining.
The plant has
world-class,
automated lubricant
blending, filling and
packaging technology.
It is equipped with a
stringent quality
control system that
tests lubricants at all stages of production to
ensure products meet the high quality
specifications associated with Shells brands.
Shell owns 100% and operates this plant, thus
ensuring full control over product quality. This
new Indonesia blending plant is also designed to
meet high environmental standards including
measures to reduce waste and carefully control
waste disposal to ensure no harm to the
environment. All processes at the plant are fully
automated and controlled at all stages by
operators based at the control room. A plant
management system will be installed and control
all stages of production.
Shell Lubricants is active both in the consumer
and industrial markets in Indonesia. Aside from
direct sales, Shell is also supported by over 30
authorised distributors throughout Indonesia. To
date, Shell has imported lubricants to Indonesia.
With this new lubricant plant, Shell is able to
manufacture and supply a full range of locally
produced, high-quality motor oils, transmission
oils and industrial lubricants to the Indonesian
mining market. Shell operates close to 50
lubricant blending plants in 32 countries, 18 of
which are in located in Asia, specifically, in China,
India, Indonesia, Malaysia, Pakistan, Singapore,
South Korea and Vietnam.
Powering maintenance
Matthew Fredericks, Aggrekos Head of Mining in
Africa told IM: Depending on size and location,
an estimated 30-50% of a mines costs are spent
on maintaining equipment. Add to this the cost of
lost profits resulting from a halt in production,
and maintenance can have a detrimental impact
on a mines finances. The flexibility, improved
efficiency and scalability of modular power,
providing the right amount of power when
needed and thus reducing costs, is key to
minimising the economic impact of these
necessary processes. This is particularly true for
mines in remote locations. Isolated in remote
areas, operational downtime caused by
unplanned maintenance can be increased
considerably if adequate power is not available
to facilitate this. Transport of generators can take
MAINTENANCE
inch-pounds to 12.1 million inch-pounds on
grinding mill applications of 4,000 hp and above.
Oil without
:&
Same oil
20 min. later
:&
C.C.JENSEN A/S
MAINTENANCE
Heikki Kamula, Maintenance Engineer, FQM
Kevitsa. "Metso has a clear, integrated view, and
a well-defined path for the long run, he
continues.
The primary gyratory crusher and the grinding
mills are manufactured by other, non-Metso
suppliers. However, careful selection and stateof-the-art design of the wear parts for these
machines are crucial to the operation. Longer
lifetime of wear parts translates to more
production hours and better profitability.
The fact that Kevitsa is entrusting new parts
of their process, whether Metso equipment or
not, to us is a clear demonstration of Metsos
deep minerals processing knowledge and of the
big difference our expert services can make in
Screening maintenance
http://im-projectnews.com/
MAINTENANCE
maintenance plans, issues occur if screen
media isnt properly selected and installed.
Sometimes producers struggle with blinding as
clay-heavy materials clog the screen openings,
or pegging, where near-sized stones get
trapped in screen media openings. Working
with a manufacturer proficient in screen media
takes the guesswork out of screen selection
and installation as well as ensuring extended
life of the screen.
Finally, Haver & Boecker says operators should
optimise production with trained technicians.
Some manufacturers include programs such
as onsite maintenance, screen installation,
training and analyses of operational safety and
performance in a single plan. These programs
might even offer complete machine refurbishment,
machine monitoring and servicing, as well as
related services to maximise uptime.
The company concludes: Overall, maintaining
equipment increases the longevity and efficiency
of machines. And, as with any business, profits
are the key measure of success. A good
maintenance program focused on preventing
downtime pulls together vibration analysis,
proper screen selection and installation, as well
as implementing in-house training and
preventative maintenance schedules. Also,
partnering with the right manufacturer ensures
peak equipment performance and reliability for
years to come.
Maintenance tools
Enerpac has introduced the SL400 hydraulic
gantry, the companys highest capacity bare
cylinder gantry with numerous mining
applications particularly for workshop service
and heavy maintenance of large open pit
machines. Equipped with three stage lifting
cylinders, the SL400 lifts up to 30 ft at the top of
the third stage and can handle up to 450 t at the
top of the second stage. Designed to meet
stringent safety requirements, the SL400
complies with the safety standards set by ASME
B30.1-2015. To ensure quality performance, each
gantry is tested to 120% of capacity at full
extension and witness tested by a qualified third
party organisation. The SL400 is also CE
compliant.
Providing a more advanced solution than
standard lifting systems, the SL400 hydraulic
gantry offers unique features such as a wireless
control system and integrated self-propelled
drive system," said Peter Crisci, Enerpac. "These
features, combined with safe, reliable
performance, allow our customers to satisfy their
complicated lifting applications.
Featuring a unique Intellilift wireless control
system, the SL400 provides optimum
performance and allows for unobstructed views
of the load. The control system allows users to
operate the lift locally at each leg or use the
Intellilift remote control. The wireless system
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MAINTENANCE
guns, has fluid flows of up
to 240 litres/min, a
designated tank for
detergent, and is built on a
chassis from well-known
suppliers. It is specially
modified for the extreme
conditions in the mining
environment, and the unit
is very durable. It is built
in stainless steel; and all
surfaces are metallised or
The Vestergaard Hi-Lift Pressure Cleaner is a
brand new washer solution aimed to help the
mining industry reduce the massive amount of
time spent on cleaning heavy mining equipment
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12/7/15 10:34 AM
Look smart
Paul Moore looks at some developments in the fatigue
management and collision avoidance technology areas of
mine safety, where there has been a lot of activity
number of different strategies have been
developed to monitor and manage fatigue
in mining, while in the area of collision
avoidance, a lot of progress has also been
made, thanks in part to the work done on semiautonomous and autonomous mining operation.
Perhaps the most significant progress in both
areas of the industry is real industry take-up
and a move from trials and pilot programs to
meaningful integration of these technologies in
working mines.Major equipment OEMs are also
moving to incorporate technologies less as add
ons and more as integrated parts of their
offering. Again this is a recognition of industry
acceptance that these technologies are needed
across all operations, both in the developed and
developing world and in both surface and
underground mining, to keep operators safe and
avoid unnecessary incidents.
with alarms.
Fatigue event recordings and data logs
provide an objective source for statistical
analysis to correlate shift times, productivity,
and even equipment maintenance to operator
behaviour. Using this information the system
can help the user develop alertness
management programs to combat fatigue,
educate operators and improve safety programs
as a long-term strategy for reducing fatiguerelated risk in mining operations.
The system has been used for example on the
Caterpillar 785 truck fleet at the Gold Fields
Tarkwa mine in Ghana where it was the subject
of a cost-benefit analysis. In a recent
presentation, Isaac Tandoh at the mining
company stated that studies have shown that
fatigue causes approximately 60-70% of mining
accidents involving haul trucks. The health and
safety benefits of mitigating fatigue risk are
obvious and incident reports often dont identify
fatigue as the cause; while financial costs of
fatigue are often not fully analysed or
understood.
The mine did a ROI study to justify the
investment including the analysis of three years
of fatigue related incidents two years predeployment, and one year post-deployment. The
cost analysis included detailed direct equipment
repair cost data and estimated indirect costs.
From January 2011 to December 2012 there were
over 32 recorded safety incidents involving the
785C dump trucks of which 19 were classed as
fatigue related incidents, all of which
represented a serious potential fatality (SPI).
The direct costs of the fatigue incidents were
calculated as $488,539 in 2011 and $202,877 in
2012. This included an incident where the
Baseline
Week 34
35.21
32.93
23.31
8.55
43.74
35.86
19.39
1.01
Week 47
45.06
38.17
16.67
0.10
Microsleep brainwaves
The SmartCap is a wearable technology that is
being used by mining operations and on-road
fleets around the world to eliminate microsleeps
from their business. Developer SmartCap
Technologies states: Being the worlds only fitfor-mining wearable device that uses the gold
standard in sleep science, SmartCap is seeing
significant demand for its alertness monitoring
solution for haul truck fleets as well as ancillary
equipment and light vehicles.
Dush Wimal, CEO of SmartCap Technologies
says he has observed a rapid change in the
mining industry throughout 2015. As the
industry matures, were seeing a big shift away
from merely counting microsleeps towards the
proactive approach of alertness monitoring.
In August 2015, SmartCap reached a
significant milestone with more than 1,000,000
hours of SmartCap use by an Australian coal
mining operator in the Hunter Valley. To date,
the figure is well over double that when
including the South American, US and South
African mines using it. Even more significant is
the unparalleled results enjoyed by SmartCap
sites that have achieved target zero fatigue
incidents for consecutive operational years
says Wimal. Our aim is to help all operators get
home safely to their families.
SmartCap says its solution is the only tool
that measures an individuals ability to resist
sleep by utilising electroencephalograph or EEG
technology. This represents the risk of a
RICHWOOD
Averting hazards
The PDS HazardAvert from Strata Worldwide,
which was first launched in 2009, remains one of
the companys best-selling products, and has
been newly upgraded in 2015 to incorporate
more rugged and robust designs as well as
upgraded software along with software system
protection.
HazardAvert is a proximity detection and
collision avoidance safety system designed to
prevent accidents and injuries by detecting when
a person or vehicle enters a specifically marked
area, or zone, around an operating piece of
machinery. When a zone is breached, the system
emits an audible and visual warning alert and can
be programmed to slow or stop the machine
automatically.
With over 1,000 systems currently operating in
the global market, HazardAvert has a proven
track record for operating in working sections
with multiple pieces of machinery and multiple
miners. Every person in the working area is
detected by every piece of operating machinery.
HazardAvert can be used in underground coal
and hard-rock mines, as well as surface mines.
While the core technology is consistent across all
types of mining, the system is specifically tailored
according to the application and mining type.
HazardAvert creates an electromagnetic
marker zone around machinery using field
generators. Generators, or Proximity Modules,
are fitted onto machinery and create zones
designated as the Warning Zone and Hazard
Zone. These marker zones can encompass the
entire machine and its turning radius or be
specific to certain areas.
Strata Worldwide recently highlighted the fact
that 58% of serious incidents and fatalities at
surface operations occurred when machinery
moved at less than 10 km/h, while in
underground operations, 87% of incidents
occurred when machinery was moving at less
than 10 km/h. So if mines can address the lowspeed incidents, a significant segment of the risk
is addressed.
Workers wear Personal Alarm Devices (PADs)
The next step is Proximity Awareness, a GNSSbased product system that allows the machine to
see the location of the other vehicles on the incab display. If a machines path of travel
intersects with another machines path, the
operator is notified with a quick audible alert and
visual information. This is especially beneficial
for large mining trucks that have longer stopping
distances as it allows operators to get a good
look at their surroundings before moving in any
direction. Speed zones and limits can be set for
specific areas on the jobsite for a more advanced
form of the detection system. Of course the
system requires a wireless network infrastructure
to function.
Object detection was launched by Caterpillar
back in 2010, and it has evolved based on
customer feedback. Weve made some hardware
improvements such as reducing the number of
radars while retaining the same amount of
coverage, but mainly weve improved
functionalities such as eliminating a physical
acknowledgement of a detected object, says
Cook. The original system required the operator
to interact with the screen by pressing to see
what was detected. The feedback was negative
on that feature, so we removed it. Another
feature change was to enlarge the cameral view
to occupy 90% of the screen. Weve also added
proximity bars to let the operator know the
approximate distance of the detected object. The
original detection product only indicated a
general zone location front, left or right side, or
back.
Recent software upgrades provide No Alarm
Zones where a designated area on a map will not
alarm when an object is detected. For example,
when a truck is backing into a covered hopper,
radar is going to pick it up as an object and
alarm, but with Caterpillars zoning capability,
that can be avoided.
International Mining Editor Paul Moore and Publisher John Chadwick go the extra mile
to report on real mines and mining projects globally, in addition to the major tradeshows
and exhibitions. So far from 2011 to early 2015, visits have included the following:
COUNTRY
AUSTRALIA
OPERATIONS REPORTED ON
FMG Christmas Creek (iron ore)
Xstrata Coal Mt Owen (coal)
BOTSWANA
Gem Diamonds Ghagoo
Debswana Jwaneng (diamonds)
BRAZIL
Samarco (iron ore)
Anglo American Barro Alto (nickel)
BULGARIA
Chelopech (gold)
CANADA
IAMGOLD Westwood (gold)
Cameco McArthur River (uranium)
Vale Orebody 114 (nickel)
CHILE
Anglo American Los Bronces (copper)
Codelco Radomiro Tomic (copper)
CHINA
SD-Mining Sanshandao (gold)
SD-Mining Xincheng (gold)
Xinjulong Jonggu (coal)
CZECH REPUBLIC OKD CSA (coal)
FINLAND
Northland Resources Kaunisvaara (iron ore)
Dragon Mining Orivesi (gold)
Endomines Pampalo (gold)
Altona Kylylahti (copper-gold-zinc)
Agnico Eagle Kittila (gold)
First Quantum Kevitsa (nickel-copper-PGM)
GERMANY
GEOMIN Erzgebirgische Kalkwerke (marble)
RWE Garzweiler (lignite)
INDIA
Kayad/Rampura Agucha (zinc)
COUNTRY
IRELAND
MOROCCO
NAMIBIA
NORWAY
POLAND
RUSSIA
SLOVENIA
SOUTH AFRICA
SWEDEN
SPAIN
UKRAINE
UK
USA
ZAMBIA
OPERATIONS REPORTED ON
Boliden Tara (zinc)
Maya Zgounder (gold-silver)
Diamond Coast
Store Norske Svea Nord (coal)
NWR Debiensko (coal)
PG Silesia (coal)
JSW Zofiowka (coal)
LW Bogdanka (coal)
KWSA Bobrek-Centrum (coal)
KRU Taldinski (coal)
Premogovnik Velenje (coal)
Frontier Zandkopsdrift (rare earths)
De Beers Venetia (diamonds)
Assmang Black Rock (manganese)
LKAB Malmberget (iron ore)
Iberpotash Cabanasas (potash)
Ferrexpo Yeristovo (iron ore)
Galantas (gold)
Compass Minerals Winsford (salt)
Duluth Complex (copper and nickel)
Stillwater Mining (platinum/palladium)
Peabody Energy NARM (coal)
Peabody Energy Rawhide (coal)
ARM/Vale Lubambe (copper)
in real time.
MARCH 6 9
PDAC 2016 CONVENTION HIGHLIGHTS
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featuring 18 sessions
by industry experts
Over 1,000 exhibitors promoting
technology, products, samples and
claim results!
Topical Short Courses
Aboriginal, Capital
Markets, Corporate Social
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Student Programming
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Awards Evening, Receptions
and Closing Party
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Mining Intelligence & Technology
CONSULTANTS
An expert ear
Increasingly, the demands of
regulators, NGOs, shareholders and a
desire to minimise risk has put pressure
on mining companies to adopt best
available practices, and Golder
Associates offers a full range of
disposal options assessments
CONSULTANTS
Modelling software
Beak Consultants GmbH from Freiberg in
Germany continues to successfully provide
services for creation of value-added products to
the mining sector with mineral predictive
mapping, geo-hazard prediction and
geodatabase development using its advangeo
software solutions.
Since 2010, Beak has been working on a
project for the Federal Institute for Geosciences
and Natural Resources of Germany (BGR) to
predict the manganese nodule coverage density
within the German licence areas in the Pacific
Ocean. By using the artificial neural network
(ANN) based advangeo Prediction Software,
Beak was able to compile predictive maps and
to estimate the mineral resources in the working
area of 79,400 km.
Andreas Knobloch at the company told IM
that between 2013 and 2015, the Geological
Left: Image from Geoscience INTEGRATOR Right: Rockburst hazard model shown on underground
model
CONSULTANTS
The resulting system will form an important
part of Mira Geosciences commercial offering of
geotechnical hazard assessment solutions
starting mid-2016.
Advisory assistance
Ta Li, Vice President, Business Development at
TetraTech Inc said the company provides full
mining lifecycle services from environmental
consulting to engineering, project execution,
operations support, mine closure and reclamation.
Its worldwide staff numbers over 13,000
employees at 300 offices in more than 120
countries on six continents. Expertise covers over
75 related technical fields. Because of our
substantial global presence, we help our clients
conceptualise and executive innovative solutions
for their most difficult problems. The five principal
areas include; water, environments, infrastructure,
resource management and energy. The
complement of Engineering Services for project
development includes completion of pre-feasibility
and feasibility studies; development of capital cost
estimates in accordance with the Association for
the Advancement of Cost Engineering (AACE)
Standards and Guidelines; detailed Engineering,
Procurement and Construction Management
(EPCM); permitting and Environmental
Assessments; mine planning and operational
support; NI 43-101 Resource Estimation, due
diligence, equity and debt financing support.
Tetra Tech has long term working
relationships with major and emerging junior
mining companies. Its resume of successful thirdparty reviews and due diligences has resulted in
an excellent reputation among the finance and
investing communities. From a strong core of
mining practice offices in Golden, Vancouver,
Santiago, London and Perth, a leading and
sustainable mining practice has emerged for the
benefit of the global mining community.
SRK Consulting is well known globally as an
independent, multi-specialist consultancy serving
the exploration and mining industries worldwide.
The company told IM: We advise clients at each
stage of the project life-cycle from exploration to
closure. Clients include mining and engineering
companies, financial institutions, and public
sector organisations. Strong working
relationships with regulators and the financing
community allow us to help reduce project
financing and permitting risks. When supporting
clients in buying or selling properties, we deliver
balanced, independent valuations and reviews
focused on identifying opportunities and risks.
For clients at the development stage, we focus on
understanding the critical issues to ensure we
get the concepts right. And for clients with
operating assets, we assist with optimising
performance and solving technical challenges.
Recent project examples in terms of
Water expertise
MWHs services to the mining sector revolve
around water, which is a key enabler but a prime
culprit when things go wrong and the nexus for
interaction with the communities supporting
mining. Resa Furey, Market Analyst at MWH
states: New mining projects and on-going
operations require regulatory and community
approval, a reliable water supply along with
dependable measures to manage mine waste and
control discharges to the environment. Our most
interesting assignments include sharing a limited
water supply with a city and neighboring
agricultural community; applying multiple
accounts analysis and stakeholder dialogue to
secure regulatory and community approvals;
safety audits for tailings and waste management;
program management for closure and
relinquishment of mines; and providing solutions
to deal with long-term liabilities at mines.
MWH says its professionals contribute to the
development of the industrys know-how in each
of these areas through knowledge sharing
short courses and lectures that it offers each
year. Because the MWH mining group is backed
by a much broader water engineering service, we
are known for bringing ideas and experience from
other sectors. This has been beneficial, for
example, when we brought mining companies
together with other industries from
manufacturing to food and beverage and oil and
gas, to share approaches to water efficiency and
re-use.
Tackling tailings
Typical tailings disposal options assessments
carried out by Golder Associates include working
within regulatory requirements and standard
practices to identify the most economical option
while considering intangible items such as long
term stability and closure costs.Increasingly, the
demands of regulators, NGOs, shareholders and
a desire to minimise risk has put pressure on
mining companies to adopt best available
practices. At the same time, the decline in
commodity prices has put increased economic
pressure on mining companies.
Chris Lee, Principal - Paste Engineering and
Design told IM: The number of assessments for
new mining projects has declined. However,
these types of assessments are still taking place
with the request frequently originating from
operating mines. These assessments evaluate
different levels of tailings dewatering; slurry,
thickened tailings/paste and filter cake and
different disposal methods including
underground backfill, co-disposal and into
depleted open pits. What is different is that the
alternatives that may have been considered too
costly in the past are being re-examined due to
significant pressure to adopt best available
practices.
This requires greater creativity and integration
with mining companies to find cost effective
solutions that allow mines to address their
technical challenges while minimising or
reducing tailings management capital and
operating costs. While it may seem impossible
to have a better technical solution that also has a
lower cost there are a number of ways in which
this can be done. Frequently this can be
accomplished by broadening the scope of the
study to include all areas that have synergies
with the tailings management option selection
such as the link between tailings disposal and
mine backfill. Golder, a global company that
provides a comprehensive suite of integrated
mining services and which has a wealth of
experience in mine waste management, is well
positioned to provide these detailed assessments
that mining companies can utilise to make the
best decision possible when it comes to
considering tailings disposal options.
CONSULTANTS
Snapshot study
SGS is well known as the leading global
inspection, verification, testing and certification
company; however it also has a network of
geological, geometallurgical, mining and process
engineering consulting services which has
evolved to meet the changing needs of
exploration and mining companies globally
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DINGO
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Multotec Group
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Normet
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PDAC 2016
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Redpath
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Richwood
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RIEGL Laser Measurement Systems
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