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www.im-mining.

com JUNE 2012

Informed and in-depth editorial on the world mining industry

UNDERGROUND FLEETS: MINING ENGINES


drilling, load/haul, utility

FINSCH
innovation continues

OPERATION FOCUS:
Iberpotash and
Galantas

HIGH PROFILE:
GE and Gemcom
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CONTENTS
10 J U N E 2 0 1 2
10 GREAT MINES FINSCH
John Chadwick examines South Africas second largest
diamond mine - a world leader in block caving and
automated loading and hauling.

14 OPERATION FOCUS Iberpotash Cabanasas


Paul Moore visited this major underground potash
operation in Catalonia, northeast Spain, to see the
companys continuous mining process for sylvinite
production.
14 18 OPERATION FOCUS Galantas Gold
Paul Moore visited the operations of Galantas Gold

18 near Omagh in Northern Ireland to get the latest on a


small but commercially successful surface operation
that is planning to mine underground.

24 MINING ENGINES
Mining engines, as other industrial engines, are
having to comply with Tier 4 Final regulation ahead of
24 2015, which is being achieved by varying technologies,
reports Paul Moore, while natural gas engines are
gaining traction.

38 UTILITY VEHICLES
Utility vehicles, both surface and underground are
often under-appreciated but, as John Chadwick reports,
they are vital to efficient mine operation.

74 CAVING TECHNOLOGY
62 In a new underground development review, Paul Moore

38 looks at some of the latest block cave projects as well


as the application of new draw-point extraction technology.

80 INNOVATION INTELLIGENCE
Ryan Siggelkow, Vice President, HLS Hard-Line
Solutions, looks at easy steps to advance remote
machine control and how that infrastructure can help all
communications underground.

84 HIGH PROFILE GEMCOM


On April 26, Dassault Systmes announced its
62 TRACKLESS TRAMMING intention to acquire mining software major, Gemcom
At the MassMin conference in Software International. Paul Moore spoke to Gemcom
Sudbury this month, LHDs and President and CEO, Rick Moignard, to get a feel for the
underground haul trucks will be deal and its implications.
widely discussed John
Chadwick looks at recent 86 HIGH PROFILE GENERAL ELECTRIC
developments. Paul Moore spoke to Peter Carter, Global Leader of
Mining Solutions at GE Energy, about its increasing
50 UNDERGROUND DRILLING focus on mining and increasing collaboration with EPC
Underground drilling remains a groups and partners.
challenging environment, so
continued improvements from 88 PASCUA LAMA DUST CONTROL
key machine and component
suppliers continue to help
74 A report on the recent trial of a customised dust
suppression solution at Barricks high altitude mine on
mines improve efficiency, the Chile/Argentina border.
particularly as operations go www.im
-minin

COVER: Mine Master


g.com

deeper, reports Paul Moore. JUNE 201


2

This months cover has an underground theme and shows a view from the rock face of Mine Masters Informe

50
d and
in-dept
h editor
ial on
the wo
rld min
ing ind

Face Master 2.3 twin boom drill jumbo, which offers a 50 m2 coverage and power shift, four wheel UNDERG
drilling ROUND FLEE
ustry

, load/
haul, ut TS:
ility
drive transmission. A mechanised drill rig for low seams, the machine is designed for drilling blast MININ
G ENGI
NES

holes of diameters between 41 mm and 76 mm with a net hole length of 3.8 m. The design allows
for effective drilling of blast holes in drift heights from of up to 2.5 m. A direct controlled drilling
system has anti-jamming, collaring, and simple frequency functions along with feed control to
optimise the drilling parameters. The B40L booms with 1,000 mm extension are directly
controlled by two-axial joysticks, which enables accurate and fast positioning between holes. innovat FINS
ion cont CH
inues
OPERAT
ION FO
www.minemaster.eu Iberpo CUS:
tash an
d
Galanta
s
HIGH PR
GE and OFILE:
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Interna om
tional

AROUND THE WORLD 3 The Leader 4 World Prospects 91 Classifieds 92 Forthcoming events

JUNE 2012 | International Mining 1


A Weir Minerals service technician is worth their weight in gold. And copper. And coal.

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your operations take you, from installation and training to engineering consulting and maintenance to on-site emergency
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THE LEADER VO LU M E 8 N U M B E R 6

Pencil this in to your exploration plans


Publisher urrently there is a huge boom in graphite tremendous amount of
John Chadwick
Email: john@im-mining.com
Editor
Paul Moore
Email: paul@im-mining.com
C exploration. It is in danger of becoming
overheated, much as rare earths is
becoming, but we have seen this sort of thing in
work with the material at
Manchester University in
England. "It is not even
the mining industry many times before. With so one material. It is a huge
Associate Editor
Chris Cann much of global exploration led by juniors, it is range of materials. A good
Email: chris@im-mining.com
understandable. comparison would be to
Editorial Board
Professor Malcolm Scoble
So what is the graphite boom all about? how plastics are used," he
Robert E. Hallbauer Graphite is a non-metallic, opaque mineral, grey to said.
Chair in Mining
Engineering., black in colour with a metallic lustre. It possesses Graphite is also used to make the brushes for
University of BC, properties of both metals and non-metals, which electric motors and generators, and it has wide use
Vancouver
Jeff Roschyk make it ideal for many industrial applications. It is as an electrode in many applications, primarily
Vice President of flexible, soft (Mohs scale 1-2), compressible and batteries (like AA or AAA batteries in torches, MP3
Product Management
& Marketing, P&H Mining, USA malleable. It has low frictional resistance, which players, clocks, etc.). The steel industry and other
Peter Knights gives it a greasy texture, making it an efficient foundry uses represent a major demand for this
BMA Chair & Prof. of Mining
Engineering University lubricant. It is thermally and electrically refractory material. It also finds application in
of Queensland
conductive. Its melting point is above 3,550C in a lubricants, brake lining materials and of course
Stephen Stone
West One Management non-oxidising environment and the vaporisation carbon fibre.
Perth, Western Australia temperature is around 4,500C and mostly Natural graphite takes on three distinct types
Dr. Andrew M. Robertson
President, Robertson infusible. It is nontoxic, chemically inert and has (flake, vein and amorphous) that differ in purity,
GeoConsultants high resistance to corrosion. Graphite has low crystal size and shape and deposit style.
Vancouver, Canada.
Ed McCord
thermal expansion and shrinkage with high GRAPHITE Black Gold of the 21st Century, by
Project Consultant thermal shock resistance. Graphite has low density Industrial Alliance Securities explains that recovery
Caterpillar Global Mining, USA
(1.1-1.7 g/cm3) relative to conductive metals such of flake graphite is generally achieved through
Jason Nitz
Mining Systems Strategist as aluminium and copper. Ultimately, all its flotation and screening after primary crushing and
Newcrest Mining Ltd, Australia
properties vary depending on the purity and size of grinding. The grind size is project-specific and
Dr Terry Mudder
Managing Director the graphite crystal. (Graphite market review 2011, requires a great deal of optimisation test work to
TIMES Ltd, USA
Merchant Research & Consulting) achieve the ideal recovery and flake sizes. Pine oil
Simon Tarbutt
Consultant, Santiago, Chile Much of the current excitement is down to is the main additive used in froth flotation to assist
Dr. Mike Daniel graphene, the developers of which won the Nobel graphite separation from gangue. The process
Comminution Process Consultant
Ausenco Minerals & Metals, Australia Prize for Physics in 2010. It is thought by many that requires a number of flotation cycles to produce
it will see the end of silicon, which has had a great clean graphite concentrate. Additional upgrading
Editorial Enquiries:
Tel: +44 (0)1442 870 829 run in electronics, and change the future of of the carbon grade can be achieved through
Fax +44 (0)1442 870 617
computers and other devices forever. It is now the thermal treatment or acid leaching.
Advertising Sales:
Phil Playle most conductive material known. Graphite concentrate is analysed for any
Email: phil@im-mining.com But it also has great potential for making undesirable oxides or trace metals, for flake size
+44 1442 87 77 77
composite materials. It is said to be the strongest distribution, humidity level and for final carbon
Advertising Production
Emma Smith material ever measured, much stronger than grade key parameters that determine its selling
Email: emma@im-mining.com
diamond the thinnest and strongest material value.
Publishing Consultant developed to date. "Our research establishes Complications with overall recovery and of the
Robin Peach
graphene as the strongest material ever measured, larger graphite flakes are the main processing
Design & Production
Trevor Sheldon some 200 times stronger than structural steel," problems. Recovery of the larger graphite flakes
Email: sheldonmann@gmail.com
Mechanical Engineering Professor James Hone, of could require significant finer grinding that will
Website:
Columbia University, said in a statement. "It would eventually destroy the larger flakes and reduce the
www.im-mining.com
take an elephant, balanced on a pencil, to break selling price. Recoveries are likely to exceed 90%
Annual Subscription Enquiries:
Emma Smith through a sheet of graphene the thickness of [cling in most cases but orebodies flooded with silica or
Email: emma@im-mining.com
film]." which are significantly oxidised might show much
Annual Subscription
UK and Europe 160, 230
Graphene is taken from graphite, which is made lower recoveries. A potential solution could be acid
Rest of the world US$270 up of weakly bonded layers of carbon. It is upgrading or acid liberation, but this is cost
International Mining is published composed of carbon atoms arranged in tightly intensive and will likely make a project
monthly by Team Publishing Ltd,
2 Claridge Court, Lower Kings Road bound hexagons just one atom thick. Three million uneconomic.
Berkhamsted, Herts. HP4 2AF, UK sheets of graphene on top of each other would be
Printed by The Manson Group, St Albans 1 mm thick.
Team Publishing Ltd 2012 "Graphene does not just have one application," John Chadwick
ISSN 1747 -146X
Professor Andre Geim, one of the co-winners of Publisher
that Nobel Prize, has aid. He has done a john@im-mining.com

JUNE 2012 | International Mining 3


WORLD PROSPECTS

Liner maximises mill availability and improves safety


Megaliner element integrates multiple lifter and
shell plate rows, and covers an area up to 4 m2.
The rubber/metal composite liner weighs
between 30% and 60% less than metallic liners
of a similar size. Overall, Metso concludes,
installing and replacing mill liners with the
Megaliner system creates a much safer and less
stressful environment for the liner handler
operator and the installation team.
www.metso.com

A liner handler operator positions a Megaliner The system makes removal


and replacement of liners just
he new Metso Megaliner shell liner as quick, safe and easy as

T keeps downtime in large mills to a


minimum, using an innovative design that
offers speedy replacement. It also improves
installation. Bolting and
unbolting is straightforward
as the threaded portion of the
worker safety during maintenance, as the liners standard hex-head liner bolts
are bolted into position from the outside of the is protected from dust,
mill, so workers do not need to stand in the corrosion and general
drop-zone of the liners. mechanical damage. Once
Mill availability is improved through faster loosened, it is often possible
liner replacement, Metso says. Megaliner uses to remove the liner bolts
larger than average liners, yet these can still be simply by hand-turning them.
placed with the same six- to eight-axis liner Pneumatic or recoilless
handlers used with many large AG mills. Using hydraulic hammers are not
larger liners means mills require fewer of them needed to dislodge worn
and Megaliner also has fewer attachment points Megaliners, as gravity alone is
compared with conventional liners, speeding up generally sufficient.
installation even further. Liners are easily and This liner is suitable for
accurately positioned before bolting with the aid large AG mills with large trunnions and where Bolts are attached from outside of the mill
of highly visible, coloured guiding markers. modern liner handlers are available. Each only

Camera systems prove themselves in collision management


at Kidd Creek, and improve productivity
ast months underground communications article also covered to standardise connection to any type of equipment.

L proximity awareness and various systems to avoid underground


vehicles colliding with each other or with people working
underground. An interesting system has recently been developed for
The cameras are positioned on the machines, LHDs in particular, to
minimise damage and maximise the field of view. Blind side cameras are
positioned to maximise coverage over direction of travel. The front camera
Xstrata Coppers Kidd Creek mine. is positioned on a light bar or the cab roof to achieve maximum forward
The installation involved designing, testing and deploying a robust video visibility. The rear camera provides a full field of view behind the
camera system that does not require or allow any operator input. The equipment.
developers integrated the camera system into the electrical control system How the LOS has been improved - greatly:
to ensure that all mobile equipment operational and maintenance LOS to ground level has been greatly improved based on
standards were met. The mine worked with PROVIX to design the camera two-dimensional visual plots presented in the Laurentian report and
system and once the prototype was ready to deploy, Laurentian University operator observation. Specifically, blind areas to the opposite-side of the
analysed the effectiveness of the camera system through established LOS machine from the operators position have been eliminated
testing methods. Working with Sandvik, an interface panel was developed LOS to ground level has been improved from values of 40 m to <4 m

4 International Mining | JUNE 2012


WORLD PROSPECTS

around the perimeter of the machine when the LHD bucket is down
LOS to a standing operator in front of the machine when operating with
a full bucket has been reduced from more than 60 m to <20 m
LOS to a standing operator height is excellent for the entire 1 m testing
boundary around the machine.
PROVIX says the camera systems are not intended to encourage
operators to drive more quickly. However, they do provide operators with
more situational awareness and enhanced vision through expanded sight
lines, and operators who have expanded vision and heightened situational
awareness, do not have to reduce speed as often. Decreased travel and trip
times are the result.
So, overall, increased productivity with safer equipment operation
around personnel is the excellent result.
There are additional benefits for remote LHD operation in that the
camera system is enabled for wireless video transmission to a safe
operator station. Remote operation requires additional camera(s) deployed
on the operator cab side. An integrated camera system that is suitable for
both remote and manned operation reduces lost time when changing
between the two operating modes. Obviously, the cost associated with
single system deployment is reduced.
Kidd Creek has completed a 12 month pilot project to analyse the
effectiveness of the PROVIX camera system. The mine deployed the PROVIX
camera system on LHDs, a breaker and a haul truck as part of the pilot
project. Kidd Creek is now in the process of equipping all loaders, haul
trucks and breakers with the camera system.
Elsewhere in Canada, Goldcorp Hoyle Pond, Red Lake and Campbell
mines are in the process of installing PROVIX camera systems on Cat 1600G
LHDs. www.provix.net

Automation for boom-mounted secondary breaking


ave mines, like most underground mines, programmed automated movements movements with vehicles (e.g. loaders) thereby

C often employ fixed boom-mounted


breaker systems for secondary breakage
at crusher dump points or on mobile equipment
at the touch of a button.
Since boom assemblies rarely
operate in isolation, Rocklogic
eliminating collision risk and increasing the
sites overall throughput.
The system
to accomplish secondary breaking tasks at allows breaker
drawpoints, etc. Transmins Rocklogic range of booms to be
intelligent control systems for fixed boom controlled from a
assemblies is ideal for any site with high remote operations
throughput demands or at risk of costly centre. Thus, one
collisions. The system recently won the operator could
innovation category at the WA Information control a number
Technology and Telecommunications Awards. of such installation
Transmin explains that this collision within one mine, or
avoidance system forms a virtual 'safety net' multiple remote
that operates during both manual and automatic mines. So, a single
movements. The locations of all static obstacles can be operator can oversee
in the scene are stored by the system, and when integrated with multiple machines in
an imminent collision is detected the movement existing plant, allowing different locations, on surface or underground,
speed is smoothly reduced to avoid the the triggering of pre-programmed movements switching between them as needed, from a
collision. (e.g. automatic parking). This enables rock single workstation in a remote operations centre
Rocklogic can rapidly execute pre- breaking operations to safely coordinate www.transmin.com.au

Australian uranium exploration deal Australias very substantial uranium potential.


We believe that exploitable low production cost
REVA and Mitsubishi, through their predetermined amount. Once the threshold is deposits will be discovered there over the long

A respective subsidiaries Afmeco Mining and


Exploration (AFMEX) and Mitsubishi
Development (MDP), have decided to work
reached and if MDP confirms its interest, MDP
will have the option to acquire 49% of the
greenfield uranium exploration permits held by
term, hence our mutual commitment to
financing such a large-scale exploration effort.
Australia produced nearly 6,200 t (about 16.1
together in a uranium exploration program in AFMEX in Australia and enter into a joint venture Mlb) of uranium in 2011. It is the worlds number
Australia. Exploration will be conducted for several owned 51% by AFMEX and 49% by MDP. three uranium producer behind Kazakhstan and
years across tens of thousands of square The operations of the new joint venture will Canada, and its uranium reserves are among the
kilometres of Australia where little or no previous be managed by AFMEX. Olivier Wantz, AREVA largest in the world. AREVA recently stepped up
exploration has yet been undertaken. Under the Senior Executive Vice President in charge of its exploration efforts in Australia, where it has
terms of the agreement entered into between mining activities stated: By joining forces discovered several deposits since commencing
both companies, MDP will cover 100% of AFMEXs through this partnership, AREVA and Mitsubishi exploration activities there in the 1970s.
exploration expenditure for several years up to a Corporation are gaining the means to develop www.areva.com

6 International Mining | JUNE 2012


Get connected

With our new app you easily and quickly get access to all information you need from
Atlas Copco. Here you nd our wide range of underground drilling rigs, loaders and
trucks in high resolution images, presented as 3D turntables. This makes it possible
for you to view the product from all angles, in the palm of your hand. The app also
contains videos, case stories and a social news ow. And thanks to the GPS function,
getting in contact with the nearest Atlas Copco representative has never been easier.
Available for both iPad and Android, youll nd it at www.underground-app.com.
Downloading is free, of course.
WORLD PROSPECTS

GE looks to buy Industrea and Fairchild


s IM went to press, Industrea and General vehicles for use in longwall and personnel

A Electric (also subject of a High Profile


article later in this issue) executed a
Scheme Implementation Agreement to effect
movement
Contractor management
Mobile asset tracking
the proposed acquisition of 100% of the Driver safety performance index.
issued shares in Industrea by General The company also distributes a select
Electric Company by way of scheme of range of OEM mining products for
arrangement. In a separate deal, GE has also Sandvik, Tagor, Pirtek, Marathon Tyres,
signed a binding Letter of Intent (LOI) to Hydco International, Filter Technology Australia
acquire Fairchild International, the and Inbye Mining Services.
Industrea longwall shearer carrier. The
independently owned and operated company expects revenue for the year to In the other deal, GE Transportation signed an
underground coal mining equipment June 30, 2012 to be A$380 million to A$390 LOI to acquire Virginia-based, independently
manufacturer located in Glen Lyn, Virginia. million, compared with FY2011: A$357 owned and operated Fairchild International. The
Industrea has maintained the ability to million company employs approximately 150 people
enhance shareholder value through the separate and manufactures a wide range of underground
sale of Industrea Mining Services (IMS). product development and innovation. coal mining equipment, including diesel and
Industreas Board has carefully evaluated GEs Industrea intends to commence an orderly battery-powered scoops, continuous miners,
offer and unanimously recommends that sale process for IMS, with the goal of realising haulage systems, shield haulers, and
Industrea shareholders vote in favour of the additional value for shareholders. maintenance vehicles. With this acquisition, GE
scheme, in the absence of a superior proposal Headquartered in Queensland, Australia, again aims to expand its product offering to
and provided that an independent expert forms Industrea comprises a group of companies underground mining but also grow Fairchilds
and continues to hold the opinion that the involved in the global provision of mining customer base beyond its core US market to
proposal is in the best interests of Industrea products and services, with diversified revenue serve mining customers worldwide. Lorenzo
shareholders. streams arising from asset management and Simonelli, President and CEO of GE
The proposal values Industreas equity at engineering services. Its products and services Transportation said: With the acquisition of
approximately A$470 million (on a fully diluted are sold on a wide geographical footprint that Fairchild International we will combine nearly
basis). includes USA, South Africa, Russia, Indonesia fifty years of leading industry knowledge and
Robin Levison, Managing Director and CEO of and Papua New Guinea with offices in five expertise in designing, building and servicing
Industrea, said: GEs capital, technical Australian locations, Santiago in Chile, South underground mining equipment with GEs global
expertise and global customer relationships are America and Beijing, China. reach, technology leadership in clean propulsion
expected to accelerate the growth of Industreas Industrea has been constantly expanding its and energy storage systems, and world-class
businesses, building on the companys strong range of products and services and the current system integration capabilities. We will bring
reputation for products and services that range of mining products includes: the next generation of top performing
enhance the safety and productivity of mining Collision avoidance systems underground mining equipment to mining
companies. New career opportunities will open Underground directional drilling including customers around the globe.
up for our people, and customers will be able to methane gas drainage www.industrea.com.au;
benefit from increased resources devoted to Underground flameproof and explosion proof www.fairchildint.com

Vehicle Projects launches fuel cell locos at Angloplats


emonstrating its commitment to the identified through a global search to

D mitigation of climate change and


sustainable mining, Anglo American
Platinum has launched a platinum-based fuel
pioneer this development. Current
original equipment manufacturers
were integrated with the fuel cell
cell powered mine locomotive prototype. This developers to ensure seamless system
industry leading project was delivered in integration. Anglo American Platinum,
collaboration with Vehicle Projects, Trident with its partners, aims to demonstrate
South Africa, and Battery Electric, and will see the superior energy efficiency and
the partnership construct five fuel cell locomotives productivity of fuel-cell powered
which will be tested for underground use at one locomotives. The new technology is
of Anglo American Platinums mines. In the short also believed to offer environmentally
term, surface testing of the fuel cell powered friendly and safer means of
locomotive is planned to take place at the mine underground transportation.
during the September quarter of 2012. After the Hydrogen powered fuel cell locomotives are increased productivity. Neville Nicolau, Chief
initial testing period the fuel cell powered more economical and environmentally friendly Executive Officer of Anglo American Platinum,
locomotives will be integrated as part of the than traditional rail transport, powered by a commented: These innovative locomotives will
mining operation. clean and more secure energy source. A fuel cell provide us with an opportunity to mine platinum
As part of Anglo American Platinums is essentially a gas battery that produces in a more economic, energy-secure, and
commitment to the development of fuel cells, in electricity as long as it is fed with hydrogen gas. environmentally-benign manner. The
2011 the company identified uses for fuel cells in The fuel cells provide availablity 24-7 and there locomotives will not require any electricity from
its own operations. Mining locomotives were is no need to change or recharge the battery it the grid to function and will not emit noxious
identified as an ideal opportunity. Partners were replaces, which means less downtime and gases. www.vehicleprojects.com/

8 International Mining | JUNE 2012


GREAT MINES

Automated John Chadwick


examines South
Africas second

Finsch
largest diamond
mine - a world
leader in block
caving and
automated loading
and hauling

hen De Beers Consolidated Mines sold system at Finsch mine commenced during the Examining a drawpoint

W Finsch, Barend Petersen, Chairman of


DBCM said: We are particularly
pleased to have been able to conclude this
middle of 2005 and was completed during
December 2006. (IM, January 2008, pp14-25).
This system was planned to be implemented in
single semi-automated Sandvik TORO 007
loader was added to the system during 2007
transaction with Petra. Their track record as a various implementation stages. During the first and operates on the undercut level of the mine.
hard rock underground diamond miner bodes stage only the dump trucks were automated and Based on the performance of the semi-
well for the long-term sustainability of Finsch in addition location and production tracking of automated loader, a decision was to be made on
going forward. The acquisition was completed all the production loaders in Block 4 was the commencement of stage 2 which would see
on September 14 last year. included with the system. This manual tracking the introduction of semi-automated loading on
Finsch mine is located South Africas Northern was considered a very important aspect in the the extraction level of the mine. These plans
Cape some 165 km west of Kimberley. It is a operation and management of this 100 m block may now change under Petra and much of the
major resource of 43.7 Mct, including 25.8 Mct cave. greater levels of automation may be held over
in reserves and 2.5 Mct in tailings. Petras Under De Beers, Stage 2 would involve the until Block 5 mining starts up.
expansion program aims to take production automation of only a few loaders together with The Finsch kimberlite pipe is a near vertical
from 1.5 Mct/y to just under 2 Mct/y. The the automated dump trucks and finally Stage 3 intrusion with a surface area of 17.9 ha, elliptical
current 1.5 Mct/y is roughly comprised of will be the automation of all loading and hauling in outline. It is a Group II kimberlite pipe with an
900,000 ct ROM and 600,000 ct from tailings. resources underground in the block cave. A age of 118 Ma that was emplaced through a
The current mining operation employs a panel
caving operation producing in the order of
16,000 t/d. Over 302 production drawpoints are
located within 11 extraction tunnels and
diamond bearing ore is also remucked from four
undercut ore passes. Sandvik LHDs tram the
loaded ore to five designated split level transfer
points located on the perimeter of the ore body
after which the ore is dumped into Sandvik 50-t
capacity 50D trucks a fleet of nine units. These
trucks run without operators on the Sandvik
AutoMine system and haul the ore and dump
into the primary crusher located at the shaft
which is located about 800 m away from the
orebody. The mixed Sandvik LHD fleet comprises
two 006 machines delivered in 2005, eight 007s
delivered between 2004 and 2007 and four
LH410s two delivered in 2009 and two in 2010.
Commissioning of the AutoMine Stage 1 Sandvik LHDs are the main laoding and hauling units

10 International Mining | JUNE 2012


GREAT MINES

thick sequence of Transvaal Supergroup Sandvik truck being loaded under AutoMine
control. MMD sizers reduce the kimberlite to
sedimentary rocks comprising dolomites, 300 mm for transport to the shafts and hoisting
banded iron formation and shales that overlie to surface
the Western part of the Kaapvaal craton
The pipe is made up of eight kimberlite to be depleted by FY 2015. The future mine plan
facies, two of which make up majority of the is to open up new cave in Block 5 - Probable
main pipe and are currently being mined. There reserves of 22.1 Mct at 47.6 ct/100 t. The mine
is significant potential for mining at least one of will maintain production levels during the
the precursor kimberlite bodies attached to the transition from Block 4 to Block 5 by developing
main pipe. smaller sub-level caves within the Precursor
The current life of mine plan extends for 18 orebody at Block 4 level and within Block 5. This
years, but the orebody remains open-ended at will enable Petra to maintain underground
depth so there is potential for a much longer production at around 3.2 Mt/y, ramping up to
life. Petra is currently mining Block 4 at 630 m at 3.5 Mt/y by FY 2018 once the Block 5 cave is
a rate of 3.2 Mt/y at some 35 ct/100 t; expected fully operational.

1961 Finsch Diamonds founded by Fincham & Schwabel


1964 All shares and rights of Finsch Diamonds acquired by DBCM
1967 Official opening of Finsch, as an open pit, and establishment of original plant At the end of 2011, the operating costs (OPEX)
1978 First stage of underground mining with start of decline and construction of shaft were estimated to be R130/t (total) treated
1980 Extensive modification of treatment plant 46% of which was labour, 23% stores, 12%
1990 Open pit mine operation ceases; opening of decline and start of underground production power and 19% other. Ongoing OPEX issues
2001 ISO14001 certification achieved being addressed:
2003 Processing of pre-79 tailings commences The rising cost of electricity through effective
2005 Commissioned worlds first fully automated underground trucking system design, maintenance and management of
2007 6.0 million fatality free shifts new and old infrastructure
2008 Undercutting of the block cave for Block 4 is completed Designs to cater for appropriate levels of
Treatment plant upgrade is completed (cost of ~$100 million) automation
2011 Acquisition by Petra Diamonds completed 14 September Advancement of a group procurement
strategy to yield benefits related to
economies of scale.

MURRAY & ROBERTS CEMENTATION


ST

MAKE IT YOURS!
Produced by Coralynne & Associates Tel: (011) 422-1949

www.cementation.murrob.com

SHAFT SINKING RAISEBORING DEVELOPMENT CONTRACT MINING MINE ENGINEERING

JUNE 2012 | International Mining 11


GREAT MINES

The new plant


The Finsch Mine Treatment Plant Upgrade
(FMTPU) was one of the last investments made
by De Beers to improve diamond recovery at the
operation. The FMTPU project was completed by
Bateman Engineering in 2008 and had the
objective of improving overall diamond recovery
efficiency as well as improving the value of the
diamonds recovered by implementing available
diamond friendly liberation processes that
reduce diamond damage.
As a result of the upgrade, the feed rate from
various feed sources to the plant increased from
960 to a maximum of 1,260 t/h and the capacity
of the plant was increased by some 25% to
process an additional 1.4 Mt/y of tailings
material. This meant an increase in total plant
capacity to 7.2 Mt/y.
Finsch is currently treating pre-1979 tailings
at a grade of about 18 ct/100 t. These are
expected to be treated at a rate of
approximately 3.5 Mt/y until depleted in FY
2015. Post-1979 tailings are to be treated
thereafter, at a lower estimated grade of some
10 ct/100 t. Diamond recovery from tailings is
expected to cease in FY 2020. A program to
increase tailings throughput to achieve 3.5 Mt/y
by FY 2014 is progressing well and could be
achieved ahead of schedule.
The objectives of the upgrade was to improve
overall diamond recovery efficiency levels, and
importantly, to improve the value of diamonds
recovered by liberating diamonds from the
kimberlite, in carefully designed diamond
friendly processes developed and implemented
by the De Beers technical project team. The new
plant includes the installation of high-pressure
roller crushers to replace the relatively dated
rod milling process used before, and two new
secondary crushers, replacing the older

Diamond recovery
Hardness (Liberation)
Diamond Mohs Scale = 10,
Tensile Strength = 2,400 Mpa
Kimberlite Mohs Scale = 6,
Tensile Strength = 10 Mpa
Density (Dense medium separation)
Diamond - SG = 3.52
Kimberlite - SG = 2.65
Hydrophobic and oleophyllic
(grease recovery)
Colour (transparent optical sorting)
Shape (shape sorting)
Non-magnetic (magnetic separation)
Fluorescence (X-Ray recovery)

12 International Mining | JUNE 2012


GREAT MINES

Murray & Roberts Cementation established an innovative emergency egress system from design diamond recovery technology. Much of the
to operation in just 11 days at Finsch. A temporary personnel escape route from the underground technology installed at Finsch was developed by
operations was needed while refurbishment work, which will take several months, was being
DebTech, the De Beers Groups technology
conducted on a decline which normally serves as the second escape route. These pictures show the
view from the control cabin onto the winch and the headframe, and the first passenger test run. An research and manufacturing division based in
existing 2.1 m diameter raise-bored ventilation pass was used that extends 280 m to the mines 35 the south of Johannesburg.
level, to create the required emergency evacuation facility. The facility comprises a small headgear, a
The scarcity of water in the region was
winder system and a wheel-guided conveyance capable of transporting 12 people at one time to the
surface in the event of an underground emergency. Murray & Roberts Cementations Neil Lane another important consideration in the design of
explains: We containerised and pre-commissioned the entire winch system, so it was a case of the more-efficient plant. A new thickener and
plug and play when the facility arrived on site at the mine. The mine cast a concrete slab in
associated infrastructure was added to the plant
preparation, and when the winder arrived it didnt take long to couple up the cables and get the
system going. The electrically-powered winch, with standby generators available, hoists at a travels to improve the internal water recoveries. This
speed of 0.5 m/s led to a lower volume of water used per tonne of
kimberlite processed.
technology cone crushers. The capacity of the converting the existing DMS plant to a fines In addition, new technology was required to
plant rose from 5.8 Mt/y of kimberlite to 7.2 DMS plant, thus allowing for a more efficient make it viable to retreat the tailings deposited
Mt/y. The efficiency improvements were DMS process. This feeds correctly prepared prior to 1979.
achieved with the addition of a coarse Dense diamond bearing kimberlite to a new final The FMTPU was one of the largest diamond
Medium Separation (DMS) Plant and by recovery plant that includes the latest X-ray contracts ever awarded to Bateman. IM

    


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JUNE 2012 | International Mining 13


OPERATION FOCUS

Potash from Iberpotash is now the only potash producing


company in Spain and the largest mining
company in Catalonia. The mines also represent

Iberia one of the most important resources of potash


in Europe.
One of the principal projects for Iberpotashs
future is the further increase of production using
a selective extraction method with continuous
miners, as well as making ongoing and
continuous investment in all the Cabanasas
mine facilities and machine maintenance
capabilities.
In the medium term, the company wants to
grow production to 1.1 Mt/y KCl and 3 Mt/y of
salt. A recent 3D seismic geological campaign to
confirm the size of regional potash occurrence
as the basis of a major reserves increase
Sandvik MR520 covered an area of 40 km2 and cost more than
roadheader in action at
the Cabanasas mine 8 million. Of the new KCl capacity, 630,000 t/y
will be granular potash and 50,000 t/y technical
potash, with the fine material forming the
Paul Moore visited the Iberpotash Cabanasas operation in remainder. About half of the 3 Mt/y salt figure
Catalonia, northeast Spain, to see the companys will be higher priced vacuum salt. Ultimately the
continuous mining process for sylvinite production, as well phasing in of increased mine production at
Cabanasas and plant production at Suria will
as to get the latest on planned expansion at the mine lead to the phasing out and eventual closure of
operations at Vilafruns and Sallent.
Mining area history and future northern England along with phosphate producer In order to achieve these production levels,
he potash ore (sylvinite) deposit was Rotem and a number of fertiliser production Iberpotash has embarked on an investment

T discovered close to Iberpotash's current


facilities in 1912 by Rene Macary and Emili
Viader, who were looking for potash following
plants. In August 2006, one of the two Suria
mines was closed commercially but there are
plans to develop it for use in earth sciences
plan, known as the Phoenix project, that
consists of a series of different phases. This
includes the building of a new ramp for the
its discovery in Germany and knew this part of academia and the tourism industry it will be part Cabanasas mine, and the building of a new
Spain was prospective. They drilled a series of of a UNESCO Geopark. As a result, Iberpotash vacuum salt plant at Suria to increase the
holes and discovered first salt and then potash. now has two production areas one at Suria profitability of the salt business. A first phase
Since then, a series of different companies have consisting of the Cabanasas mine and Suria was approved in 2011 by ICL, based on an
exploited the potash ore in this areas of the processing plant; and other in Sallent composed investment of 160 milion, and is now being
Catalan basin, which is found close to the towns of the Vilafruns mine and Sallent processing plant. implemented.
of Suria and Sallent, some 60 km from The long term importance of the operations to the The system of management for achieving a
Barcelona and close to the town of Manresa. In area has been considerable, with almost 1,200 sustainable mining industry that is in use in
1918, the first granted mining concessions were employees, of which 350 are contractors. Iberpotash is supported by the international
granted and in 1925 the Suria potash mine
started operations, followed by the Sallent Underground trucks of 30
potash mine, operated by Iberian Potasas, in t capacity with ejector
bodies are used
1929. The current Cabanasas mine began
operations in 1960 under the ownership of MPS.
In 1972, Potasas del Llobregat then began
operation of the Vilafruns mine.
The major change came in 1982 when MPS
was nationalised and from then on known as
Suria K. Then in 1992, Suria K merged with
Potasas del Llobgreat to become Grupo Potasas
Group and from this date, the Catalan potash
mines, after many decades of history under
separate owners, were finally organised under
one managerial unit.
Finally, in 1998, Grupo Potasas was acquired by
Iberpotash SA, a division of ICL Fertilisers, an
Israeli multinational company and one of the
major global fertiliser producers, that also owns
the Cleveland Potash Boulby operation in

14 International Mining | JUNE 2012


OPERATION FOCUS

certificate ISO 9001 and according to averages 6-6,500 t/d of silvinite but
the group it is the only mining new development underground,
company of Spain that can extend together with an advanced
this certification to all of its mining continuous mining system, will
and processing facilities . The allow this figure to increase to over
company also obtained in 2008 the 7,000 t/d. The Vilafruns sylvinite
additional ISO 14001 certification for averages 22% KCl, versus
environmental performance and at Cabanasas at more than 27% KCl.
the end of 2009 obtained the The fleet at Cabanasas is formed
international certificate in prevention of 30 t trucks that include eight
and safety, OHSAS 18001. Atlas Copco Minetruck MT436Bs as
well as additional six GHH
Mining method Fahrzeuge trucks, both of which are
Both mines exploit sylvinite ore (a loaded by a fleet of seven Sandvik
mix of sylvite: KCl and halite: NaCl) electric roadheaders four newer
from the same orebody, with Vilafruns machines delivered as MR520s and
extracting potash ore via a 2,400 m three older machines with the
12 grade decline, with a production previous AM85 model name. Both
of some 10,000 t/d of sylvinite. the truck models have ejector
Cabanasas exploits a part of the bodies for more efficient unloading.
deposit north of the El Tordell fault A significant investment
and Vilafruns to the south of it. A programme in recent years has
major aspect of mine development is allowed Cabanasas to develop its
to initially remove about a third of the current continuous mining process,
ore tonnage that is richest in salt based on the electric roadheaders,
(halite) which is used to backfill the which allows the maximum amount
empty potash ore galleries. of sylvinite selectivity to be
Cabanasas has a vertical shaft with a achieved versus conventional drill
30 t skip, running at up to 16 m/sec, and blast. The very exact profiles as
allowing a potential production rate Sylvinite ore entering feeder breaker before a result of this style of extraction,
of 10,000 t/d. Actual Cabanasas extraction being conveyed to the hoist level also increases gallery and pillar stability.

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JUNE 2012 | International Mining 15


OPERATION FOCUS

The Iberpotash Cabanasas mining operations


will form the basis of future expansion, along
with the nearby Suria plant

The mine also has a fleet of Atlas Copco


ST1030 LHDs, used for development work; and
Liebherr road maintenance vehicles. No
shotcreting is required in the mine, but bolting
using Sandvik Robolt models is conducted,
mainly with Minova Lokset resin cartridges.
The main hoist level is at 680 m from surface
with the main production level at 800 m and the
main workshop at 834 m, with the main
development level at 900 m. In addition to the
main production shaft, a second shaft is used
for worker access to the mine. The production
areas are located just above the main ramps in
the potash rich zones; with the development
area in the salt below.
The underground 30 t trucks empty potash
ore into vertical ore passes that feed temporary
stockpiles known as under which are located diesel machine from an electrohydraulic then ground to -1.5 mm and treated to remove
chain conveyors similar to those used in the coal machine and adds a new bolter to the rock waste clays.
industry. The ore is conveyed a short distance to support fleet at Cabanasas. Other improvements Then, using conventional flotation and
a feeder breaker that feeds a suspended include the construction of a completely new constant oversaturation of the water with the
conveyor positioned perpendicular to it. There enclosed operator cabin with improved controls mineral salts, the potash is separated from the
are two main conveyors that go directly to the and display. salt. Achieving the potash buoyancy does not
hoist and skip via two main ramps connecting require xanthate as it is not a sulphide, and is
the production and hoisting levels. One of these Processing and marketing instead achieved by adding pine oil or guar
carries intake air and the other return air and The main objective of the downstream process gum, which makes the potash hydrophobic; and
the two ramp areas separated by ventilation is to separate by physically the salt and potash, the particles adhere to the air bubbles. The
doors. The air is circulated using a network of which as stated occur together in the mine in foam is dried using natural gas fuelled fluid bed
Zitron fans. the form of sylvinite. The processing plant at dryers. The final product is 95.5% KCl. After
The Cabanasas ROM production is about Sallent (ore from Vilafruns) has a capacity of drying, the flotation concentrate is divided into a
6,500 t/d. Currently the company uses road 450,000 t/y of KCl, while Suria (ore from standard or further processed into a granular
haulage trucks to take ROM ore from the mine Cabanasas) has a capacity of 580,000 t/y of KCl. type. The standard potash has a grain size of 0-
to the nearby Suria plant but is planning an Both plants use conventional grinding followed 1.5 mm and granular potash 2-4 mm. Final
underground tunnel connection to link the by flotation and achieve an average recovery of potash transport is by truck or train. Iberpotash
mining operations and processing facilities, 89.5% and a concentrate grade of 95.5%. The relies on four rail terminals for bulk salt and
thereby removing a significant about of road plants together are now producing some potash transport, and has its own terminus in
traffic from the local area. 800,000 t/y of potash but as stated, as Suria the Port of Barcelona.
Local company Codina has the contract for undergoes a major planned expansion, Sallent The impure sodium salt from the flotation
service and maintenance of the mine fleet both will be phased out. rejects is sold to the chlor-alkali industry as well
within the mine and at a local service facility. At both plants, the sylvinite is primary as for road de-icing. The principal use of potash
Codina recently completed the rebuild of an crushed to -150 mm and transported to large is as a fertiliser as a component in NPK and
older Robolt H530 rig, originally delivered in sylvinite covered storage areas. Before flotation other fertilisers, with some 95% of KCl
1996. The machine has been converted to a it undergoes secondary crushing to -10 mm and production from Iberpotash used in this market,
with the remainder used in a variety of chemical,
pharmaceutical and other industrial markets
Sandvik units delivered to Iberpotash (1995 to 2012) such as crystal manufacture. The company
exports over 70% of its potash production to
Model Units Year delivered fertiliser operations in Asia, North Africa, Europe
Pluton (Axera) D6 jumbo 1 1999 and South America. This includes fertiliser
Robolt 5 (126XL) bolter 1 2006 production by ICL Fertilisers itself but also by
MR520 roadheader 3 2008 other companies, particularly in China and India.
MR520 roadheader 3 2009 Despite potash being the main economic
MR520 roadheader 1 2010 product, salt production is actually higher in
MR520 roadheader 1 2011 tonnage terms, reflecting the fact that the
MR520 roadheader* 1 2012 proportion of halite in sylvinite is higher than
*Formerly the AM85 sylvite generally over twice as much. Salt
production is over 1 Mt/y. IM

16 International Mining | JUNE 2012


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OPERATION FOCUS

Gold breakthrough The main current pit exploiting the Kearney vein

the Kearney structure, commencing some 44 m


north of the Riofinex excavation and in 2000 and
2001, carried out selective mining trials at the
southern end of the Kearney structure and
produced high grade, sulphidic gold ore. In the
following years Omagh Minerals produced gold
Paul Moore visited the bullion with full accreditation of the Irish source
operations of Galantas Gold and produced and sold 18 ct gold jewellery
under the Galantas brand name of a wholly
near Omagh in Northern Ireland owned subsidiary.
to get the latest on a small but EGR then commissioned ACA Howe to prepare
a technical report in compliance with Canadian
commercially successful surface National Instrument 43-101 which significantly
operation that is planning to broadened the scope and increased
mine underground and unveil a understanding of the gold mineralisation
leading to further resource increases based on
signicant increase in resources sampling conducted at the OMAC lab in Galway,
now part of Alex Stewart Assayers. European
t could be said that Galantas Gold is one of phase in terms of investor awareness and Gold Resources was renamed Galantas Gold in

I the great unknowns of European mining a


commercial, producing gold mine (the only
one in Great Britain or Ireland) that has been
recognition of the potential of the project. While
the marketing of Irish gold is a great concept
and has every chance of success in the future,
2004 and it was Galantas, beginning in 2005,
that initiated mine development by engaging
technical staff, updating engineering design,
operating for a number of years with significant for the moment the company is focussing on procuring both mobile plant and processing
potential and likely future increases of continuing to make the mine work as a plant equipment and removing further
resources to over 1 Moz. But the mine remains commercial operation. overburden. The company also conducted
relatively unknown even in the rural area airborne time-domain electromagnetic (VTEM)
where it is located near Omagh in the west of Background and geology and magnetic surveys to improve the quality of
Northern Ireland. Welsh gold marketed by Following the discovery and exploration of vein geological mapping of the poorly exposed area.
Clogau is well known but was and is produced in gold at Curraghinalt in the Sperrin Mountains of The ore is hosted in Dalradian strata,
minute quantities; while the pursuit of gold Northern Ireland by Ennex International in the metamorphosed as a result of the Caledonian
mining in Scotland is still some distance from mid 1980s, Riofinex commenced exploration of a orogeny. Most of the gold bearing veins are
becoming a reality. geological inlier known as Lack. Riofinex found close to and in association with the
The reasons for Galantas being relatively discovered the gold-bearing Kearney vein Omagh Thrust Fault. Mineralisation occurs in
unknown up until now are varied. It is partly structure and the surrounding swarm of gold metamorphosed sandstone horizons,
related to the fact that the company has veins during the course of an exploration and particularly in brittle psammite, which are
previously met with mixed success in its resource delineation programme. Due to the broken up by some ultra-basic intrusives.
attempts to make inroads into the jewellery early discovery of the Kearney vein swarm, the Steeply dipping quartz veins are present, mostly
market with its 100% Irish gold, so there has efforts of Riofinex were more concentrated in a on a north-south orientation, which carry more
been confusion about the fact that it also a relatively small area in the eastern part of the than one phase of mineralisation. The minerals
successful commercial mine in its own right. project area. present in the quartz veins are calcite, pyrite,
There is also the point that there are so many In 1990 the Riofinex project was transferred galena, gold and silver with minor sphalerite,
gold juniors around, most of which never even to Omagh Minerals who commissioned Kilborn arsenopyrite and chalcopyrite. The rocks have
get to a scoping study stage, so investors have a and Knight Piesold to study metallurgical been up-faulted in a block (the Lack Inlier) and
tendency to only have the largest projects in the recovery and the practicalities of mining with a part of the lithological sequence has been
more exotic locations on their radar. In addition, focus on the Kearney deposit. Simultaneously, inverted by another fault which is a major
those responsible for making the mine a reality Wardell Armstrong carried out an environmental feature and it is thought that the mineralisation
formerly Jack Gunter, Chairman and more Impact Assessment (EIA) which was completed is related to this structure.
recently Roland Phelps, President and CEO by late 1992. The Crown Estate Commissioners There are two current licence areas, OM1 and
have been waiting for the right time, while awarded a Lease of Rights to work gold and OM4, covering a large area. Of the known
quietly advancing the operation to a point where silver (Crown Estate mining lease) in 1993 with a steeply dipping gold veins, Kearney remains the
it is profitable, has significant long term ten year initial term, over land including the richest to have been discovered to date. Kearney
potential through a near mine and regional Kearney vein, with effect one month after the ranges between 0.5 to 3 m in width and deep
resource base, and has the right team of people award of Planning Permission. Following a hole drilling on this vein has been conducted
involved. public inquiry, conditional planning permission since July 2011, with some samples showing 10.9
With a major new interim resource for a mining and processing operation was g/t in places. The Joshua vein is the second
announcement due by end May 2012 at the time granted in 1995 over land owned by Omagh main target currently, and has been sampled
of publication, and with future updates expected Minerals. In 1997, European Gold Resources using channel sampling along its 785 m strike.
to see a total resource of over 1 Moz of gold, this (EGR) of Ontario acquired Omagh Minerals. Joshua has also been drilled, with 36 holes
very much seems to represent the breakthrough Omagh Minerals excavated another open cut on completed since March 2011 at 25 m intervals.

18 International Mining | JUNE 2012


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OPERATION FOCUS

by gravity methods environmentally safe for sale to other markets.


but the majority of The company is obliged to backfill the open pit,
the material, mixed restore the site and dispose of the surplus rock
with water and a from the site under restoration arrangements.
small amount of The mine operates a very successful natural
xanthate, is passed dewatering programme using paste cells, with
to froth flotation. The the waste dewatered without the need for any
rougher circuit thickener additions.
consists of two A mill refurbishment and upgrade program,
banks of four Denver including the installation of a new jaw crusher,
(now part of commenced in the fourth quarter of 2010 was
FLSmidth) DR-30 completed in the second quarter of 2011. In
Partly backfilled pit from cells, the cleaner total, tonnes milled during the year ended
where the cut and fill tunnel circuit consists of December 31, 2011 increased by 29.2% to
and subsequent decline will
be developed on the left of one bank of four DR- 46,871 t and concentrate production for 2011
the picture 18 cells and one increased by 51% to 2,265 dry tonnes. Some
bank of two DR-30 6,479 oz of gold, 17,082 oz of silver and 280.1 t
Current operations cells while the scavenger circuit consists of two of lead were produced.
Galantas subsidiary Omagh Minerals owns the banks of DR-20 cells.
freehold title to over 220 acres on land upon Final concentrate is fed to a thickener, which Advanced exploration
which the initial open pit mine, processing also acts as a buffer tank, then to a manually Following a channel sampling program in the
plant, tailings facility and water clarification operated Perrin filter press and finally into bags latter half of 2010, a drilling contractor was
ponds are situated. The sulphide ore, containing ready for dispatch. Final concentrate has a engaged, starting at the end of February 2011 to
gold associated with some silver and galena (for moisture content of approximately 8% with a core drill priority targets. Five rigs are operating
which a smelter premium is gained), is mined gold content of between 100 and 130 g/t on a contractor basis and one rig has been
from the steeply dipping veins within a small dependent on the feed material. Typically 28 purchased new, an Atlas Copco CS14. The new
open pit, with a second open pit under bulk bags, each containing approximately 850 rig has been commissioned, the crew is trained
development and a third mined out pit that is to kg of concentrate are then loaded into a and the rig operating well using new Boart
form the start point for the underground mine. standard container for despatch to the Port of Longyear coring bits. The CS14 diamond coring
The Kearney vein is the one currently being Belfast. The number of bags per container is rig is capable of drilling at angles between 45
mined. The ore and overburden are mined aggregated to achieve maximum permissible and 90. It is diesel powered and is towable
separately, without the need for blasting, as it is weight of 24t. The concentrate is shipped to an behind a tractor or excavator. Core diameter is
mainly friable due to deformation and can be Xstrata smelter in Canada, with which Galantas HQ using triple tubes and core recoveries have
ripped effectively using the fleet of hydraulic has a long term offtake agreement. been in the region of 90%. The use of a triple
excavators and crawler dozers. Planning consent The washed, fine sand that is left behind is tube is to ensure no quartz is lost through
for blasting has been obtained but is not very clean and is routinely tested several times a flushing as the quartz breccia is an important
currently required, though will be used once the day to ensure process efficiency remains high host of the gold mineralisation. The official core
operation proceeds underground. and that minimal metals are left behind. grades are slightly lower than the reality found
The conventional open pit fleet mainly Independent laboratory tests show that the in the mine; this is due to dilution due to
consists of 35 t and 40 t ADTs, principally the clean tailings sand produced by the process is flushing of clay, which hosts small amounts of
A40D and A35D from Volvo; loaded by quarry
class excavators such as the Volvo EC290BLC The Galantas owned Atlas Copco
and the Hitachi Zaxis 470LCH and Caterpillar CS14 exploration rig, used along
with five others in an intensive
330CL. The operation has been quite innovative
15,000 m core drilling programme
in retrofitting small, narrow buckets onto
excavators for selective mining of the narrow
veins after they are exposed following
overburden removal. Unusually for a small,
focussed mine, the whole fleet, aside from some
contractor operated Caterpillar dozers, is fully
owned by Galantas.
At the plant, the ore after being passed
through a grizzly is crushed in three stages (two
jaw, one cone) to achieve a -2 mm product that
goes to a spiral classifier after which the
classified solids go direct to the ball mill. Spiral
overflow goes to a sump for settling and
subsequent batch recirculation direct to the ball
mill. The ore is ground together with water in
the ball mill to achieve a product of 50% -75
micron. Some of the ground ore is then treated

20 International Mining | JUNE 2012


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OPERATION FOCUS

cover tunnel within the backfilled open pit, on


which work is set to commence with a view to
enhancing deep drilling access, followed by a
spiral decline to the base of the Phase 1
underground mine at 350 m below surface. A
raise bored shaft will also be excavated to
provide emergency egress and ventilation.
Potentially the mine may progress to deeper levels
than that planned for Phase 1 but this will be
subject to the identification of resources by
drilling.
The question was raised during the visit as to
why an underground project was not pursued in
the first place. One of the principal reasons is
that even to get the surface project up and
running saw the management having to endure
Diagram showing planned
layout of underground one of the longest public inquiries in Northern
operations at Galantas Irelands history. In addition, the gold price was
much lower at the time due to different
gold. A tracked rig has also been purchased. A had lapsed in 2010. Fieldwork was carried out economic conditions, which would not have
used machine, it requires conversion and within three areas of the OM4 licence during the made the underground option as attractive. As
refurbishment and this is underway. fourth quarter of 2011. In addition, an CEO Roland Phelps told IM: The surface mining
Up to 15,000 m of core drilling is planned in application was made for four exploration strategy we opted for then was the only
the current program. The initial phase of the licences in the Republic of Ireland, covering an practical option at the time.
program includes the Kearney, Joshua, Kerr and area of 160 km2, that forms a westerly extension As stated, production at the Omagh mine
Elkins Vein systems. Over 6,500 m had been to the existing OM4 licence, which was during the year ended December 31, 2011 was
completed at the time of the IM visit. In March subsequently granted in March 2012. A publicly above production levels of both 2010 and earlier
2012 the company engaged ACA Howe funded geochemical and geophysical program is years with record production levels being
International once more to provide an interim presently being carried out in these border achieved during the second quarter. However,
updated resource estimate for the Omagh mine areas and it is anticipated that Omagh Minerals mining from the Kearney pit was restricted
to be prepared in accordance with Canadian will benefit from the additional data. during the second half of 2011 due to limitations
National Instrument 43-101 standard, and which in the disposal of surplus rock which had been
will estimate all resources discovered to early Future development underground stockpiled over a period of time, which resulted
April 2012 in the current drilling program. This The company is convinced that the future of the in additional ore being mined from other lower
end-May 2012 report will also address the property lies in the development of the grade areas. Whilst the mine is required under
underground mining scoping study currently underground mine. The underground mine its planning permission to dispose of the
underway at the Omagh mine. The drilling planning application is approaching completion, surplus rock, the consent to transport the
program will continue beyond April and a with aspects of it in pre-consultation. The cost surplus rock offsite from the current stockpile
second interim report with a further updated scoping study has been completed, and all had not at that time been confirmed by the
resource figure, is expected to be released necessary land ownerships acquired, including relevant local authority, though it has been
during the fourth quarter of 2012. the required new tailings area. In addition, the given subsequently. This has resulted in the
The campaign has focussed on 15 of 50 well Environmental Impact Statement is at an level of stockpiled surplus rock now being at
identified targets. Drilling on the Kearney vein advanced draft stage and near completion. capacity levels which has and will have a
has been carried out at depth with the objective Development will be using trackless significant adverse impact on production from
of gaining a more accurate picture of the zone of equipment, expected to be 20 t underground the Kearney open pit going forward. Subsequent
mineralization for the purpose of underground trucks teamed with narrow vein one boom drill to this Omagh Minerals obtained confirmation of
development. Channel sampling was also jumbos, small LHDs and vertical production planning permits to transport the surplus rock
carried out on the Joshua and Kerr vein systems drills. No decision on equipment to be used has offsite to be integrated into the local aggregates
with the focus being mainly on Joshua due to yet been made. The mining method will be industry. However, due to the conditions
higher grades and widths of mineralization. conventional shrinkage stoping with cemented attached to the permit it will be some months
Assay results released to date from both the backfill and tailings storage using encapsulated before the transportation of this rock can
drilling and channel sampling program have cells. Processing will be similar to the current commence. This will result in lower grade
been encouraging with significant gold polymetallic concentrate production through low material being worked in 2012 which is resulting
intersections being identified. toxicity, non-cyanide utilisation, froth flotation. in both revenues and cash generation being
Galantas also continues with exploration The planned nominal gold production from the reduced during 2012. Because of this ongoing
outside the mine and focus OM1 licence area, underground mine will be 50,000 oz/y. The restriction in mining, together with the positive
and in early 2011 a new licence area, OM4, underground strategy will be similar to some of assay results from the deep drilling program, it
covering an area of 252 km was granted for a the smaller, rapid underground development is likely that future increases in production from
two year period. This licence area covers most of gold mines in Australia and elsewhere such as the lower levels will not be achieved until
the previous OM2 licence area and the northern those operated by Troy Resources and others. mining commences from the planned
section of the OM3 licence area both of which The initial plans include include a cut and underground mine. IM

22 International Mining | JUNE 2012


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ENGINES

The final tier


The first commercial customer for the GFS EVO-
MT dual fuel technology is Alpha Natural
Resources, which has installed the retrofit on
three Caterpillar 793B trucks in Wyoming

mining countries outside of North America and


the EU as it relates to emissions targets. As an
example, globally, more than 2,300 MTU Series
4000 Tier 1 engines are in operation in mining
equipment and the company continues to
support this fleet.
The acquisitions in the market are also
affecting engine approach. For example, the
Caterpillar Unit Rig line of trucks is being
transitioned to Caterpillar engine power from
other manufacturers. Several MT4400 trucks
have already been manufactured at the Acuna,
Mexico facility with Caterpillar engines and this
trend is expected to continue throughout the
whole Unit Rig range. This model was formerly
offered with either a Cummins QSK60 or MTU
Series 4000 engine.
Atlas Copco has been a major user of
Caterpillar engines for years, but with the
Bucyrus acquisition, Caterpillar is now
producing competitor surface drilling equipment
to Atlas Copco while continuing to supply it with
engines independently. This may continue
unchanged, but for many of these products,
Atlas Copco can offer either a Caterpillar or
Cummins engine so going forward, any change
in the Caterpillar strategic approach may not
have that much of an impact. The Pit Viper 351,
for example, is offered with a Caterpillar 3512 or
Mining engines, as other industrial a Cummins QSK45 engine.
engines, are having to comply with
Tier 4 Final regulation ahead of The largest engines
The largest mining trucks, wheel loaders,
2015, which is being achieved by blasthole drills, gensets and hydraulic
varying technologies, reports Paul excavators are powered by engines from
Caterpillar, MTU and Cummins which at the top
Moore, while natural gas engines end includes the Caterpillar C175-20, the MTU
are gaining traction Series 4000 and the Cummins QSK78 (and its
new QSK95).
Caterpillar has begun its journey to Tier 4
Final with the new 91 t 777G truck, and while its
here has been a lot of activity in the additional 80% reduction in nitrogen oxides other key mining truck models are currently

T mining engines market, as manufacturers


release Tier 4 Final compliant versions
ahead of the 2014/2015 deadlines; but also key
(NOx) from previous regulations.
It is also an important time for engine
development given the series of new mining
equipped with Tier 2 compliant engines, the
777G serves as a guide to future developments
on the larger trucks. New emissions control
progress in the development of natural gas machines that are set to be launched, from the strategies enable the Caterpillar C32 engine on
solutions for engines and the diesel savings that new Liebherr T284 to the Hitachi EH5000ACIII the 777G to meet Tier 4 Final emissions
this will bring the downside being the and even a 450 t class model under regulations in the USA and Canada. The strategy
infrastructure that will need to be put in place development at BELAZ. At the same time, it is includes the Cat NOx Reduction System and two
for mines to store and distribute LNG. worth remembering that the majority of the Diesel Oxidation Catalyst canisters, one for each
US Tier 4 Final and European Union Stage IV mining equipment that is out there and in use bank of cylinders in the V-configured C32.
emissions regulations for mobile off-highway is still powered by older engine technology, with Working in combination with ACERT, the Cat
diesel engines 56 kW (75 hp) and above will be the transition to the latest low-emissions NOx-Reduction System diverts a small volume of
implemented in stages starting in 2014 and variants largely dependent on incremental mine cooled engine exhaust back to the combustion
2015. These standards maintain the particulate fleet replacement with new models as OEMs chamber. The result is reduced cylinder
matter (PM) levels established by Interim Tier stop supplying older engine options, as well as temperatures and reduced NOx formation. This
4/Stage III B regulations while requiring an the ongoing regulatory situation in the major NOx reduction system takes full advantage of

24 International Mining | JUNE 2012


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ENGINES

mine in Nevada to field test a 12V4000 4000-powered trucks are also currently
Tier 4 engine in a Komatsu 930E haul operating in trolley-assist applications such as
truck. Test operations will begin June the Hitachi EH4500-2. In the mining industry,
2012. From 2015, MTU has said that it will the Series 4000 powers not only mining trucks,
offer the Series 4000 Tier 4 Final engine but also hydraulic excavators, wheel loaders,
with 8, 12, 16 and 20 cylinders. Production blasthole drills, electric shovel motivators and
series supply is phased-in for each Series dewatering pumps. MTU states: The hydraulic
4000 cylinder size, but essentially the 8V, excavator is a very challenging equipment
12V, 16V and 20V will be available within application, given the demanding load profile.
months of each other, beginning January MTU currently supplies Series 4000 excavator
2015. In addition to field testing, the truck engines to Liebherr with the most notable new
OEMs will have access to Series 4000 Tier model being the R9800, which is powered by
4 engines in 2014, to accommodate twin 12V4000 Tier 2 engines. Our repower
The Caterpillar Tier 4 Final strategy has started required engineering, lead times and testing. successes include Hitachi excavator models
with the 777G but will eventually apply to the
MTU has maintained its success in engine EX2500, EX3600, and EX5500 which are
largest engines such as the C175-20, used on
the 363 t 797F supply for the largest haul trucks the company operating in the USA and Australia. Mine
told IM it sees this success as result of the operators are looking for longer engine life,
the cleaner, less corrosive properties of ultra- Series 4000 range offering a combination of greater reliability and improved fuel economy,
low sulphur diesel fuel and low ash engine oils safety, high reliability, reduced total cost of which are the compelling reasons they selected
to maintain service intervals and component life. ownership, high power density, reduced fuel the Series 4000 engine. In mining trucks, MTU
The two Diesel Oxidation Catalyst canisters trap consumption and longer times between has supplied the Series 4000 engine for the
residual hydrocarbons in the exhaust. This 777G overhauls. Three main 12V, 16V, 20V Liebherr T282 for many years with more than
Tier 4 Final strategy is transparent to the configurations are available and produce 1,600 250 of the 20V4000 engines in use currently
operator and does not require additional service to 4,000 hp. operating in T282B and T282C trucks. Liebherr
for the machine. With no after treatment needed, the basic has also recently introduced a 4,000 hp MTU
MTUs Series 4000 Tier 4 Final engine for engine envelope remains nearly the same. engine configuration model of the T282, which
mining will be available in 2015 for production Mounting points and fan location are consistent is expected to be referred to as the T284, and
series supply. The Series 4000 T4i (Interim) is with the T4i models leading to simple T4f four of these trucks are operating at high
already available for oil and gas applications. installation without the need for altitude in Chile, while the model will also be on
MTU has achieved Tier 4 emissions with no truck/application redesign, saving customers on display at MINExpo 2012. The Hitachi
after-treatment, having applied several key installation costs. MTU has also recently EH5000ACII also has an MTU engine, and
engine technologies to accomplish this, introduced a remote diagnostic system. This Hitachi is working on a new EH5000ACIII model.
including the implementation of their own feature provides supports personnel and users As previously stated in IM, Chinas XEMC has
LOrange design for fuel injection and MTU turbo with immediate or on-demand valuable utilised the Series 4000 Tier 1 engine in its
systems. In 1996, MTU introduced high pressure performance and diagnostic parameters through SF33900 240 t truck. Four units are currently
common rail fuel injection for large engine a secure internet connection. operating in Australia at a Rio Tinto operation,
power and now, 12 years later, the company is High altitude performance has been a feature and MTU states that China, both in terms of its
launching its third generation common rail of MTU engine success, where the major mining industry and as an equipment OEM base,
system which operates at 2,500 bar. In challenge is low air density. MTUs key engine remains a key focus. However, the majority of
combination with their own injector and engine technology and design has enabled the Series XEMC trucks including the SF33900 and the new
management system design, it enables the fuel 4000 to maintain power requirements while 300 t SF35100 have Cummins QSK60 engines.
injection system to achieve much greater control operating in high altitude environments. Series The largest BELAZ model, the 360 t 75601, has
of fuel metering. For Tier 4, MTU increased the
air induction pressure with an arrangement of
three regulated 2-stage turbochargers. MTU has
also developed and patented a unique cooled,
regulated EGR system. The company told IM:
Collectively, these core technologies and
several others form a complete engine package
which enables us to improve engine
performance and achieve Tier 4 emissions
without after treatment.
MTU began the development of Tier 4
technology in 2004. The final development
phase has arrived and involves field testing the
complete engine in a challenging operating
environment. MTU has an agreement with a gold

Cummins sees the QSK95 as having significant


potential in the next super ultra-class of
mining trucks

26 International Mining | JUNE 2012


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50 / 0 0 less diesel fuel
24 / 7reliability

Introducing the tm

GFS EVO-MT System:


Groundbreaking.
Visit us at MINExpo International 2012
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GFS introduces the worlds first natural gas retrofit solution for open-pit mining operations.The EVO-MT System
substantially reduces operating costs and improves sustainability without compromising production or safety.
Learn more about how our technology can fuel your performance, call +01.954.693.9657 or visit us on the
web at www.gfs-corp.com
GFS Corporation, 3360 Enterprise Ave., Suite 180, Weston, FL 33331
ENGINES

largest ever high horsepower engine, the 16


cylinder, QSK95 or Hedgehog in 2011, which
will have limited production starting in 2014 and
full production from 2015.
While for the moment, the QSK60 and QSK78
engines remain the focus for existing mining
trucks and excavators, the QSK95 sets the
company up well for future truck developments
in the ultra-class sector. The new QSK95 engine
will provide a 4,000-hp (2,983 kW) capability for
ultra-class mine haul trucks, representing the
highest-ever power output introduced by the
company for severe duty-cycle operation. The
95-liter displacement QSK95 is purpose-
designed to provide enhanced strength 327 and
363 t class trucks, with the capability to
increase truck speeds for climbing steep-
gradient haul roads and boost hauling
The MTU Series 4000 engine has been highly R996B and offered as an option on the R9800); productivity with reduced operating cycle times.
successful in the large mining truck market, but also in its global partnership with Komatsu. The QSK95 will be available as a global
such as on this Liebherr T282B at Codelco
Chuquicamata This covers all the key Komatsu mining truck, mining engine platform capable of operating at
hydraulic excavator and wheel loader models, as mine sites anywhere in the world and meeting
an MTU Series 4000 engine as does the 220 t an example with the SSDA16V160 engine on the all emissions standards, including Tier 4 Final in
75302. 930E effectively a Cummins QSK60. Hyundais North America by using Cummins proven
Cummins is the other key player in the three new 120 t R1200-9 mining excavator is powered Selective Catalytic Reduction (SCR) after
majors, both through supply of engines to by a high-performance 23 litre, 6-cylinder treatment. The 16-cylinder QSK95 reaches the
Hitachi for models such as the EH4000ACII Cummins QSK23-C rated at 760 hp (567 kW). mining power output previously available only
(QSK60), a number of the BELAZ mining trucks Particular attention has been paid to the from 20-cylinder engines. High power density is
such as the 220 t 75306 and 320 t 75600; and insulation to achieve low internal and external achieved with a hardened power cylinder
most of the key hydraulic mining excavator noise levels. featuring the strongest single-piece forged-steel
models from Hitachi and Liebherr (up to the In November 2011, Cummins launched its piston available in the industry, according to

28 International Mining | JUNE 2012


ENGINES

Cummins. Deep structural strength is provided


by an all-new ductile iron skirted block. The
group argues that this increased strength
contribute to higher engine uptime availability,
extended life-to-overhaul and more cost-
effective rebuilds.
The QSK95 is designed to meet the highest
expectations in the mining industry for uptime
availability, reliability and durability that will
exceed all other previous engines intended for
ultra-class haul trucks, said Jason Rawlings,
Executive Director Cummins Mining Business.
This combination of deep inherent strength
and proven systems means that the QSK95 will
be ready to provide outstanding performance on
the mine site from day one. The QSK95 will fully
complement the success of the QSK60 and
QSK78 engines in ultra-class haul truck
applications. These engines offer the widest and
most flexible power choice in the industry, means more reliability in-service and less to Westport Innnovations is advancing the HPDI
added Rawlings. rebuild at engine overhaul, considerably engine technology, where 95% of diesel is
displaced
The 4,000 hp (2,983 kW) output of the QSK95 reducing total life cycle costs, states Cummins.
engine is well within its design capabilities, with The QSK95 will provide an exceptionally long up to 2,200-bar high-pressure fuel injection,
potential power increases available in the future life-to-overhaul, capable of achieving 1.7 million MCRS reduces noise, offers smooth idle stability
to provide the possibility for the next generation gallons and more of fuel consumed before and eliminates visible smoke across the entire
of ultra-class haul trucks to move beyond the rebuild, with the added advantage of no mid-life operating range. Cummins new NanoNet fuel
363 t payload capacity. BELAZ has already intervention required. filtration gives superior fuel cleanliness and
stated its intention to build a prototype of a 450 A Cummins next-generation Modular enhances the durability of the MCRS system
t capacity truck in 2013, so this super ultra- Common-Rail System (MCRS) enables the an important advantage for mining engines
class of mining trucks is soon to be a reality. QSK95 to achieve high fuel-efficiency, even required to operate anywhere in the world with
The stronger engine design of the QSK95 when operating at maximum power output. With varying fuel quality.

JUNE 2012 | International Mining 29


ENGINES

compression stroke. HPDI allows replacement of


Caterpillar 777C truck with
GFS EVO-MT system during approximately 95% of the diesel fuel with
a test at a Kentucky coal natural gas.
processing facility GFS Corp is the main group currently
progressing the dual fuel solution in mining. IM
spoke with Jason Green, GFS President, about
the market niche and the technology. GFS
initiated mine truck development with its
technology in 2007, followed by a 2008 mine
truck field test using CNG and a 2010 mine truck
field test using LNG, with EVO-MT as a
commercial solution launched in 2011.
The GFS technology is comprised of patented
and proprietary technologies that allow diesel
engines to safely operate on gas percentages
ranging from 50% to 70% of the total fuel
requirement. Engines converted to gaseous fuel
operation exhibit diesel-like performance in
such critical areas as power, response and
efficiency. A key feature of the GFS system is its
A quad-turbocharging system brings the regard to any servicing which is required. This ability to switch fuel modes without interruption
simplicity of a single-stage air handling system information is advantageous to operators, and in vehicle operation. Conversion to GFS
already proven on the QSK60 engine. The four offers higher operational reliability, and allows operation does not require modification of the
compact turbochargers, one arranged for each for better maintenance scheduling. engine and can typically be completed in a
bank of four cylinders, provide outstanding The MANN+HUMMEL SintDOC, SintAC and matter of hours. The GFS system is compatible
step-load acceptance and transient response. SintROC diesel particulate filter systems are with both compressed natural gas (CNG) and
This enables the QSK95 to deliver more rapid equipped with the new electronics. The SintROC liquid natural gas (LNG) fuel storage systems.
power across the entire rpm range to improve diesel particulate filter for example is designed FSs commercial offering EVO-MT does not
haul truck speed at full payload capacity. for machines with engine outputs up to 600 kW. represent a full conversion but a retrofit for
Meeting strict emissions targets with existing mining trucks that allow them to use a
technologies such as DPF and EGR also involves Natural gas engine technology mix of diesel and LNG but also having the
specialist component suppliers. The whole arena of natural gas engines is really flexibility to allow the truck to run full on diesel
MANN+HUMMEL has further developed the gathering momentum in the industry. This is if required. The 2011 test on a Caterpillar 777C
electronics integrated in diesel particulate filters perhaps to be expected, as its use is already with a 3508B engine was very successful and
for non-road applications. Depending on the well established in on-road and marine because it was at a Cumberland, Kentucky coal
emissions, the self-learning system calculates applications. Driven mainly by sustained high processing facility a number of mining
its own regeneration strategy for the application diesel costs, a group of independent companies, companies had the opportunity to see the
in question and thereby reduces costs. The new along with the major engine OEMs and the results, which saw up to 60% replacement of
electronics also improves operational reliability, mining equipment OEMs are all involved. And diesel with LNG with no loss of performance.
installation and servicing. The modular system the savings of displacing diesel do not just This year, GFS is working with its launch mining
comprising software, sensors and actuators relate to the mining haul trucks they also customer, Alpha Natural Resources, at its Eagle
improves the operational reliability, installation relate to the engines on wheel loaders, Butte coal operation just outside Gillette,
and servicing of MANN+HUMMEL diesel excavators, ancilliary equipment such as Wyoming, with the system installed on three
particulate filter systems. graders, engines on ore trains, and the engines Caterpillar 793B trucks. GFS is also in
Depending on the machine application, the on the on-road trucks that bring in mine bulk discussions with the other major coal mining
electronics can be used just as a basic data supplies. groups in the Powder River Basin.
logger to acquire temperature and pressure On the technology side, there are two main For mining groups, utilising the system can
data. It can, however, also be used to control a approaches so-called dual fuel solutions, that potentially allow them to make huge fuel
complete diesel particulate filter system with use a bi-fuel mixer and port injection to allow an savings, while also offering the flexibility of still
passive or active regeneration. In this case only existing diesel engine to be retrofitted with an using as much diesel as they want. The retrofit
a few small extensions are required to convert LNG tank and run with up to 70% of diesel nature of the offering means they can use it on
the data logger into a control system. All replacement by LNG; and the high pressure their existing truck fleet, which in an uncertain
connected components are subject to direct injection (HPDI) technology that uses economic climate is very attractive. Most mines
continuous diagnosis. They are continuously natural gas as the primary (95%) fuel along with retain their fleet as long as possible, while
monitored and a message is sent if the a small amount of diesel as a pilot ignition buying new machines on an as needed basis as
component has a malfunction. Furthermore, the source. At the heart of the engine is an injector the oldest trucks are phased out, rather than the
electronics checks whether the components are with a dual-concentric needle design. It allows wholesale purchase of a whole fleet. GFS
exactly suitable for the installed system. A for small quantities of diesel fuel and large estimates that there are 35,000 trucks working
display with standard international symbols quantities of natural gas to be delivered at high with older Tier 0 and Tier 1 engines on which the
constantly informs the machine operator about pressure to the combustion chamber. The system could potentially be installed. Diesel
the status of the diesel particulate filter with natural gas is injected at the end of the prices tend to be quite volatile and LNG prices

30 International Mining | JUNE 2012


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ENGINES

combined their respective technologies and


The Sandvik LH621 LHD is powered
components to develop a fuel system that will
by a Volvo Penta D16 engine
be evaluated on a multi-cylinder test engine.
The statement said: Through this evaluation
project, Westport and Caterpillar are seeking to
demonstrate that the integration of their
respective direct injection, natural gas
technologies can deliver the high performance
and high efficiency requirements large engine
applications will demand. Under the terms of
the agreement, the evaluation is expected to be
completed in 2012, with program expenses
shared by both Caterpillar and Westport.
"We are excited to work with Caterpillar, the
worlds leading manufacturer of construction
and mining equipment, diesel and natural gas
engines, industrial gas turbines and diesel-
electric locomotives," said Bruce Hodgins, Vice
less so. The retrofit option means that mines do the company advancing the technology but its President, Market Development of Westport
not have to commit to LNG infrastructure to the business model is to work together with the key Innovations. "This is a significant opportunity
same extent and means they do not have to wait engine OEMs as opposed to acting as a third for both companies to demonstrate the viability
for an OEM gas engine solution to become party as in the GFS model. While HPDI could be of direct injection natural gas technology on
available. retrofitted, Westport believes that the market in large engines.
Natural gas perhaps unfairly is perceived as the long term wants more wholesale More recently, Westport announced that it
inherently dangerous by some, so safety has replacement of diesel with natural gas to had signed a development agreement with a
been a major focus for all the companies maximise savings. IM spoke with Paul leading but un-named global engine
involved. GFS for example supplies its system Blomerus, Westport Innovations Senior Director, manufacturer to develop a heavy-duty truck
with a variety of sensors installed including High Horsepower, accepts that moving to HPDI engine featuring Westport proprietary high
multiple flame detection sensors, a combustible engines would require a full commitment on the pressure direct injection (HPDI) technology for
gas detector, operator E-stop and status display, part of major mining groups to set up the the North American market. Under the terms of
as well as exhaust gas temperature and necessary LNG infrastructure, but addresses this the agreement, each partner will contribute
manifold air pressure / temperature readings. with the point that the major LNG suppliers such significant resources and pay for its own people
The gas / diesel mixture is non-explosive / non- as Shell, Chesapeake Energy and others, would and costs of the program but Westport will lead
flammable until compressed in the combustion potentially set up much of the the program. Westport expects to invest
chamber. infrastructure/supply chain themselves, such approximately $12 million and the schedule
Given the current market pricing differential would be the size of the potential market in calls for product launch in 2014. When the
between diesel fuel and LNG, customers using mining. This may even extend to building gas product is launched, Westport will supply its HD
the GFS EVO-MT system could see a total fuel liquefaction facilities at large mines or system components for an agreed upon amount
cost savings of up to 30%. important mining areas. The company also per engine, comparable to other such
In addition to GFS, American Power Group believes that gas technology offers the engine arrangements previously announced.
(APG), a subsidiary of GreenMan Technologies, OEMs a way to achieve Tier 4 Final compliance Westport has also announced the
also has a dual fuel technology, that is currently but without any after treatment or EGR system, introduction of China's first natural gas engine
focussed on the oil and gas drilling market, but which would narrow any cost differential featuring HPDI technology. The product
mining will be a future key area for the company, between the two solutions and further support introduction is the result of China's first joint
and has just announced that APG and Linde for the level of diesel displacement offered by venture for HPDI natural gas enginesWeichai
North America have established a formal HPDI. Westport and fills a gap in the natural gas
business relationship to introduce and expand Ultimately, Blomerus sees a future that may engine market for heavy-duty trucks. Based on
the use of LNG for APG retrofitted dual-fuel have space for all three solutions dual fuel, full the Weichai Power WP12 engine platform, the
diesel engines and diesel pumps in the oil and diesel engines and HPDI gas engines with the 12-litre engine features Westport HPDI
gas industry. APG states that its patented eNRGy choice dependent on customer preference. As in technology which maintains the power and
Pac PLC and ECU Controls system ensures that the GFS model, there is likely to be a significant performance of the base diesel engine, but
dual fuel fed engines operate at their normal ongoing market for retrofitting existing trucks. allows the replacement of up to 95% of diesel
temperature and at full horsepower. The group But as the use of LNG in mining grows, there fuel with cleaner burning, less expensive natural
has also worked on a project with Wesfarmers may be more take up of the OEM gas engines on gas.
LNG in Australia with regard to dual fuel retrofits new trucks. Cummins itself has just announced its plans
on its heavy duty diesel haulage trucks but has In May 2011, Westport announced that it has to produce dual fuel engines from 800 hp to
also had discussions with Wesfarmers about entered into an agreement with Caterpillar to 3,500 hp (597 to 2,610 kW) for high-horsepower
possible future co-operation on mining trucks, evaluate high pressure direct injection (HPDI), markets, which includes mining. The first in the
given that the company is also a major coal natural gas fuel system technologies for product portfolio, however, will be the QSK50
miner through its Curragh mine. possible use on Caterpillars large engines. As Tier 2 for oil and gas well servicing applications,
In the HPDI space, Westport Innovations is part of the agreement, the parties have for which production is to start in mid-year 2013,

32 International Mining | JUNE 2012


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ingenious solution Exactly

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ENGINES

sealed diesel particulate filter and regeneration


achieved either by combustion or controlled air
throttling.
The water-cooled TCD 6.1 L6 covers the 100 to
180 kW power range and, with its maximum
torque of 1,000 Nm, promises a performance
enhanced by up to 25% compared with its
predecessor. This 6-cylinder in-line engine, with
its turbocharger and charge air cooler and
electronically controlled Deutz common-rail
(DCR) high pressure injection system, offers
long engine life and extended servicing
intervals. The 160 to 250 kW power output of the
water-cooled 6-cylinder TCD 7.8 L6 engine
makes it the most powerful engine in the
medium power category, while the 240 to 390
The Ferrit DLZ210F coal mining monorail system L580 models also run on Liebherr engines. kW power range is covered by the water-cooled
incorporates a John Deere PowerTech 6068T Liebherr was exhibiting its new R950 SME TCD 12.0 V6 engine. An electronically controlled
engine
crawler excavator for the first time at Intermat. wastegate turbocharger ensures optimum
with other QSK Series engines to follow, With an operating weight of approximately 44 t, equipment performance. Designed for high
including engines capable of meeting the it is positioned between the standard version of loads, the TCD 12.0 according to Deutz features
mentioned EPA Tier 4 Final emissions the R946 and the next-larger model, the R956 outstanding ruggedness and long servicing
regulations. which are also newly developed models that intervals, thus making certain that operating
The company states: Cummins high- comply with Stage IIIB exhaust emission costs are optimised. Its compact V-design plus
horsepower dual fuel engines will operate with standards. front and rear power take-offs with up to three
common integrated controls, making a seamless The R950 SME was developed specifically to auxiliary drives reduces installation costs and
transition from diesel fuel to dual fuel operation. increase productivity in tough quarrying increase the number of potential applications.
By default, an engine will run on diesel fuel until applications. The SME acronym stands for Deutz has also announced that along with
the operator selects the option on the control Super Mass Excavation. Compared with the Volvo Group, it is exploring the extension of
panel to run the engine on a blend of diesel and standard version, the R950 SME has a higher their long-term cooperation and that a new
natural gas fuel. The engine will switch to dual engine output. Its new 6-cylinder common-rail generation of medium-duty engines for non-
fuel mode and automatically select the diesel engine, from the Liebherr Competence road applications is under study as part of a
substitution rate for the operator. Centre for Diesel Engines in Bulle, Switzerland recently signed a non-binding memorandum of
This technology investment by Cummins delivers 220 kW (300 hp) from a displacement of understanding. The partnership includes
further demonstrates our position as a 10.5 litres. This engine complies with Stage analysis for a Deutz majority-owned production
technology leader in the high-horsepower IIIB/Tier 4i exhaust emission standards, for joint-venture in China to manufacture these
markets. Cummins is committed to delivering which purpose its specification includes an engines. The production company is intended to
reliable, high-efficiency products capable of external exhaust gas recirculation system and a provide support for the Volvo Groups
meeting emissions regulations and operating diesel particulate filter with active regeneration. anticipated growth in non-road applications in
wherever our customers are, said Mark Levett, Deutz has recently introduced the entire Asia.
Vice President of the Cummins High-Horsepower range of its engines and DVERT components for In January 2011, Volvos specialised engine
Engine Business. the EU Stage IV/ US EPA Tier 4 Final emissions manufacturing subsidiary, Volvo Penta,
In traditional operating conditions, the standards. The range extends from the smallest introduced its range of engines compliant with
company states that a maximum substitution model, the TCD 2.9 L4, which was specially Tier 4 Interim/Stage 3B. This solution was based
rate of diesel fuel with natural gas of 70% can developed for very tight and narrow installations on the Selective Catalytic Reduction (SCR)
be expected, with average substitution rates of and covers the 30 to 55.4 kW power range. technology. For 2014, the company states that it
greater than 50%, depending on application and Available either as a naturally aspirated or will meet the much more stringent Tier 4 Final
duty cycle. The Cummins dual fuel solution will turbocharged engine, with or without charge air standards using the same technology. A further
be applicable to both new QSK family engines cooling, equipped with cooled external exhaust development of the SCR catalyst has improved
and as a retrofit on existing QSK family engines gas recirculation and a common-rail high the NOx conversion to very low levels. Adding a
in the field today. Cummins global distribution pressure injection system, the compact 4- light EGR system to the engines provides
network will handle up-fit, commissioning and cylinder in-line engine offers high specific power further emission reduction and will at the same
warranty on dual fuel solution engines. and torque combined with very smooth running time help keep the SCR catalyst operating at an
characteristics, according to Deutz. The optimal temperature. Volvo Penta states: The
Mid-sized and smaller engines completely redesigned TCD 3.6 L4 industrial innovative EGR system on the engines is lightly
Liebherrs own diesel engines are already used engine covers the 55.4 to 97 kW power range cooled or not cooled at all. This serves two
on a range of its equipment, including the R9100 and the water-cooled TCD 4.1 L4 engine the 80 purposes: First of all, it will not add extra
mining excavator, with the larger models to 115 kW power range, which generates cooling requirements to the existing cooling
employing Cummins engines except for the maximum torque of 610 Nm at an engine speed system. Secondly, it will not be subject to
R9800 which is offered with MTU or Cummins. of 1,400 to 1,600 rpm. This engine benefits from exhaust gas condensation and thus the potential
Liebherr wheel loaders such as the L576 and an exhaust-gas after-treatment system with a corrosion that can lead to downtime. By

34 International Mining | JUNE 2012


ENGINES
NEW RIEGL VZ-4000
avoiding a costly Diesel Oxidation Catalyst (DOC), the company believes
that installation is greatly simplified. David Hanngren, Manager Product
Ultra Long Range 3D Terrestrial Laser Scanner
with Online Waveform Processing
Planning Industrial at Volvo Penta, comments: With our new Tier 4 Final
engine range, we will also meet our customers primary objectives: no re-
generation, limited installation challenges, continuous optimised fuel
consumption and low operating costs. With as few and as simple changes With the VZ-4000 Laser
as possible, we aim to make our customers job as easy as possible. Scanner and specifically
The new Volvo Penta engine range for off-road applications consists of designed software pack-
five basic engines. Thanks to the SCR system it has been possible to meet
ages, RIEGL provides a perfect
the new emission standards with only a limited number of technical
changes. Here, the component commonality of the engines is particularly
solution for the demanding fieldwork
valuable to OEMs who include several engine sizes in their product in open pit mining and topography.
applications. All engines in the range will be ready for delivery in 2014 but
were displayed at Intermat. They include the D5, a completely new Volvo
Penta design a 5 litre, 4-cylinder, 105-160 kW engine with a maximum
torque of 900 Nm. The D8 is also new and is an 8-litre, 6-cylinder, 160-235
kW engine with a maximum torque of 1,300 Nm. The D11 is an 11 litre, 6-
cylinder, 235-285 kW engine with a maximum torque of 1,950 Nm. Finally
there is the D13, a powerful 13-litre, 6-cylinder, 285-405 kW engine, and the
D16, the most powerful engine in the range. This 16-litre, 6-cylinder, 405-
565 kW engine has a max torque of 3,200 Nm.
In 2011, Volvo Penta and Sandvik Mining and Construction signed a
cooperation agreement with the goal to enhance the long-term
competitiveness of Sandviks products. Up to now, Sandvik has introduced
Volvo Penta engines in several models from its product lines for crushers,
drilling rigs, loaders and haulers. These include the Sandvik UJ440i mobile
crushing plant powered by a Volvo Penta D13 diesel engine and the
Sandvik LH621 LHD that uses the Volvo Penta D16 diesel engine.
Installing after-treatment systems have proven to be a major issue for
many equipment builders in the US and the EU. For Sandvik engineers, the
SCR technology has not been a major challenge. This is just another
regular engine installation, commented Seppo Karhu, Manager for Engine
Installations at Sandvik Mining, after the first-ever loader with SCR for
mining and tunnelling applications had been developed. With the SCR
technology, ventilation rates become so low that it is no longer toxic
emissions, but CO2 or fuel consumption that sets the limits. And the Volvo Highlights RIEGL VZ-4000
engines have low fuel consumption, says Olli Koivisto, Global Product Line
Manager for Load and Haul at Sandvik Mining.  range up to 4 ,000 m HMI interface and built-in
In 2011, Volvo Penta was one of the first diesel engine manufacturers to
SSD data storage media
 eyesafe @ laser class 1
for stand-alone operation
receive stage 3B and Tier 4i certificates for its entire engine line-up. For  on-board inclination
multiple target capability
many years these engines have been successfully proven for use in the sensors, GPS receiver
(excellent penetration of
demanding underground mining segment. Now, the same engines are also and compass integrated
dust and vegetation)
certified by MSHA and CANMET. Volvo Penta has received Mine Safety and  connector for external
waveform data output
GNSS receiver
Health Administration (MSHA) as well as CANMET-MMSL certification for its (optional)
13L interim Tier 4 diesel engines. The 13L is the first engine to receive the  built-in camera
certification and the rest will follow. The 350-550 hp,
TAD1360/61/62/63/64/65VE-series of diesel engines offers ventilation
Highlights Mining Software
rates that are among the lowest in the industry for the given power RiMONITOR: monitoring of terrain deformations by analyzing
category. The ventilation rate is around 30 CFM/hp which is considerably the changes of surfaces
lower than traditional diesel engines used in mines today. RiMINING: optimized and simplified scan data registration
John Deere Power Systems (JDPS) has announced the naming convention and processing workflow for open pit mining,
and power ratings for its complete Final Tier 4/Stage IV mobile off-highway offering, e.g., automatic extraction of break lines,
contours, profiles, and calculation of volumes
diesel engine line-up. Building on previous tier nomenclature, John Deere
Final Tier 4/Stage IV engine names will start with the PowerTech brand and
add a three-letter suffix that specifies the engines technology package. For
Final Tier 4/Stage IV, the three letters will identify the engines technology
platform, turbocharger and aftertreatment, respectively. An example of a
John Deere Final Tier 4/Stage IV engine name is PowerTech PSS 6.8L.
www.riegl.com
The group states that it will continue with its planned building-block
approach to meet the challenging Final Tier 4/Stage IV regulations. To achieve
5,(*//06*PE+, Austria 5,(*/86$,QF 5,(*/-DSDQ/WG
compliance, John Deere developed the Integrated Emissions Control system

JUNE 2012 | International Mining 35


ENGINES

a solution that optimises engine performance, Asian market, says Robert Sobocki, Senior Vice
operating efficiency and reliability. For engines 56 President and Head of Scania Engines. Doosan
kW and above, the Integrated Emissions Control Infracore is well positioned within the Chinese
system will consist of a diesel oxidation catalyst market. Several models from a total of over
(DOC), a diesel particulate filter (DPF) and a 20,000 machines sold annually in China will be
selective catalytic reduction (SCR) system powered by Scania engines. We have tested
specifically designed to meet the demands of off- Scanias engines in our products and they meet
highway applications. The DOC/DPF exhaust filter our expectations for reliability, outstanding
reduces PM while cooled EGR and the optimised performance and high fuel efficiency. We also
SCR system reduce NOx to the regulatory levels of appreciate Scanias modular concept. One
Final Tier 4/Stage IV. engine platform for all emission levels is of
When combined with cooled EGR technology, great benefit. For instance, it helps in our design
the Integrated Emissions Control system will installation work and thanks to Scanias global
enable John Deere engines to meet emissions service network, our customers also get access
requirements while utilising less diesel exhaust to excellent support, stated Andrew Choi,
fluid (DEF) than alternative Interim Tier 4/Stage Sourcing Director at Doosan Infracore. Scania
III B SCR solutions. DEF consumption with John industrial engines will manage Stage IV and Tier
Deere Final Tier 4/Stage IV engines will be 1 to 4 final with EGR and SCR technology but without
3% of diesel fuel consumption depending on a particulate filter. The newly developed engine
the application. Lower DEF consumption means Scania is working closely with Doosan in the platform is the same for all emission levels
supply of engine technology for ADTs, wheel
DEF tank size can be smaller minimising the loaders and other equipment applicable to ranging from Stage II to Stage IV and is
impact on vehicle applications while extending mining described as extremely reliable.
DEF filter service intervals and reducing Scania industrial engines will manage Stage
operator involvement. Increased pressures their demands and expectations in terms of IV and Tier 4 Final without a particulate filter.
created by John Deeres Final Tier 4/Stage IV traction parameters, easy yet high-tech With only EGR and SCR technology, the
high-pressure fuel systems will reduce engine- operation, diagnostics and safety. installation will be unaffected. The company
out PM and extend intervals between active Also in the underground mining market, John states that its long-standing experience of EGR
exhaust filter regeneration, improving fuel Deere engines have been used on the UiK and SCR from trucks and buses has meant that
economy from Interim Tier 4/Stage III B. GLS150 mining locomotive from Polands these developments could be applied to Scania
Ferrits DLZ210F suspended underground Urzadzenia Konstrukcje. Working closely with industrial engines as well.
mining locomotive can work in almost any John Deere distributor Techbud, the company All engines will in other words have the same
topographical conditions and on slopes of up to modified the PowerTech 6068TFM marine footprint, enabling the same installation to be
30. It has two cabins one on either side engine to suit the demanding mining used, irrespective of emission level, significantly
and is equipped to pull up to 12 driving units environment and make it fully ATEX certified. reducing the efforts required from OEMs that
that can carry personnel, heavy loads and Four GLS 150s are already operating in Polish are active on the global market. Scania uses the
auxiliary materials. John Deere states that its coal mines transporting personnel and same modular engine platform for all steps in
PowerTech 6068T engine proved the most materials. With tracks just 550 to 900 m, it can emission legislation. Hence, there is no need for
suitable engine in the market for the model as handle steep inclines at the deepest mine global OEMs to redesign their equipment for
relatively few modifications were needed to levels, where working conditions are most Stage II, III or IV markets.
make it explosion proof. Ferrit states that it challenging. Urzadzenia also see opportunities The Scania modular system is implemented
chose the John Deere 6068 engine based on for the modified 6068T engine in rail systems in throughout the engine range, which greatly
proven performance in its DLP140F rail KGHMs copper mines, and are considering facilitates servicing, repairs and parts supply,
locomotive. The DLP140F was the first machine designing a range of smaller locomotives for since the engines all share the same cylinder
operating in explosive environments driven by a underground mining, powered by a modified design, featuring for instance separate cylinder
modified, electronically controlled engine. The John Deere 4045T marine engine. This smaller heads and replaceable liners and many of the
John Deere engines require relatively few engine will allow it to reduce the engine moving parts.
modifications to make them suitable for compartment size, and the overall machine Key characteristics of Scania's new engine
operation in explosive environments which is a weight. The company has also opted for a range are the Scania XPI common-rail fuel
key advantage. To meet ATEX standards, the stationary 36 kW John Deere 3029D engine to injection, and a revised bore and stroke that
PowerTech 6068T required changes to the power a future 8 t underground locomotive. provide improved performance and increased
suction and exhaust pipeline. The company had Scania and South Korean mining and swept volume. A waste-gate turbocharger and
to develop a new water-cooled exhaust pipeline, quarrying equipment manufacturer, Doosan increased combustion pressure contribute to
a water-cooled turbocharger, and a dry cooling Infracore, have agreed to further increase their efficiency. The use of Scania's own engine
system for exhaust gases. Also, Ferrit modified current cooperation. According to a letter of management system enables high-precision
the electrical system for use in an explosive intent, Scania, from 2014, will not only supply control of combustion and easy adaptation to
environment. engines for Doosans ADTs and large wheel different applications and operational
The first DLZ210F units are already operating loaders but also other products within the requirements, as well as fine regulation of
in coal mines in the Czech Republic, Russia, Doosan range. In the long term, we are exhaust after-treatment systems. The new
Poland, Mexico and China. Ferrit states: estimating delivery of well over 3,000 engines range includes three variants of the DC09 up
Customers have responded very positively to annually to Doosan Infracore. This cooperation to 294 kW and five variants of the DC13 up to
the new suspended locomotive, which meets all has strengthened our position in the growing 405 kW. IM

36 International Mining | JUNE 2012


Designed for the future. Built for your success.
The new MTU Series 2000 Tier 4i.

Advanced diesel engine technology for your success.

MTU engines are designed with the operational safety


and environmental consciousness of our customers
in mind. At the same time, we remain committed to
the supply and support of customer-specic power
requirements for the most challenging drive solutions.
Our Series 2000 Tier 4i is based upon a simple formula:
apply the most cost-effective and robust diesel engine
technology, engineered to your specic mining
requirements. The result: Highly reliable performance
and low cost of ownership while meeting Tier 4i
emissions regulations.
And with the Series 2000 Tier 4i as the technology
base for Tier 4 nal, MTU is your partner for success
today and into the future.

www.mtu-online.com
UTILITY VEHICLES

Keep the mine


running

Utility vehicles, both


surface and
underground are often
under-appreciated but,
as John Chadwick
reports, they are vital
to efficient mine
operation

tlas Copcos recent acquisition of GIA striking rate (blows/min.) of 480-960. masted-forklift trucks (M-series) are compact

A Industris underground business brought


electric mine trucks and utility vehicles,
ventilation systems and other new products to
Offering high speed and high charging
density for face and up holes, the charging truck
has been developed and tested over many
and robust machines built from experience of
more than 60 years, can enhance basic handling
and material shifting in underground workings.
its product range. IM published a detailed report years. A radio remote option is available for They are compact, with four-wheel drive, and
on one of the latest electric truck installations charging. capacities from 2.5 to 7 t.
last September (pp8-18). Bob Fassl, Business The MEGCIS cable bolter can be mounted on Godard says the fixed boom telehandlers
Area President for Mining and Rock Excavation the mines choice of carrier. It will install steel (MT-series and MHT-series) bring the versatility
Technique commented: We especially look cable up to a borehole depth of 40 m. The boom to enhance costs, the efficiency to reduce
forward to offering the Kiruna Electric haulage coverage area is 84 m (12 m x 7 m). There is a downtime and the safety to ensure the highest
truck with its strong environmental profile. radio remote controlled cable and hose feeder protection of operators. Manitou offers a wide
Bjrn Lifvergren has been appointed General unit with cable cutter and cable buckling. There range of combinations possible for tyre
Manager of Atlas Copco GIA and is also cable feeding depth measurement. handling, personnel elevation, material carrying,
commented: Not only Water and cement are mixed in all with unrivalled reliability and adaptation to
do the products of GIA a twin-mixer system and the its environment. Machine capacities from 2.5 t
complement our range grout is pumped into the hole
of underground with the aid of a double acting
products extremely well; piston pump.
they also open up many new The Manitou Group provides a large
possibilities for future co- range of utility vehicles for underground duties.
operation around the world. The French manufacturer of rough terrain
The scissor lift unit has a maximum lifting handling equipment, offers four technical
capacity of 1,500 kg to a height of 4 or 5.5 m. approaches resulting in myriad handling Getmans A64 Pipe Hanger/Fan Handler scissor
The service truck offers 75 m to 170 m of possibilities to manage all kind of jobs in the lift is specifically designed and built to bring
coverage and lifting capacities of 400, 500 or mine. From true logistical support to machinery safety, efficiency and speed to the installation
of fans and pipes underground. Base-pivoting
800 kg to a maximum height of >10 m. maintenance or infrastructures maintenance, pipe jacks with hydraulic extensions and
The GIA scaler features a boom system and a there is a safe and efficient solution to match hydraulic pipe grapples can be moved
powerful, 321-kg hydraulic breaker that will mines requirements within the range, says independently to precisely locate pipe during
installation. An internal fan and vent tube lift
operate in the most demanding environments. It Baptiste Godard, New Business Marketing & allow fast and safe installation of mine
delivers impact energy of CIMA (J) 375 at a Sales Support Manager. The Rough terrain ventilation equipment

38 International Mining | JUNE 2012


UTILITY VEHICLES

up to 22.5 t and lifts up to 18 m all comply with and lifting equipment and also
most tremendous stability and safety provides extra manufacturing
standards. Four-wheel drive and four-wheel capacity. The company will also
steer allow these machines to pick up and be the development and
carrying loads in the most difficult condition competence centre for truck
with total safety and efficiency. based equipment including
Rotating telehandlers (MRT-series) are also a existing Essverk offering,
strong asset. This compact equipment with concrete spraying and new
lifting capacities of 4-5 t simplifies and developments.
enhances the safety environment where a crane Paus Maschinenfabrik offers a
type lifting process is required. Godard explains wide product range of utility
that the ability of the MRTs to cover a large vehicles, mainly based on the
working envelop from a stationary base Universa 50 and MinCa concept.
simplifies your handling process while The former is an articulated all-
improving safety in the working area by using a wheel driven mining vehicle with a payload Paus Minca 18
compact, controlled machine. capacity of 15 t. On the rear frame is a rigid
There are also rough terrain aerial work superstructure or a quickly changeable cassette platform, without using stabilisers up to a
platforms (ATJ-series) with working height up to is mounted. Typical machines are scissor lifts, working height of 5 m.
20 m on compact safe machines. Godard says extendable boom with basket, service units, The new Paus MinCa is also an all-wheel
the class leader in rough terrain personnel loading platforms with crane, and combinations driven vehicle using quick change systems. The
elevation self propelled platform, the ATJ range with personnel transport. The Universa 50 can basic platform can be mounted with different
ensures safe and efficient use for all also be used as a concrete mixer and Anfo cassettes like a loading platform with crane, oil
infrastructure maintenance duties. loading vehicle. and fuel tanks, personnel transporter, boom and
Normet introduced its new Alpha series The customer can basket, ambulance or a fire tender. The MinCa
concrete sprayer, the Semmco Alpha 30, at the choose between many 18 has a payload of 4 t and is optionally
Convencion Internacional de Mineria 2011 in Universa options: for available with all-wheel steering.
Acapulco, Mexico. The machine is a example open or closed It was developed for mines with really bad
diesel-hydraulic mobile cabin, engine types, exhaust road conditions. The MinCa employs an
concrete sprayer designed systems, fire extinguishing and innovative frame suspension consisting of a
for tunnel profiles of up to attachments like compressors. An example combination of springs, shock-absorber and
7 m in height and 9 m in that demonstrates the flexibility of the different types of transverse link. Both axles are
width. The new NSP 30 concrete pump has a Universa 50 was to develop a special cassette to oscillating, increasing driver comfort. The new
maximum pumping capacity of 30 m3/h and transport 10 oxygen bottles. This was specially ROPS/FOPS cabin offers the driver much more
accelerator dosing system with a total 550 litre customised because the customer requires free space. In addition, Paus has improved the
accelerator volume is designed for a variety of different numbers of tanks and different tank noise insulation of the MinCa cab.
modern accelerators. The spraying operation is volumes. Easy maintenance was also important in the
controlled with a radio or wired remote control. Customers can order engines with higher design. So the drivers cab can be hydraulically
Marcelo Anabalon, COO Normet Chile said at power, which is beneficial in mines with steep tipped out of the way, simplifying repair and
the time: The new Semmco Alpha 30 is inclines. As a new option, the Universa 50 is maintenance. Furthermore greasing is
designed to meet the latest market and now available with a Mercedes OM 904 LA accomplished using central lubrication bars.
customer needs with more emphasis on diesel engine developing 90 kW. Both utility vehicle types can be delivered in
environmental and safety issues. Therefore it A new Universa development is an additional flameproof (ATEX) or non-flameproof versions.
has a Tier 3 diesel engine and a FOPS & ROPS drivers position on the platform. The vehicle can Engine emissions comply with EURO IIIa and
canopy. Its four-wheel drive and four- wheel be driven and steered at walking speed from the IIIb. All vehicles are available with a display so
steering makes for easier manoeuvring in
narrow tunnels. The Alpha 30 began deliveries In developing the
new Minecat UT99C
in January 2012.
Industrial Fabrication
Earlier last year Normet acquired Swedish built upon the proven
Essverk Berg. The acquisition of Essverk gives and tested success of
its Minecat 100
Normet a physical presence in Sweden and
Series see also IM,
allows us to better serve our customers in April 2012, p38. Now
Sweden and Norway, said Aaro Cantell, with the Minecat
Aerial Boom, Anfo or
Chairman of Normet. Essverk will be the base
Emulsion loaders
for our operations in Sweden and Norway and with a 6 m by 6 m
we have a very strong commitment to develop coverage are
available. The
and grow the combined business, under the new
company says miners
name of Normet Scandinavia. can work at the face
From a technology point of view, Tom and not have to reset
the machine to cover
Melbye, President of Normet Group, said,
it all, for more
Essverk is completing very well the Normet productivity and a
product range with its expertise in truck-based safer system.

40 International Mining | JUNE 2012


UTILITY VEHICLES

increase safety, along with productivity for the


mines infrastructure for installation and
maintenance.
Rob Emond, the MMMS northern Ontario
Accounts Manager, came to the factory with the
concept of a unit that can be more than just a
scissor lift, fan handler, pipe handler, tyre
handler, crane truck or flat deck. MMMS
representatives along with Dan Vallee, (Mine
The Kowari cab chassis is innovative in design, Services Superintendent), Bob Peeken (Mobile
robust and simple to maintain and dedicated to Maintenance Specialist) and their team came up
applications in the mining industry as a Arvas Model SV 12000 service vehicle platform
with a concept that will change the way with a payload of some 6,500 kg is now
personnel carrier, utility or an emergency
service vehicle infrastructure maintenance and installations will available and working in the field. This vehicle
be handled in the future. is capable of 35 km/h and supports an air bag
suspension system which increases operator
that all operations can be analysed via Marcotte has taken the conceptual input and comfort and safety in the harsh mining
diagnostic systems. developed a unit that actually covers all the environment. Here is the vehicle with optional
The Kowari is an Australian desert marsupial, units mentioned. The company believes it has deck and AR 0114 (1 t) crane. Features include
full ROPS/FOPS Certified Cab, four-wheel drive,
a little smaller than a house rat but considered the multi-purpose utility unit of the future. When three modes of steering (two wheel front, four
the power house of Australian marsupials, it is the unit is not needed for fan installations or wheel co-ordinated and crab) and Tier III 99 73
often described as the roughest toughest little replacement, it can install pipes or tyres using kW Cummins diesel engine
bloke on four legs.Underground mining has the pipe/tyre handler attachments. It also can
always required the use of light vehicles to work be used to drill and carry out maintenance from lifting platforms carrying 750 kg each at
in a harsh environment. Kowari Motors says the elevated platform and the boom can be used maximum reach, with a single lifting platform
conventional 4WD vehicles often have major as a crane. With the boom fully stored, deck in carrying up to 2,500 kg at maximum reach or
failings causing excessive downtime, high the lowered position and the railings removed, with extendable platforms with handling devices
maintenance costs and early replacement costs. the units onboard storage is maximised. It can for the installation of steel arches. Another
Therefore heavily modified production vehicles now move material around the mine as a flatbed example, the NormSpray, is equipped with
have been the preferred option until now. truck with a reliable, high-speed powertrain. remote controlled shotcreting pumps and
The custom built Kowari mining vehicle has Based on vast experience with boom- nozzles.
been created to fill a void in the market with a mounted platforms, GTA has developed working All NormUnits fulfil the latest requirement of
vehicle designed to do certain jobs in certain platforms for heavy loads and for extreme long European legislation. The cabin is equipped with
conditions. This niche allows for the Kowari to reach mounted on vehicles, satisfying the needs a ROPS canopy; the engines conform to the
be custom designed, in conjunction with the of large tunnel cross sections. The units are latest exhaust regulations. During stationary
customer, to tailor exactly the type of vehicle marketed by NormRent, a reputable company in operation, NormTrucks are operated electrically.
needed for each individual's end use. Designed machine rentals for tunnelling and mining. Other options for tunnelling operations are
for simplicity in maintenance, ease of repair, and Consequently, the new product line was named available.
coupled with components and systems of NormLifter. NormLifters may be hired for long- The single boom NormLifter 2500A is
proven record, reliability and availability of parts term projects but also for short periods. particularly designed for the installation of
and service, the Kowari is engineered for The NormTruck, manufactured by GTA as the heavy steel arches. Even connected segments
superior performance and handling. basic vehicle, can be equipped with double can be installed in one pass operation at 12 m
height. The articulated telescopic boom, with
Versatile specialists The innovation of this multi-purpose unit from the turnable and inclinable platform together
Marcotte has eliminated the hurdles of having
With Xstrata Cooper Kidd Creeks request and multiple units operating underground, therefore with the arch handling unit provide fast and safe
input into the design of the unit, Marcotte reducing maintenance, ventilation air volume operation.
Mining Machinery Services (MMMS) has requirements and units sitting idle when not The double boom NormLifter is mainly used
required
developed a utility carrier aiming to greatly for the installation of steel grid arches and steel

42 International Mining | JUNE 2012


UTILITY VEHICLES

Putzmeisters new low-profile concrete mixer


The NormTruck,
manufactured by for mining, MIXKRET 4, has been designed and
GTA, can be developed to complete and improve the
equipped with a
concrete spraying process. The concrete mixing
variety of utility
platforms drum has a maximum concrete capacity of 4 m3
and the equipment includes an additive tank for
pouring concrete to the concrete spraying
equipment. The six-cylinder, 130 kW engine
provides great climbing power and the hydraulic
anti-pouring lid allows concrete transport on
steep slopes without material loss.
The longitudinal cabin and the rear night-
vision camera facilitate driving with the best
possible visibility at all times. A compact design
with state-of-the-art axles, both directional and
powered, offers great mobility and
manoeuvrability through galleries and tunnels
with small cross sections. In order to guarantee
safety on declines, MIXKRET 4 has an automatic
speed regulation system, which allows travel at
full load in total safety, the company says.
The transport capacity of 4 m3 enables
savings on each journey. Its low centre of gravity
offers reliable and stable behaviour during
transport, improving safety. The technology
used in the design of the drum and blades
mesh. Individual movement of the platforms and dimensions and has been proven successfully in ensures perfect concrete mixing, as well as
the extreme reach of 12 m height and 16 m width tunnelling and mining. By offering multipurpose quick and effective pouring. MIXKRET 4 is
make the double boom NormLifter the ideal tool platform vehicles for high loads, GTA has equipped with a heavy duty ancillary
for large tunnels and underground caverns. succeeded in installing the upper level (high- transmission that provides high load and
NormSpray is designed for the same tunnel capacity-platforms) on trackless vehicles. rotation capacity. The rotation speed sensor and

S AT
VISIT U
-27
Sep 24 E 2012
50, IM P
20
Stand e Ind
lh i ia
New D
-26 2012
Sep 24 RNATIONAL
IN T E
INExpo A
1066, M as Vegas US
Stand L

44 International Mining | JUNE 2012


UTILITY VEHICLES

dual manual control (external and in the and back injuries being
cabin) ensure high reliability and transported to the surface. The
sturdiness. rough ride via mantrip caused the
The equipment has an easy-to- miner additional pain and the
access driving cabin with wide front driver had to slow down greatly to
visibility. For reversing, MIXKRET 4 has ease the pain. Roth saw that a
a night-vision camera with infrared vehicle better suited to this need
lighting that facilitates movement could save time and get the injured
without aid from anyone and without miners the treatment they needed
the need to step down from the cabin, much more quickly.
maximising time and increasing safety. The Pillar worked with mine safety
cab is ergonomically designed to minimise managers and a federal mine inspector
driver fatigue and increase productivity. As an to develop a vehicle that was specifically
option, MIXKRET 4 is available with a closed cab designed for use as an ambulance. The EMU-
and air conditioning for cold and warm ALR is a modified version of the popular EMU-LR
temperature. Putzmeisters MIXKRET 4 is equipped with a (Low Rider) designed for roof heights of 1,143
US-based Pillar Innovations original EMU powerful six-cylinder, 130 kW engine with mm. The EMU-ALR features front-mounted red
ACERT technology, which provides great
was developed in 2009. Since that time, the line and blue strobe lights, a padded kneeling
traction and driving capacity. The engine has an
has expanded to service a variety of needs. The AAC (Automatic Altitude Compensation) system cushion for an attendant, a polished aluminium
line includes vehicles to transport two or four that enables its operation at high altitude with stretcher deck with above LED lighting,
no loss of performance. The electronic engine
miners and vehicles designed specifically to plumbed emergency oxygen with wall
control balances durability, fuel efficiency and
navigate low seam heights. low emissions, so it offers the best possible receptacle and flow meter, and LED lit storage
We are always listening to our customers, performance with the lowest consumption. It is cabinets for supplies.
equipped as standard with a catalyst, which in
trying to figure out a way to meet their needs, The EMU-ALT is available for mines with a
combination with the electronic engine control,
said Adam Brenneman, Director of Sales & minimises ventilation requirements. This height of some 1,780 mm and above. Similar to
Marketing. This is especially true with the EMU electronic engine control allows for total control the other products in the line, the ambulance
of the operating temperature, avoiding
line we are always expanding. can be built to a mines specifications, including
overheating. An easy-to-use electronic display
This was exactly what one Pillar employee records and diagnoses failures, minimising vehicle height, equipment, and lighting.
had in mind while he was working at a mine. maintenance periods. The easy access to daily Right now we have four in the field so far,
service points simplifies tasks and reduces the
Stephen Roth, an employee at the companys said Roth. Its really great to see your idea turn
time dedicated to scheduled maintenance
Evansville, Indiana office, saw a miner with head procedures into something real.

www.normet.
www.taminternational.com

SOLUTIONS FOR TOUGH JOBS


www.coray.com

JUNE 2012 | International Mining 45


UTILITY VEHICLES

combined with an intelligent, on-board battery


management system (BMS) and the unique
operator interface, the level of safety surpasses
any vehicle, electric or not.
The battery pack gives the trucks the
capability to travel 120 km per charge; these
vehicles are a perfect replacement for any diesel
truck operating underground. Charging times
can be tailored to a specific mine depending on
the available electrical grid underground.
Outfitted with the rapid charge option these
vehicles can be fully charged in under an hour
giving them the capability to run 24/7. If
charged at lunch break and crew change, these
electric vehicles are capable of nearly 500 km
per day.
Damascus Corps new MAC-XP AC is a 1,575
GHH Fahrzeuge's new MK-A 5m Mixer is based on its MK-A 20 truck. Ten of these machines will mm wide, MSHA-approved explosion-proof
work on a large project in Chile. It is an inclined concrete mixer (5 m capacity) featuring four- wheel
drive, swivel joint and articulated steering. The drum speed can be adjusted and a water cleaning personnel transporter with a 7.35 kW AC electric
system completes the mixing package. The canopy is side-seated for bidirectional operation fitted motor. This is an updated version of the well-
with a camera system, heating and air conditioning, as well as an Ansul automatic fire suppression established MAC-XP. Like it predecessor, it has
and a central lubrication system
enclosed wet disk brakes and regenerative
braking to provide additional braking force. The
Electric power spring suspension system. The high torque at MSHA approved explosion-proof motor and
The latest product development from PapaBravo low RPM means full power at low speeds and controller box are aligned in the middle of the
Innovations, the Badger EV, is indeed innovative: the ability to climb, push or pull through almost vehicle, creating plenty of room for the driver
a full size, heavy-duty work truck that is purely any terrain and extreme grades. The hauling and passenger. Both XPs have a double
electric. The new 4x4 electric vehicle with rapid capacity of this truck is 1,815 kg, making it one reduction rear end to eliminate the need for a
charge and extended range opens opportunities of the highest capacity 1-t trucks, the company speed reducer.
to a new era of underground mining; clean and
emissions free. This electric drive, 1-t truck
allows mines to reduce ventilation
requirements.
With direct drive to both front and rear Dana
60 axles, this unit with a gross vehicle weight of
4,400 kg is designed to take abuse. PapaBravo
says the suspension and steering design on
this truck are second to none; aftermarket, off-
road, rock-crawler components make sure this
4x4 vehicle can go through anything.
It features 280 mm of travel and a custom-
designed, triangulated four-bar linkage and coil

Six vehicle platforms are available for The Damascus MAC-XP AC rides comfortably
PapaBravos Badger EV, and it is offered in says. This electric truck can also be outfitted
with the Soft Ride five point rubber mounted
2,794 and 3,581 mm wheelbase as well as the with a Class V hitch giving it a 4,535-kg towing front suspension with Air-Ride and adjustable
12 passenger transport vehicle suspension seats
capacity.
It is powered by
lithium-iron-phosphate
(LiFeP04) batteries. Light vehicle safety
PapaBravo says these Light vehicles are of course widely used, both
are proven to be the on surface and underground, for supervisor
safest existing battery transport, carrying materials and many other
technology; these sealed tasks. With light vehicle accidents on mine sites
batteries are stable, (such as rollovers) increasing, there is a strong
require no maintenance need for operators and contractors to implement
and do not have any quality roll over protection systems (ROPS) to
gases present during help safeguard mining employees. A number of
charge or discharge. the worlds major mining and exploration
Incorporating this into a companies have mandated that all light vehicles
sealed battery pack on their work sites be fitted with ROPS.

46 International Mining | JUNE 2012


For Your Toughest Jobs
With 40 years of experience manufacturing and servicing
underground equipment for mining and tunnelling projects
worldwide, DUX offers outstanding reliability so you
can maximize productivity at the lowest cost per ton.

HAULAGE EQUIPMENT

DUX four-wheel drive articulated haulage


trucks provide fast tramming up steep ramps.
Available with patented telescopic dump or
ejector box for high capacity hauling in areas
previously limited to scoop loaders.
DUX S1-SL6000 SCISSOR LIFT TRUCK
Custom machine widths and box sizes
available to suit different requirements.

UTILITY EQUIPMENT

Scissor Lift Trucks


With up to 2 720 kg (6,000 lb.) safe lift capacity
and heavy-duty scissor mechanism, DUX scissor
lift trucks offer a stable elevated mobile work
platform for surveying, scaling, roof bolting,
pipe installation, cable stringing and more

Multi-Purpose Cassette System


Using the DUX Porter one person can load and
DUX S2-PORTER WITH FLATBED CRANE CASSETTE unload multi-purpose cassettes smoothly and safely
in minutes. The system cuts down dramatically
on idle equipment and achieves higher utilization
than equipment built for one specic task.

SCALING EQUIPMENT

DUX Scalers are cost efcient, reliable,


high production machines that safely and
efciently scale loose rock from up to 9.14
meter (30 foot) high tunnel backs and ribs.

Contact DUX today for innovative eld-proven utility,


haulage and scaling solutions for your toughest jobs.

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Underground Mining
Equipment Worldwide
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615 Lavoisier, Repentigny, Quebec Canada J6A 7N2
TEL (+1) 450 581-8341 FAX (+1) 450 581-5138
www.duxmachinery.com
UTILITY VEHICLES

Minecorp manufactures ROPS to an


international and consistent standard to
provide clients with a globally recognised and
compliant product across their worldwide fleet.
Its fit outs are designed to comply with site
regulations to get vehicles onto mining sites
quickly and efficiently

When operators implement ROPS, its Rated mesh load guards to AS/NZS4034
essential that the manufacturing and fit out protect all occupants in both internal and
quality is compliant as this will determine the external ROPS systems
real level of passenger safety. Compliant with Head Impact Criteria (HIC) of
Australias leading light vehicle safety the latest code LK14/15 of VSB14 NCOP and South America. What was most significant to
operator, Minecorp, says there are a number of ADR3/0 the delegation was the keen interest that the
suppliers fitting light vehicles with ROPS that All ROPS are fitted with both a manufactures South American mining operators have in
are not compliant. This dangerous practice and installers compliance plate in line with accessing Australian innovations and
places mining staff at a much higher risk, likely the National Code of Practice (NCOP). Each technology. Colombia in particular wants to
to cause more harm than good compared to ROPS is supplied with an engineering catch up on technology very quickly. Mining is
those vehicles with compliant and high quality certificate and are approved for installation 2.7% of Colombias GDP compared to 20% of
constructed ROPS. by most Australian transport authorities. Chiles, said Schultz. IM
The major difference that compliant ROPS As mine safety measures increase in
has over poorly constructed ROPS is they are Australia, so too do they increase internationally
manufactured with the right strength and in developing areas such as Asia and South
flexibility to absorb the energy created by a America. To have an international standard for
INVEST IN
rollover accident. This flexibility significantly
minimises the effect of roof crush and maintains
ROPS allows operators to save time and costs
associated with transferring and rolling out
PROJECT NEWS
the occupants survival space. compliant vehicle fleets to these regions, and
ROPS provides much needed strength to the employees can experience increased safety Published every two weeks, IM Project News is
crammed with valuable information incorporating the
A and B pillars of the vehicle which maintains through consistent and familiar vehicle fit outs.
latest news on projects within that fortnight.
the integrity of the vehicles roof when it is Minecorp considers South America to be the
It is specifically about projects (not speculative
overturned. Quality ROPS also feature industry largest region globally for mining, and with exploration reports) featuring operations embarking on
compliant padding to protect occupants from investments of $236 billion in the industry for scoping studies or those further advanced to
prefeasibility and feasibility.
head injuries. Padding must be able to be hit by the next five to ten years, the demand for light
Beyond that, we look at projects in
an unprotected head (unlike racing padding vehicle safety products including ROPS is fast
development, publishing regular 1

where helmets are worn). increasing. updates as they get closer to Contact
1

production. We also detail expansion


emma@im
News PROJECT -mining.com
from those proj

Minecorp guarantees the following safety Recently at an AusTrade delegation mission


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Manufactures in accordance with ISO 9001


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worlds largest mine sites and gained a rare


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drilling projects underway, 1,500


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insight into the mining operations of Chile, reserve-definition studies, 800


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feasibility studies and 400 mines


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engineers and CAD design team Colombia and Peru. During the trade delegation,
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Material selection and design criteria


RALIA DIVO
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mass limits ensuring vehicle compliance were already demonstrating a strong attention and learn about key project personnel, subscribe
Carries out finite element analysis (FEA) of all and need for safety and energy saving practices. now to IM Project News.
ROPS and has extensive real world testing Director of Minecorp, Ian Schultz said the
results South American AusTrade trip was a great
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48 International Mining | JUNE 2012


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Copyright 2012 Getman Corporation


UNDERGROUND DRILLING

Facing the future

Underground drilling remains a


challenging environment, so
continued improvements from key
machine and component suppliers
Boart Longyear
continues to help mines improve
Stopemate S36
operating at a mine
efficiency, particularly as operations
in Sudbury, Ontario go deeper, reports Paul Moore

orizontal development is common to all currently in negotiations regarding further attention to detail has been put into the visuals

H underground mines and new technology


improvements that help to increase
development rates are vital for the industry.
orders.
Training is just as important for underground
operators as it is for those in surface mines.
for the drill, setting new standards in 3D
graphical machine models for mining
simulations. The simulator utilises the full 360
Mine Master, the manufacturer of face drilling Immersive Technologies continues to further degree display of the Immersive Technologies
jumbos including the Face Master 1.4 (very low expand its offering for underground mining with UG360 simulator platform in order to provide a
seams); 1.7 and 2.3 (low seams); 2.8 CC (twin the development of a simulator (Conversion Kit) highly realistic underground setting within
boom, computer controlled) and the 3.0 (twin for the Sandvik DD420 jumbo drill. The company which to conduct training. Other aspects of
boom with basket), told IM it is now currently in believes that the new jumbo drill simulator machine operation such as tramming and jack
the advanced stages of developing a super- particularly represents a leap forward in operation are covered by a comprehensive set of
efficient drilling system for spiral rods with and innovation, design and application due to highly scenarios, resulting in a complete training
without air flushing. Due to exceptional test realistic drilling physics coupled with an experience for all jumbo drill operators.
results the company says it has secured an eight ingenious 'drilling assistant' feature to Atlas Copco has announced two new face
drilling rigs deal with Estii Energia mines, the maximise operator training effectiveness. The jumbo rigs the Boomer E1 C-DH and the
major Estonia based oil shale mining group. company states: The Immersive simulator Boomer M1 L. The single-boom, diesel-hydraulic
These machines will be used for carrying out provides an authentic and comprehensive multipurpose Boomer E1 C-DH is specifically
preparation works and the new technology has recreation of the DD420, with cabin comprising designed for mines or construction sites lacking
made it possible to reduce the drilling time by of tramming controls, drill and boom controls, water and electrical infrastructure. The machine
60% according to Mine Master. The company jack controls, dials, gauges and a variety of the comes with dual onboard 450 litre water tanks
has also signed a contract with Polish salt ancillary functions. The controls are all based on and a six-cylinder, 173 kW Deutz diesel engine
mining group, KS Klodawa, which has ordered a the fully-hydraulic version of the machine, with to drive the rig, its boom and the drills hydraulic
number of new Mine Master drilling machines. the software supporting both closed-cab and pumps. The rig is one of the largest diesel-
There it estimates that it can reduce drilling open-cab arrangements. hydraulic face-drilling rigs on the market, with a
times by 40% over alternative technology. A new type of "Special View" is also offered coverage area of up to 95 m2. This is a 38%
In terms of growth markets, Mine Master in which the operator can use an integrated improvement over its predecessor, the Boomer
highlights Turkey as an important focus area dash-control to "walk" around the outside of L1 CDH drill rig. According to Johan Jonsson,
due to the rate of development in the last the cab and navigate within the 3D virtual world product manager for Atlas Copco Underground
eight years Turkey has been achieving 3-15% to inspect aspects of the development heading. Rock Excavation, the new rig provides unique
growth year on year. New mining projects along This is a key feature for jumbo operators where advantages in the field. In the case of a new
with highway infrastructure and tunnel works all regular external inspections can form part of project, the Atlas Copco Boomer E1 C-DH drill rig
make it a key market for drill jumbo suppliers. their daily routine in ensuring correct drill hole can be used to get started even before water
Mine Master has just signed an order to deliver alignment. and electricity are installed at the job site, he
more than 15 rigs to the country and is also Immersive says that particular care and said. Mines begin earning sooner, and

50 International Mining | JUNE 2012


UNDERGROUND DRILLING

manoeuverability and air quality to operator


convenience and safety. Its recently expanded
line of drill jumbos includes two new models
the DPIN and DPXH. The single-boom DPIN
features a 1.98 m chassis and provides 6.7 x 9.5
m boom coverage. The high-volume twin-boom
DPXH features a 3.22 m chassis and provides
optimum boom coverage of 12.2 x 18.9 m.
Oldenburg also offers a variety of power
options including diesel, electric and dual-
powered. The drills are equipped with Tier 3 and
Tier 4 compliant engines for maximum
production, with the all-electric option MSHA-
approved for mines with gas risks. An improved,
sealed cab design with expanded certified ROPS
and FOPS options has reduced noise and
increased safety and working conditions for
operators. In addition, High Efficiency
Particulate Air (HEPA) Filtration improves air
quality in the cab. Improvements to the cabs
interior allow for enhanced comfort, and
recently introduced ADS 400 and 500 operator
A Doofor DF550L rockdrill installed on a This is the perfect rig for the rough and assistance packages make the jumbos easier to
Herrenknecht TBM
tough world of low vein mining in room and operate. Oldenburg says it has experienced
pillar operations especially where there are significant growth in its core North American
contractors are able to get ahead on their long distances to be covered, says Peter Bray, and Latin American markets by solidifying
schedules. Jonsson also pointed to the new Product Manager at Atlas Copcos underground strong partnerships throughout both regions.
drill rigs advantages in widening existing equipment division. Other advantages include The company believes its main strength is in
tunnels or adding bolts in older workings, as it an improved flexible boom, simple controls unique modular designs that allow its jumbo
is not necessary to install power and water (Direct Control System 2 - DCS 2) as well as a drills to be equipped for each specific mine.
infrastructure to support the rig on-site. choice of COP 1638 or COP 1838 rock drills. The Mining Technologies Internationals (MTI)
The multipurpose capabilities of the new rig rig is also designed to be extremely easy to drilling knowledge and experience has been
are enhanced with the addition of the optional service to keep downtime to a minimum. A developed in its home market of the Sudbury
basket attachment. This allows the Boomer E1 C- prototype of the Boomer M1 L was successfully Basin nickel mines, but the company argues that
DH rig to be used as a bolting rig and as a utility tested by the Polish mining company KGHM this has allowed it to develop unique strategies
rig for drilling holes and installing ventilation which has since placed orders for several units. that is has also been able to apply successfully
ducting, among other tasks. The Boomer E1 C- Oldenburg Mining offers a complete line of in the international mining market.
DH drill rig comes standard with Atlas Copcos drill jumbos for applications in underground Aside from its full line of OEM drill jumbos
Rig Control System (RCS) with the option to face drilling and benching. Doug Wilson, including the Drift Runner, Ramp Runner, Tunnel
upgrade to an even higher degree of Director of Marketing told IM: The modular Runner and Vein Runner models, MTI Product
automation. The model comes with a COP 1638, product offering is designed to meet the unique Specialist Paul Morissette points to
COP 1838, or COP 2238 rock drill with a dual- challenges of each mine from developments in modular conversions as the
damping system for optimum service life. The
BUT 45 heavy-duty boom is equipped with a
double-rotation unit for plus/minus 190 feed
roll-over and plus/minus 135 feed rotation,
providing the operator with fast and accurate
positioning between holes. It comes with a 2.5
m boom extension and 1.8 m feed extension.
The new Boomer rig also has a BMH 6000 series
hydraulic feed.
The latest single-boom face drilling rig from,
the Boomer M1 L was specially designed for
development and production drilling in low-to-
medium height mines. With a height of 1.8 m,
which is slightly higher than previous low profile
rigs of this type from Atlas Copco, it is aimed at
room and pillar mines with roof heights of 2.2
The new jumbos from Oldenburg have a
2.5 m. The company states that it has an modular design to allow for a high degree
extremely strong carrier as well as oversized of customisation for each mine
wheels compared to similar rigs in the range.

52 International Mining | JUNE 2012


UNDERGROUND DRILLING

main reason for MTIs international success. In the end of the boom with a beam manipulator where the holes are designed to end. Round
MTIs Modular Conversion service, the Sudbury- arm, allowing steel beams to be set in cycle length is one of the most important parameters
based manufacturer builds and assembles during mining. Behind the operator station was in designing excavation work, as the excavation
components that fit part of a module which can a lifting, extending platform, allowing the advancement depends on the selection of an
then be fitted onto any other manufacturers miners to bolt the beam assemblies together. optimal round length. Savings in excavation
carrier. The entire process, says Morissette, This was important in reducing potential injury work are largely based on a carefully created
saves the customer from making high-cost during lifting and reaching, while also increasing plan, and on the drill rigs accuracy in
capital replacements from OEMs before the productivity. implementing the excavation according to the
vehicle's lifespan is complete, with the long lead plan. A good drill plan is created with good
times that can involve. The boom and the front Benefits of instrumentation theoretical knowledge of the blast as a basis.
of the frame are what get most of the action, so Jussi Puura, Product Manager Tunneling Jumbos Hole distances are designed based on the type
we can set up a new drill panel or a new boom at Sandvik, recently authored a paper on the and amount of explosives used or vice versa. A
individually, and have the module fit perfectly benefits of instrumentation in face drilling. The good plan can be created but its full potential
onto their carrier. MTI believes this service is paper states: The goals of successful may not be reached because of inaccuracies in
unique to its offering, and allows operators to excavation are to achieve the highest quality the execution phase.
preserve their equipment value by replacing possible of the mine tunnel profile, a high Hole start positions are not a problem
only vital components providing ultimate advance rate and to minimise the drill and blast because the operator can see the starting points
flexibility and most cost effective approach to cycle time while maximising the utilisation of of the holes for example by aiming to a painted
renewing and replacing parts. the equipment. In the future, development will pattern on the wall. All may seem perfectly clear
Contract mining group Cowin & Company, move toward increased production rates and in the mine drift, but due to operators or drill
recently made a request to JS Fletcher & Co for tighter regulations regarding excavation quality rigs inability to drill holes exactly on correct
an explosion proof diesel powered jumbo drill and environmental considerations. All of this angles without aiding functions, the actual holes
with an enclosed operators cab. In response, will put pressure on the functions of the inside the rock end up having distances
the engineering department developed the first equipment used in excavation, and on the different to the planned pattern. This in turn
MSHA approved diesel drill working in West management of excavation. Use of instrumented means that the explosives inside the rock will
Virginia, and the first in the US in decades. The drill rigs is gaining support in the mining not be in their designed places. The resulting
cab is certified for the MSHA canopy ratings and community as the benefits of these systems are inaccuracy in the hole bottom leads to bad pull-
is kept cool by a hydraulically adjustable fan. becoming apparent. While the traditional way of out, poor advance or in the worst case a failed
Having an MSHA approved explosion proof working is based on the operators expertise in blast.
diesel was important to Cowin, protecting the drilling process, instrumentation on drill rigs Ability to see the angles of the drilled holes in
employees from potential methane explosions, provides possibilities to achieve the same the drill rig gives immediate benefit in
while also eliminating reliance on an electrical excavation quality as with an experienced eliminating problems. Added with a hole
power source and cables. operator regardless of the operators position instrument, the designed pattern can
JS Fletcher sees one of its main strengths as competence level. Adding data collection be executed correctly every time. Hole position
its vast in-house database acquired from many features to the drill rig provides also and angle display for the operator completely
previous custom-built equipment endeavours. possibilities to identify problems in the drilling removes the need for marking up the face or
This allows Fletcher to have a quick design and blasting process and correct them to spotters in the tunnel which leads to further
turnaround, by having answers ready at hand. achieve better working efficiency and cost time saving. This also removes the human
When presented with the concept of an savings. aspect of variation in the painted pattern. Higher
explosion proof electric jumbo drill for coal The progress of excavation work in probability of a successful blast and higher
mining group, Alpha Natural Resources, Fletcher development drilling is described by parameters advance per round translate to savings in time
was able to simply reconfigure a previous carrier such as pull-out and advancement per round. and money in the excavation operation.
design to house the electrics instead of the Pull-out refers to the percentage of the drilled Inaccuracy in the hole length can lead to
diesel components and traded the enclosed cab round's length that has been advanced after the difficulties during blasting and cause
for an open operators area covered by an blast. The advance per round on the other hand unevenness in the tunnel walls, back, and floor.
operators canopy. indicates the distance advanced in the tunnel An error in depth alignment will repeat itself in
Both the Cowin and Alpha machines made after the blast. The length of the round is the following rounds and make the next rounds
use of Fletchers existing considered to be the perpendicular depth from even more difficult to drill and load. A good
designs, including the the plane where the holes are designed to start advance and well designed hole angles also
PERB45 boom, feed and to the plane help in coping with sockets (commonly called
rockdrill. The boom, used bootlegs). Bootlegs are hole ends of the
since early 2000s, is both previous round that are left
proven and reliable, when the full length of the
according to the company. round is not achieved. Not
It also provides convenient drilling in or near bootlegs
manoeuverability in smaller is both a legal
drift applications. requirement and a critical
Alpha then requested the safety issue because there
creation of a beam setter with the same basic can be un-detonated explosives left behind in
carrier as the jumbo drill. Fletcher was able to Simba: Atlas Copcos new Simba E7 C the bootlegs. If the pull-out of the round is
do this by creating a similar machine, replacing production drill improved it is easy to see that the bootlegs get

54 International Mining | JUNE 2012


UNDERGROUND DRILLING

rigs also come equipped with emergency stop


circuits to cut the power to the drill in the event
of an incident.
Creating larger stopes can help underground
mines accomplish greater productivity, by
allowing to use of larger equipment and the
faster removal of materials. The same also
applies to long-hole drilling, releasing more
material per blast. But larger stopes and longer
holes arent always possible, as not all rock
formations are suitable for this application.
These situations requiring a need for narrow
vein use and tight space access are the core
markets for the StopeMaster and the StopeMate
machines. Both are equipped with a pneumatic
top hammer production drill that features a 360
rotation for greater flexibility. With a
rotating/pivoting traverse allowing for versatile
configurations, these top hammer drills are
better suited for smaller hole drilling. This
Arctic Drilling Company supplies underground coordinates are as planned for blasting, has big configuration ensures precision drilling in both
exploration rigs with a 180 vertical drilling effects on the excavation cost by improving pull- parallel and straight applications, and accurate
radius
out, and securing successful blasts. operator control in drop-raise, cable-bolting,
The TCAD position and angle system is fan-drilling, ring-drilling and parallel-drilling
shorter and the problem is minimised. delivered with tunnel curve and drill plan design applications. Designed for bulk mining
Profile quality also has an effect on the software. Drill plans can be transferred to the applications, the StopeMaster is capable of
function of other underground drills in the mine drill rig with a USB memory stick. Before drilling holes measuring 64 to 106 mm in
site beyond the work cycle of drilling and operation the operator simply selects the correct diameter - at up to 35 m depths; while the
blasting for drifting purposes. A good profile drill pattern and curve from the memory. The rig smaller, more compact StopeMate can fit into a
quality with low blast damage will also reduce position and orientation is determined by using lift cage and drill holes at depths of 12 to 15 m.
scaling time and lessen the need for immediate the tested tunnel laser method. Both drills are offered in standard and HX
rock reinforcement. A good quality floor profile Both systems are designed for robustness. versions. The StopeMate HX features an added
has long term effects on the durability of the The systems are completely parallel to the drill hydraulic positioner, and the StopeMaster HX
machines by creating a more even road bed. rigs normal operation. In case of failure in the features the same positioner as well as a self-
Sandvik DD and DT-series drill rigs can be instrumentation system, operation of the drill rig propelled diesel option. The self-propelled
equipped with instrumentation to provide the is unaffected and still able to carry out boom version can disengage gears in order to facilitate
operator with accurate boom positions and movements and continue effective drilling. This towing where required.
angles and to provide the worksite with valuable separation is important in aggressive mining In long hole production drilling, a range of
feedback information about the actual drilling environments. new Simba drill rigs have been developed by
done underground. Sandvik instrumentation Atlas Copco. The company has introduced four
options TCAD and TMS can be fitted on non- Production drills different versions of its Simba rig concept
instrumented rigs to combine the benefits of Production drilling requires a unique approach, Simba ME7 C, Simba E7 C (plus an ITH version)
instrumentation and automation with the particularly with regard to access in the and Simba W7 C that it believes give miners
robustness of traditional hydraulically or production area as well as operator safety. The the widest possible choice of solutions for
electrically controlled drill rigs. TCAD stands for StopeMaster and StopeMate rigs from Boart different mining environments and the ability to
Computer Assisted Drilling and it is a complete Longyear are designed for the tight and narrow adapt each unit to suit individual conditions and
navigation and aiming tool designed for spaces typically seen in underground mining requirements. All four rigs are designed for long
accurately executing pre-designed drilling plans operations. Sid Gaitonde Global Product hole drilling (up to 51.2 m, theoretical depth) in
with Sandvik drill rigs. The TCAD system Manager for Capital Equipment at Boart medium to large drifts. Equipped with COP1638,
provides the operator with a drilling pattern on Longyear told IM: Each is specifically designed COP2550 and the powerful COP 3060MUX top
screen together with boom positions and for underground applications allowing for hammer rock drill, they perform ring drilling
angles. It can also be equipped with data superior access, mobility, flexibility and both upwards and downwards. Together with
logging capabilities to report the actual realised productivity in tight access locations. Both offer the ITH version of the Simba E7 C, which is
drilling patterns and drilling parameters such as durable and compact solutions for developing equipped with a DHR6 rotation unit, the rigs
penetration rates and drilling pressures. underground shafts. For enhanced safety, the form a complete production fleet range.
The TMS measurement system is aimed to rigs are developed with heavy-duty hydraulic The Simba ME7 C drills parallel holes spaced
harsh conditions, especially for machines with hoses to protect the driller from hose rupture up to 6. 9 m apart with a hole diameter of
only a safety canopy, to provide the operator and guarding for protection from moving parts. 51-89 mm; while the Simba E7 C drills parallel
with accurate information on hole angles and Removing the operators from the immediate holes spaced up to 6. 1 m apart with a hole
lengths. As seen in the examples, even having drilling area, the rigs can be controlled with a diameter of 89-127 mm. The Simba E7 C-ITH
an angle display to ensure that the hole end remote positioning system up to 25 m away. The drills parallel holes up to 5.2 m apart with a hole

56 International Mining | JUNE 2012


Ramp UpYour
Construction
Drill Jumbos -
Operation
single and dual-boom models.
Roof Bolters -
operating in heights from 40 to 40.
Beam Setters -
transport, place and hold heavy beam
assemblies during installation.

All are powerfully built to withstand years Roof Bolter


in punishing underground applications.

Beam Setter Drill Jumbo

Time and money spent on constructing slopes and tunnels is


serious business, demanding efficiency for that competitive edge.
Call on Fletchers expertise for your construction needs.
Engineered for productivity with a focus on safety to meet
your most severe requirements.
Scan this code to
Booth 2615 J.H. Fletcher & Co. learn more
Email Ben Hardman at 402 High Street
bhardman@jhfletcher.com or call Huntington,WV 25705
304.525.7811 for product details 304.525.7811
and information. www.jhfletcher.com

D R I L L J U M B O S RO O F B O LT E R S B E A M S E T T E R S
2012 J.H. Fletcher & Co. All rights reserved. L&A 112-885
UNDERGROUND DRILLING

diameter of 92-178 mm. The Being able to take


Simba W7 C is fitted with the advantage of the latest
Wassara water-powered hammer diamond bit technology, the
for special applications. LM Series can use the
The BUT 45 boom used on companys new Ultra Matrix
these rigs is extremely sturdy, (UMX) bits. The series include
enabling them to carry the most the SSUMX, 07UMX, 09UMX
powerful rock drills and other and the recently released
types of equipment. At the same 10UMX.
time, Atlas Copco states that the Sid Gaitonde comments:
boom increases accuracy and Engineered to drill faster, last
control and is highly adaptable longer and outperform
for different needs. Automatic existing bit technology in a
rod handling is also a standard wide range of drilling
feature on these rigs. conditions and ground
The new Simba range has formations, the UMX uses
been field tested successfully in advanced metallurgical
Sweden and Australia and have formulas with larger
been available since March 2012. impregnated diamonds to
At the Zinkgruvan mine in provide increased penetration
Sweden, the Simba ME7 has been drilling A Boart Longyear LM90 underground capabilities. The UMX bits transfer easily from
exploration rig at the St Ives gold mine,
significantly faster and better than the older one ground formation to another.
Western Australia
Simba M7 according to the company. Arctic Drilling Company (ADC), based in
LM30SS, LM55, LM75 LM90, and the LM 90A. Rovaniemi, Finland manufactures innovative
Underground exploration The drills range from small-compact to robust underground drilling rigs as well as distributing
Exploration in existing underground mines is drills that use electronics and can be used by high-quality products from other manufacturers
crucial to increase reserves and locate orebody operators learning the trade. The LM series in the industry. Customers include Agnico Eagle,
extensions. Boart Longyear offers an innovative components can be interchanged to adapt to Gold Fields Arctic Platinum, Kevitsa Mining and
range of underground diamond coring diverse on-site situations, and are capable of Lappland Goldminers. The custom-made
equipment the LM Modular diamond drill both conventional and heavy duty wireline core diamond core underground exploration drilling
series. The LM series includes the LM30, retrieval. rigs have a minimum-rated traction force of 6 t,

58 International Mining | JUNE 2012


UNDERGROUND DRILLING

a 360 horizontally rotating drilling platform, a have specifically been designed to deliver Robit Rocktools, the Finnish manufacturer of
180 vertical drilling radius, and a wireline winch extreme performance under challenging high quality drilling tools for mining
with a 1,500 m drum capacity. ADC cites the key conditions encountered during the drilling of applications, is known for its threaded button
benefits of the rig as its fast and easy set up hard rock such as abrasive sandstone, quartzite bits for rock drilling. The company told IM that it
time, because of the rig having a rubber, track- and basalt. The company says the PDIs are now has a strong foothold in the underground
mounted chassis; the fact that it is easy to drive highly compatible with the majority of drilling business, and that its bits designed for
in any terrain (including gravel, sand or mud); a bits and comprise Element Sixs new multi-layer tunnelling and mining have proven popular in
driving speed of 5km/h, making them easy to polycrystalline diamond technology. This key markets. In 2011, Robit states that it
steer. technology ensures the efficient delivery of continued to have a strong presence in the
energy to the rock face through high impact Scandinavia and CIS underground mining
Rock drill and bit technology resistance and exceptional wear resistance in markets but in addition has made significant
Doofor has successfully introduced a new demanding formations during drilling operations strides in its presence in Asia due to a new
underground mining rock drill, the Doofor in underground mining. These characteristics factory in South Korea. This factory has also
DF550L, in the 17 kW class. The rock drill has a result in a consistent rate of penetration in hard opened new doors for the company in Africa and
patented Doofor piston, which enables the rocks, outperforming bits using conventional the Americas, due to a new ability to offer the
strike impulse to travel efficiently in the drill tungsten carbide inserts, according to the whole package between the drifter and the rock.
steel. The company states that DF550L has a company. Element Six has conducted extensive Last year, Robit launched a completely new
high frequency and an efficient valve system for field tests in Europe, South Africa and the US, product line of button bits the HTG series. In
improved penetration and prolonged drill tool which it says have demonstrated an 2012 Robit says that it focussed on fulfilling
life time. Rotation is created by Danfoss OMS improvement in the insert life by four to six this product line to meet all customer needs
rotation motor and the rotation motor can be times compared with conventional inserts. and to further improve the series based on
installed on the right or on the left hand side Joe Dalton, Mining Business Unit Manager at customer feedback.In 2012, Robit has also
according to customer requirements. The Element Six Hard Materials comments: these launched a tool that will assist customers with
DF550L has a very low overhead profile, which is technically advanced properties translate into high demands for hole straightness, as well as
suited to mine drifting. It has also been a tangible economic benefits to rig operators. testing a new bit design for extremely abrasive
component of choice for TBM manufacturers. The PDIs significantly crush the drilling cost per conditions and the results so far have been
In drill bit technology, Element Six, a global metre, providing a competitive advantage and very successful.
leader in synthetic diamond supermaterials, is higher profitability. The percussive diamond Rockmore International has a new DTH
launching a range of new highly engineered inserts also enable rig operators to improve the hammer in its emerging Deep Hole series, the
percussive diamond inserts (PDIs) for drilling rig utilisation and reduce downtime as the need ROK 500DH, which has both underground and
operations in underground mining. The PDIs to regrind the inserts is eliminated. surface applications. This 127 mm range

JUNE 2012 | International Mining 59


UNDERGROUND DRILLING

hammer has a number of new innovations and developed for this hammer in order to alleviate the hole while drilling. But due to the design
features characterised in this new Deep Hole broken bit heads falling to the bottom of drilled advancements, Rockmore states that the new
class of hammers, according to Rockmore. It is holes when bit shanks fail catastrophically. A ROK 500DH drills exceptionally fast in dry hole
the first release in this new hammer series and new bit shank, the DH500, was developed in conditions as well as under high water
is targeted to drill 140 to 152 mm diameter conjunction with the new retention system, volumes.
holes. Designed to increase drilling eliminating the need for bit retaining rings As with all of Rockmores DTH hammers, the
effectiveness and efficiency in deep hole present in conventional hammer designs. The bit 500DH uses Rockmores patented SonicFlow
applications, the ROK 500DH incorporates is retained in the driver sub by uniquely technology, which optimises airflow by
engineering advancements for drilling in DTH designed lobes located on the bit shoulder. If in simplifying and streamlining the air path to
applications. Unique drilling requirements in the unlikely event that the bit breaks from the minimise backflow and turbulence, thus
some applications demand drilled holes shank body during drilling operations, the bit delivering more energy to the piston. Optional
exceeding 300 m deep and include high head may be retracted out of the hole as back reaming buttons on the top sub also
volumes of water, thus presenting great retained by the lobes on the bit and driver sub, contribute to increase hammer life. Field testing
challenges for conventional DTH hammers to thus eliminating bit retrieval that is often timely of the SonicFlow design was found to result in
drill effectively. The ROK 500DH has been and costly. faster penetration rates and greater overall DTH
designed specifically to handle these challenges The traditional foot valve, or blow tube hammer efficiency.
by incorporating new airflow and component component, has also been eliminated in the The company states: The ROK 500DH has
design advancements, primarily in the air ports DH500 shank concept. Foot valve breakages on been engineered to withstand the toughest rock
of the wear sleeve and piston. The hammer is DTH bit shanks during drilling operations are drilling conditions. The solid piston design is
rated for use with large compressors: 24.1 bar at catastrophic since the hammer will cease to made from an advanced material that is case
25.2 m3 / min; however, it can readily accept function immediately after such a failure. This is hardened, combining high strength with
greater air volumes and pressures from larger particularly damaging to drill time efficiency if supreme wear resistance. The high frequency,
air compressor packages. The upper and lower such interruptions occur in deep hole reciprocating piston is designed to strike the bit
hammer air chambers of the 500DH have been applications, requiring the hammer to be with maximum force. An innovative design,
modified accordingly in order to achieve retrieved out the hole for bit replacement. The unique to Rockmore hammers, reduces the
optimum drilling efficiency. The advanced piston DH500 shank alleviates such down time risk number of hammer components, thus reducing
design also offers maximum blow energy with by the elimination of the foot valve the amount of component wear points, making
each stroke to the bit, allowing for superior component. hammer service simpler and less expensive.
hammer and bit penetration rates in all drilling Conventional hammers often exhibit low Unique lead threads on the top sub and driver
conditions. penetration rates when used in deep hole sub ensure easy coupling and uncoupling of the
A new bit retention system was also applications when high water volumes exist in hammer. IM

Drill More
with RockMore

Bits
Bits Mining
Mining
Rods
Rods Construction
Construction
Couplings
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Quarrying
Shanks
Shanks Tunneling
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DTH
D TH Water-well
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R o c k M o r e
International
Rock Dr
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rilling Tools
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Wilsonville, Judenburg, Austria
Tel +1 (503) 682-1001
Tel Tel
e +43 3572-86300
Tel
info@rockmore-intl.com austria@rockmore-intl.com
www.rockmore-intl.com
www
w..rockm
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60 International Mining | JUNE 2012


UNDERGROUND LOAD AND HAUL

Trackless
tramming

At the MassMin conference in


Sudbury this month, LHDs and
underground haul trucks will be
widely discussed John Chadwick
looks at recent developments
ith haulage costs representing one of important in current markets. The Minetruck Hauling at 11 km/h on a ramp with a 15% a

W the most crucial items on the miners


balance sheet, Atlas Copco says its
Minetruck MT6020 stands out as the
MT6020 is another step in the development of
the articulated underground truck and is being
adopted by the industry.
typical scenario for a large underground mine
the Minetruck MT6020 claims to be as fast as
trucks with smaller payload ratings but delivers
productivity winner. Haulage efficiency is a Atlas Copco confirms the trucks continuing 20% more tonnage. And despite its 60 t
tough nut to crack in underground mining. success in Australia and says its reliability and capacity, it does not require larger excavation
Trucks need to be powerful enough to carry performance has made this 60 t capacity dimensions.
heavy loads for long periods and often over long machine the leading truck in its class. Among the upgrades for 2012 is the
distances, yet also compact and robust to Speaking last year, Business Line Manager installation of a Cummins Tier 2 engine offering
access the most challenging of ramps. MT6020 Matt Cobham explained: We have sold 60 extremely low emissions as well as substantial
delivers on both counts and continues to break tonners to both contractors and miners in equal noise reduction. According to Matt Cobham this
records for productivity and cost-efficiency. numbers and we believe the Minetruck MT6020 upgrade will be even more significant as the
The company says the success of this unit is is the clear, current first choice. Sixty trucks larger underground mines go deeper and
largely thanks to the vehicles pay-load of 60 t, were delivered to Australian customers during grapple with ventilation efficiency and increased
ease of servicing and the ergonomic operators 2011, and more than half of those replaced other power costs.
compartment which has been given an extra trucks at mine sites. In late February, Sandvik Mining launched two
strong and highly durable shell weighing We have also upgraded the entire drivetrain new underground trucks. It says the new
approximately 1.5 t. since the original Minetruck MT5000 axles, TH550 and TH540 are the first in the
Minetruck MT6020 was launched in 2008, dropbox, upbox, transmission and engine. Our underground mining world to offer energy-
giving mines the opportunity to increase their oldest Minetruck MT6020, which is working at efficient and low-emission EPA Tier 4i/EURO
tonnage kilometres per hour and also to save Stawell Gold Mines in Victoria, has racked up Stage IIIB engines. Compact and agile, they
costs through reducing the size of their fleets. more than 25,000 hours to date and is still offer the biggest payload per envelope size and
These benefits were quickly realised, notably going strong. empty vehicle weight.
in Australia where mining contractor ACM
(Australian Contract Mining) last year took delivery The Minetruck MT6020 in a
of the countrys 100th Minetruck MT6020. nutshell: Payload: 60 t, length:
11,227 mm, width: 3,440 mm and
Weve expanded our fleet of MT6020 trucks
height: 3,170 to 3,470 mm. Tyre
because it is the most productive underground size: 35/65R33. Engine: Cummins
truck available today by a fair margin, says QSK 19-C760 HP - top speed (at
full load): 36 km/h. Front axle
Brian Rodan, Managing Director of ACM.
suspension. Maximum torque at
Stuart Tonkin, Chief Operating Officer at 1,300 rpm: 3,084 Nm. Air
Barminco, which operates the largest fleet of conditioned operators
compartment, ISO ROPS/FOPS
MT6020s in Australia and Africa, has also noted
certification. Fuel tank capacity:
significant gains. He says: Reducing fleet size 844 litres and fuel consumption
and fleet kilowatts enables cost savings which is 67 litres /h. Turning radius: 44

62 International Mining | JUNE 2012


UNDERGROUND LOAD AND HAUL

The new TH550 and TH540 are based on the costs through lower fuel
old workhorses, Sandvik T50 and T40, which consumption, a
Sandvik says were widely regarded as the best substantial reduction in
underground trucks in the market. The all-new ventilation requirements
TH trucks were born as a result of provides even greater
comprehensive research, customer feedback savings. Uptime hours are
and modern thinking. One of the main increased with practical,
advantages of these trucks is the optional Tier time-saving features such
4i/IIIB engine that consumes less fuel, produces as a large tank capacity,
fewer emissions and has better torque centralised ground level
characteristics for trucks than its predecessors. maintenance and easily
Currently, the TH550 and TH540 are the only cleanable radiators. The The articulated DUX DT-50 underground
four-wheel drive truck is well suited for
trucks in the market available with these new cooling system, even hauling ore, waste and backfill on level
engines. safer electrical wiring, new and steep grades
If these engines were left running, for steering cylinders and
example, in the centre of some large city, the durable tires, combined with the other new ADTs
exhaust fumes coming out of the engines would features, are designed to increase operating Articulated dump trucks (ADTs) from
be cleaner than the air they took in from the city. hours per year and extend the overall service life manufacturers like Volvo, Komatsu and
These trucks can thus provide a healthier of the trucks. As a result, increased uptime and Caterpillar continue to be widely used
environment for all personnel working prolonged service life provide the ultimate in underground. Both Doosan, pictured in this
productivity. article, and Bell have new models. With a new-
DUX, which offers a full line of shape hood, more imposing styling and
haulage trucks ranging from 7 to 50 extensive technological improvements, Bells E-
t, featuring standard dump, Series looks well poised to grow Bell
teledump and ejector boxes, recently Equipments heritage as a premium ADT supplier
introduced its DT-50 dump truck and is planned to go into production in 2013.
equipped with 429 kW Detroit Series Certain improvements are being kept a closely
60 DDEC engine and Dana guarded secret, but the E-Series promises
powertrain. Measuring only 3.1 m higher payloads across the range as well as
wide and 2.85 m high, this truck improved safety features and better durability.
offers a 50 t payload capacity. With a The 30-t B30E on show at the Hillhead
dump box capacity of 28 m3, Dux exhibition in the UK shared the stand with some
says it features excellent load of Bells current D-Series ADTs. Bell has a
retention and fast tramming up steep tradition of pioneering industry firsts and
ramps highest power to weight various ground-breaking ADT innovations are
underground, says Tomi Pikala, Marketing ratio in its class. It permits efficient chute, side promised for the new generation of trucks. They
Support Manager at Sandvik Mining and end loading in narrow drifts with low include: standard on-board weighing, keyless
The TH550 and TH540 are engineered and headings. Clean and rapid discharge cycles are ignition, Hill Assist, i-Tip with inclinometer, Auto
designed with special emphasis on facilitated by the 65 dump angle and smooth Park Application (APA) and standard Turbo Spin
environment, health & safety (EHS), productivity flow, wear resistant alloy steel dump box. The Protection.
and reliability. New features, such as the electronically controlled engine reduces fuel
possibility to conduct all daily maintenance from consumption and reduces ventilation Automated LHDs
ground level, offer enhanced safety and requirements. The DT-50 is equipped with a Automated LHDs are becoming almost de
usability. Operator comfort and overall four-wheel POSI-STOP brake system for rigueur for new cave mines. Sandvik Mining has
productivity are improved with a remodelled maximum safety, reliability and low had considerable recent success in Australia
cabin featuring a new ergonomic, vibration- maintenance costs. Centralised service points recently. It has supplied 14 LH517 for the initial
reducing seat, a new dashboard, a new control and modular design offer easy service access production phase of Newcrest Minings Cadia
system screen, automatic gear shifting and and fast component exchange. East mine near Orange in central west New
adjustable climate control.
While the Tier 4i/IIIB engines cut operational

The new Doosan DA30 ADT is the latest in a line


of redesigned machines offering increased
engine power and torque, higher payloads,
lower fuel consumption, enhanced operator
comfort and faster travel speeds. It is powered
by an interim Tier 4 compliant diesel engine
with a gross power output of 272 kW.
Contributing to the overall 8% reduction in fuel
consumption is the new transmission offering
eight forward and four reverse speeds. The new
transmission improves the transfer of power
from the engine to the wheels, improving
traction

64 International Mining | JUNE 2012


UNDERGROUND LOAD AND HAUL

of Sandvik LHDs panels are progressively developed. Broken ore


Paus PMKT haul globally. is removed by the LHDs and ore conveyors.
trucks are only 1.9 m
The very large http://www.im-mining.com/2011/09/23/cadia-
wide and the PMKT
8010 shown here Cadia East orebody east-to-be-australia-biggest-underground-mine-
has a load capacity comprises a mineral chooses-sandvik-lhds/
of 15 t
resource of 2,347 Mt Released in late 2009, the Sandvik LH517 is a
containing 33.2 Moz high capacity LHD offering improved safety and
of gold and 6.59 Mt higher productivity than previous models,
of copper, along with through redesigned hydraulic and electronic
a current ore reserve systems, the company says. Powered by a Volvo
of 18.7 Moz of gold TAD 1361VE engine rated at 285 kW, it has a
and 3.16 Mt of tramming capacity of 17.2 t, and can handle
copper. It will bucket sizes from 6.5-8.6 m3. It is the first of
underpin production Sandviks LHD with a Tier 4 (3b) engine in
from the Cadia Valley Australia and the first with a Volvo engine.
for at least the next Features include a strengthened operators
South Wales. This involves the development of 30 years. cabin with efficient air conditioning, fully
the massive Cadia East deposit - one of the The project enables production from Cadia adjustable seat and controls, and a single all-in-
worlds largest gold deposits - into Australias Valley Operations to increase to a range of 700- one digital display which interfaces with the on-
first panel cave mine. It will be the deepest 800,000 oz of gold and from 75,000 t to in board vehicle control and management (VCM)
panel cave in the world and Australias largest excess of 100,000 t of copper per year over the system.
underground mine. The Sandvik LH517s are first 10 years. Servicing and maintenance is made easier
being deployed in Cadia Easts initial production The massive underground resource is suited and safer through ground level daily service
phase (Lift 1); deliveries commenced in Q3 2011 to the low cost, bulk underground mining points, three-point mounting and fall-protection
and were completed in Q1 2012. They will be method of panel caving. This is a natural caving systems. A built in fire suppression system
equipped for fully autonomous operation using method which uses ground stresses, rock significantly enhances mine and operator safety.
Sandviks underground mining AutoMine structures and gravity to break the rock. A fleet of 11 Sandvik 514E LHDs on AutoMine
system, which is currently used at Newcrests Orebodies best suited to panel caving are those has been ordered for the Argyle diamond mine
Ridgeway Deeps project (also near Orange, see where the horizontal dimensions are greater when its block cave comes into operation (IM,
IM, July 2009, pp8-12). Newcrests huge Cadia than those that are suited to block caving. Ore January 2009, pp8-14). This mines development
Valley Operation is now among the largest users extraction advances across the orebody as has been delayed by weak diamond markets.

Driving the Industry


yyears
for over 50 yea

Electric | Hydraulic | Pneumatic

Tel +44 (0) 1476 566301 Fax +44 (0) 1476 590145
Email sales@invictavibrators.co.uk Web www.invictavibrators.co.uk
A Division of Grantham Engineering (Established 1946)
Invicta Vibrators, Harlaxton Road, Grantham, Lincolnshire, England NG31 7SF

66 International Mining | JUNE 2012


U/G LOAD AND HAUL

See you at booth 215.

Sandviks LH514E-157

Scott Rowe, Sandvik Product Line Manager, explains that the Delivery of
the LH514Es to Argyle has now been delayed until January 2013. We
expect to start delivery late in 2012 for commissioning in 2013.
The 514E with the standard 5.4 m3 bucket offers a tramming capacity of
14,000 kg and breakout forces of 275.4 kN (28,082 kg), lift, and 241 kN
(24,574 kg), tilt.
One of the plans for when the machines are in production is to have
three operators working from surface on each shift. Each one will control
three machines each. AutoMine will ensure that the units tram to and from
the dump points autonomously. The operators will only be required to
monitor the machines and loading them at one of the 16 drawpoints. These
will be arranged to feed two separate dump points that will each empty
into a Thyssen Krupp BK gyratory crusher.
Consideration was also given to basing the LHD operators in Perth,
2,500 km away from the mine. Rio Tinto is already doing this with surface
mining equipment in some of its remote Western Australian iron ore mines.
While this is not currently the right option for Argyle it is certain that
operation of remote mine underground equipment from major cities will
come in the future.
Remote monitoring of these machines is important and Advantage
PressurePro, the developer and marketer of the PressurePro line of tyre
pressure monitoring solutions (TPMS) reports growing interest in the
technology. PressurePro explains it "has been involved in the TPMS
industry since 1991 and is noted as a pioneer in the market - known for the
reliability, durability, accuracy and ease of use of the solutions. The only
TPMS provider to offer numerous advanced monitoring options,
PressurePro was the first TPMS Company to add communications
capabilities across the product line, bringing to life remote monitoring
options alongside of the worlds leading telematics products. PressurePro
also remains the only TPMS provider to offer fully automated drop-and-
hook applications and data logging abilities."
Vanessa Zaroor, Director of Marketing, explains: We can outfit all
vehicles with pneumatic tyres with our systems so as to provide the drivers
with real-time tyre pressure readings and alerts to low and high pressure
situations. Though this information is vital in all types of operations as it
gives fleets the information needed to extend tyre life, add safety and
decrease downtime and maintenance, it is perhaps even more vital to
underground operations as a tyre problem, let alone a complete tyre

JUNE 2012 | International Mining 67


UNDERGROUND LOAD AND HAUL

Aramines L150D will be has been designed to facilitate the drivers well
unveiled in September being. This include the side seating for better
visibility in both directions, the suspension seat,
armrests and safety belt and the ergonomically
located steer and bucket pilot joystick.
Lepetit: The success of this narrow vein
range is leading Aramine to extend the family
and welcome a new member. Aramine is
currently planning a new narrow vein machine,
the L150D mini loader. This new machine, which
will be available in September, is a little bit
bigger than the last ones; in fact the mini loader
has a width of 1,205 mm. However, it keeps all
the advantages of the others and has some new
improvements.
Firstly, this new narrow vein machine will
failure, in a below ground operation causes Deutz with high altitude capability, developing allow more capacity (1,400 kg). Secondly, the
further troubles. They cant simply pull off the 50 kW. L150D will be faster than other machines. In
road and into maintenance and if in cramped Additionally, the L130 is available with a fact, the speed of this mini loader once loaded is
underground tunnels; a downed vehicle could variety of very practical and 10% superior to the others. Finally, this new mini
cause a complete shutdown of valuable modules. So, loader will allow better productivity. The
movement until remedied. this mini loader can be combination of increased speed and the greater
Further, on top of maintenance a drill jumbo, scaler, lift capacity come together with new, faster
and tyre issues, one really cool option platform and more. This hydraulic movement. It helps you to be almost
with TPMS is what we are seeing emerge in allows, Patrice Lepetit, 20% more productive, Lepetit says.
remote applications. Much as Telematics Purchasing and Lastly, the L150D offers an improvement on
technology is allowing mining operations, the security and the stability.
both above ground and below, to use remote First, an entry door with a
control options to run their machines, safety interlock has been
PressurePro's technology is able to added in order to increase
monitor tyre pressures on vehicles and security. Then, Aramine has
display the real time readings back to the improved the stability of
control house alongside of other vehicle this new member by keeping a
information. This allows fleets to utilise our full low centre of gravity and extending the width to
GHH Fahrzeuge says the driver compartment of
monitoring options - and gain the full benefits of the SLP-6 is designed for long-term operations 1.2 m. The capacity increase is also allowed by
TPMS - in remote applications. with high comfort and excellent visibility the changing the tyres and using the Michelin
8,5R15 X-Mine D2. This type of tyre guarantees a
Narrow vein innovation good quality in all conditions and a good
Aramine, in addition to being an Atlas Copco Marketing Director, explains, A very useful stability of your machines.
and Getman distributor and a specialist in rationalisation of the fleet with a fast and easy GHH Fahrzeuge's newly designed SLP-6 is
remanufacturing mining equipment, way to go from one kit to another. Moreover, the a super low profile LHD in the 6 t class. It was
manufactures its own range of narrow vein simple and robust design makes maintenance designed in collaboration with customers for the
mining machines. This Aramine range has been very easy. Southern African chrome and platinum mines to
very successful worldwide and the company In addition to its small size, the L130 offers fill the gap between the SLP-5 and SLP-8. With a
now has narrow-vein equipment being used in great operator comfort. The operator position total height of 1,700 mm and a width of 2,462
more than 50 countries. It recently delivered a
set of narrow vein machines in modules to a
customer in Russia. They were assembled
locally with help from an Aramine service
engineer. Other fleets of L110 and L130 LHDs
have already been delivered to mines in Peru
and Kazakhstan.
The L130 mini loader is designed to be used
in narrow sections and narrow-vein mining.
Indeed, its small size, 1,040 mm width, allows
this machine to slip into very little mines.
Furthermore, it is available in both diesel and
electric version. For the diesel version, there is a
choice of three engines. One liquid-cooled RDH Mining Equipment will be
introducing the Muckmaster 800D
Perkins developing power of 43 kW, one air- underground loader at MINExpo
cooled Deutz developing 50 kW and finally a

68 International Mining | JUNE 2012


POWERTRAIN PARTS
FOR MINE TRUCKS, LOADERS & SCOOPTRAMS
TRANSMISSION TORQUE CONVERTER DIFFERENTIAL PLANETARY AXLE

DOWN TIME IS EXPENSIVE.


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ATLAS COPCO DUX EIMCO GHH MTI TAMROCK TORO VOLVO WAGNER
UNDERGROUND LOAD AND HAUL

designed to provide the power and performance


With a standard bucket
volume of 3.5 m(6,500 kg required to perform under the toughest
payload) in this popular conditions. Its powerful 257 kW Mercedes Tier
LHD class, Schopfs SFL65 IV Interim engine meets stringent emissions
offers 2.5 m tipping height
in its Hi Lift version, limits while also achieving valuable cost savings
answering the demand for through low fuel consumption levels. RDH says
a team mate for the with heavy duty Dana 21D axles, a full power-
increasing use of 25 t
payload, narrow-width shift four speed Dana 6000 series transmission
trucks with higher box and Dana 9000 series torque, the Muckmaster
heights. A choice of Tier 2 800D has been specifically designed for the
(EU Stage II) mechanically
governed up to Tier 4A (EU most demanding underground environments.
Stage III B) electronically- Its powertrain has been designed to deliver
controlled engines can be constant power to the wheels, providing high
installed
operating efficiency for virtually any
application.
With bi-directional operator seating, the
ergonomic operator station comes standard with
ROPS/FOPS canopy or optional fully enclosed
cab and includes an electronic touch screen
mm it matches exactly the profiles of the mines MINExpo in September. The compact, powerful monitoring system which provides a constant
mentioned above. The tractive force of 149 kN, workhorse can get into tighter spaces and has display of vital machine functions as well as
load sensing hydraulics and its bucket size of more power than other models in its class, RDH service and diagnostic tools. A door-mounted
2.7 m3 (width 2,650 mm) boost production to says. The 14,000 kg tramming capacity LHD can electric joystick provides steering and
the next level. Powered by a Deutz BF6L914 be fitted with a range of bucket capacities of 4.6 transmission shifter controls. A responsive
COM II air cooled developing 104 kW engine and to 7.6 m. To reduce wear and increase life, armrest mounted joystick controls boom/bucket
a Clark series RT 20 000 transmission it delivers buckets are fitted with wear strips and a bolt-on functions. The ride control system feature
low operational cost and high availability. lip, allowing users to replace the bucket lip dampens movement of the boom and bucket
without welding. The Muckmasters loader during travel over rough terrain, increasing
Exhibition highlights linkage geometry has been designed to provide efficiencies by improving cycle times and load
RDH Mining Equipment will be introducing the optimal mucking and loading performance. retention as well as providing a more
Muckmaster 800D underground loader at The Muckmaster 800Ds powertrain has been comfortable ride for operators.

70 International Mining | JUNE 2012


UNDERGROUND LOAD AND HAUL

Immersive Technologies offers simulators for


Caterpillar R1700G and R2900G LHDs.
Immersive continues to further strengthen its
offering for underground with the development
of simulators (Conversion Kit) for the Sandvik
DD420 drill jumbo and Atlas Copco MT6020
truck see the drills article in this issue

Schopf, together with its Chilean partner


Mainservice, took the opportunity of Expomin
2012 in April to present the new SFL 100 a
powerful midsize production LHD with a
standard 5 m3 bucket. With an operating weight
of 34,300 kg, it is powered by a 200 kW engine.
Schopf says the SFL100 is the ideal match for
trucks of over 30 t payload. The raised seating
position enables the driver optimal all-round
visibility, making the loader safer and more
productive. POSISTOP brakes come as standard,
and all important components such as the Z-
linkage are made to last.
We place special emphasis on the the Schopf loaders. Separate hydraulic cooling when we all need to look at the real cost of the
straightforward construction of our hydraulic circuits for brakes, engine radiator and hydraulic equipment.
systems, which operate without electric or functions keeps the hydraulic temperature down As of the beginning of this year Paus is
electronic interfaces. This simplifies and so guarantees a long life for the independent in its production and sales of PFL
maintenance, enabling fast and efficient components, with the result of a low total life LHDs. Now Paus can offer the whole range of
repairs. cycle cost, compared to other loaders. Besides LHDs from 1.5 to 9 t. These machines represent
Schopf reports general success with its latest the ergonomic and comfortable drivers position some of the most popular Paus products and are
LHDs. KISS (Keep It Strictly Simple) method in in all loaders, components are in accordance working successfully in mines around the world
the design is one reason for the success story. with the latest environmental and safety for many years.
Many decision makers had Advertisement
a very close look into M4-2012,
requirements.IM2, International Mining, issue June
These 2012 and compact LHDs offer
manoeuvrable
our design and appreciated the excellent Many of our customers will confirm that excellent operator comfort. All clearly arranged
serviceability and straight forward technology of quality pays off. This is even more true today operating elements are within easy reach of the

When performance really matters: SCHOPF!


More and more companies are making their hard Dependable. Trustworthy. Like our SCHOPF SFL 140
going easy with the MINING POWER of SCHOPF. Underground Loader. The ideal team-mate for
And with good reason. In the rough and tough loading 30-ton plus dump trucks thanks to its
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Phone +49 (0) 7 11 3 40 00-0 Fax +49 (0) 7 11 3 41 10 87 www.schopf-mining.com schopfsale@schopf-mining.com

JUNE 2012 | International Mining 71


UNDERGROUND LOAD AND HAUL

drivers seat. There are two joysticks: one On May 9 the first of the five fuel cell-
multifunction joystick for driving direction and powered locomotive prototypes was delivered,
gear shifting and another for the bucket in collaboration with Vehicle Projects, Trident
INVEST IN
hydraulics. Depending on the requirements,
customers may choose between air-cooled and
South Africa, and Battery Electric, and will see
this partnership construct five fuel cell
PROJECT NEWS
water-cooled engines complying with Tier 3 locomotives which will be tested for Published every two weeks, IM Project News is
exhaust gas emission standards. The excellent underground use. The first locomotive is to be crammed with valuable information incorporating the
latest news on projects within that fortnight.
quality of the machines, Paus says, is surface tested over the next few months at the
completed by using Kessler axles for the models Amplatss Khomanani mine, in Rustenburg. After It is specifically about projects (not speculative
PFL 12 to 30. the initial testing period the fuel cell powered
exploration reports) featuring operations embarking on
scoping studies or those further advanced to
Paus LHDs are designed to customer request; locos will be integrated as part of a mining
prefeasibility and feasibility.
so different bucket types are available, such as operation. Amplats CEO, Neville Nicolau,
side dump bucket or ejector bucket. A special commented: These innovative locomotives will
Beyond that, we look at projects in development,
publishing regular updates as they get
feature is the optional use of hydraulic quick provide us with an opportunity to mine platinum
closer to production. We also detail
coupling systems, so that attachments like in a more economic, energy-secure, and 1

expansion projects at existing mines. 1

forks, working or scissor platform or pipe environmentally-benign manner. The


Contact
emma@im
News PROJECT -mining.com
from those proj Proj NEW
A colle ects mak ectCon News
(21) June S

At any one time there can be 8,000


ction of ing progtact
proje New
ctssarou recent ress emm towaa@im 10, 2007
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be in ction
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starts and e likelymaktoing repos rts (21)from S more ever
progress beprog June 10, y two

transporter can be interchanged within minutes. locomotives will not require any electricity from
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for rece reports in the ress towa arou weeks
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to be inGUIN - COPP
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drilling projects underway, 1,500


the marke and progr be projects ices
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......... .................. ......... .........
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......... ......... .........
......... ......... aroun .........
.................. .........
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rces
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AUST ZAM

Battery power offers great potential. Not only the grid to function and will not emit noxious
/SILVER...
ORE ER/GOLD .................. .......3
.........
RALIABIA -xAfrica Minera iganYBDE Gold NUM ......... .................. .................. ..................
.................. ................................3.........
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.................. ..................
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reserve-definition studies, 800


RUSS CANA -DA y Andes Resou
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ER .........
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.................. .................. ...5
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e Group
.................. .................. .................. .................. ......6 .......4
..................
- GoldeTY STAG Mines - GOLD ................... ..................
etal
- GOLD .................. ..................
.................. .............6.............5

is the power clean and cost-effective, the gases.


AUST BURK n China E .........
INA - MOL
YBDE
..................
......... ......... ......... .........
......... ..................
......... ......... .........
.................................... .........
RALI FASO ......... .................. .................. .........
.........
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......... .................. .................. ..................
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GOLDResou......... ......... .................. ......... ..................

feasibility studies and 400 mines


AUST AUST
tar Resou ..................
......... .................. .7 ......6
elt
Basin ......... .................. .........
RALIA RALI rnA Goldrces - GOLD - GOLDrces -......... GOLD .........
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.................. .........
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RALI - Easter China ation/- MOLYBDE /SILVER .........
......... .........
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rces -Resou NUM .................. .........
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aters GOLD .........
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Allianc - Easter Servic /SILV es/ Great .................. .................. .................9
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batteries can provide the counterweight so Anglo American Platinum is collaborating with
MEXICO - Atlant - COAL n &Platinu
can eLignite r Gold
/ Codel Resou River
.........Energ ..................
.................. ......... .........
......... .8
Corp
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under construction.
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essential to the balance of machines like LHDs. the South African government and technology
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So, to keep up with projects


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Great progress is being made in battery partners to further explore prospects of fuel
t is copyrigUS unless NICK
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ht. IM otherwise stated, EL/CO im-min Group
to IM
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Projec .................. .........
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getting close to completion


units are
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as photoc al and
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technology these days, as we saw in the utility cells as an integral part of the energy sources and learn about key project personnel, subscribe
vehicles article. that contribute to reduced carbon footprint. By now to IM Project News.
Vehicle Projects (VP) of Golden, Colorado, establishing the Platinum Group Metals
USA, and Anglo American Platinum (Amplats) Development Fund (PGMDF), Anglo American
are collaborating on a project to build five fuel Platinum is working towards expanding FOR A FREE TRIAL!
cell mine locos to be demonstrated very soon at industrialisation and beneficiation of PGMs. The Contact: emma@im-mining.com
Amplats Dishaba underground mine in Limpopo fund partners with innovators and entrepreneurs +44 1442 87 08 29
province, South Africa. This was covered in in PGM technologies and has identified Annual subscription is only 260, $410 or 315
detail in our March issue, pp93-94). opportunities in fuel cell technology. IM

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72 International Mining | JUNE 2012


In-Pit Crushing & Conveying
Grand Hyatt Bali Hotel Bali Indonesia
24 26 October 2012
Join us at the only global IPCC conference
Presentation update new keynote session!
The following shows 12 of the confirmed papers, with Please also contact us with offers of papers to IM
a number of others also being finalised. It includes a Events Director, Paul Moore at paul@im-mining.com.
keynote session, in which we have two leading figures For those accepted, registration fees are waived for
from the Indonesian coal mining industry, who will be speakers. For those accepted, registration fees are
giving the audience an overview of mining in the waived for speakers. News of the planned Workshop
country along with aspects of the industry structure, and Field Trip will be updated on our website,
rate of growth and the new Mining Law. http://corporate.im-mining.com/imevents/

KEYNOTE SESSION:
 Jeffrey Mulyono, President Director of PKN Coal  Mangantar Sabungan Marpaung, Mining Strategist
and former Chairman, Indonesian Coal Mining and former Director, Indonesia Energy and
Association (ICMA) Mining Ministry
 Bob McCarthy, General Manager, Snowden:  Rico Neumann, Senior Mining Engineer, Takraf:
Developing a coding system to better classify fully Reviewing 20 years of IPCC system development,
mobile IPCC layouts and systems practice and study work
 Christian Dirscherl, Drive Technologies Division,  Ruediger Durchholz, Managing Director
Siemens and Peter Sehl, General Manager, Engineering, RWE Power International:
ThyssenKrupp Robins: Latest Developments in Determination of performance and utilisation of
Gearless Conveyor Drives IPCC systems the key role of the conveyor
 Doug Turnbull, Principal Mining Engineer, Sandvik  Ian Gibbs, General Manager, RCR Mining: Mobile
Mining & Construction Materials Handling: Real mining units innovative solutions
mine case study of a new IPCC concept
 Stephen Kou, IPCC Business Development Director,
 Marcilio Cenisio, Project Coordinator - Planning and FLSmidth: Innovative New Technologies for IPCC
Development Department, Vale: An application
study of IPCC technology on a developing project
Registering
Moatize case study The rate for full attendance at the event is $1,600, which
will include the evening Welcome Reception on 24th
 Lynn Peterson, Product Sales Manager, FLSmidth:
Economic evaluation of next generation IPCC October, two full days attendance at the event, as well as
systems two lunches. The easiest way to register is online at
http://corporate.im-mining.com/imevents.asp though we can
 Mario Dilefeld, Chief Engineer Conveyor Systems, also accept bank transfers and other forms of payment;
Takraf: Gearless drive solutions for IPCC systems
please contact Paul Moore for more details.

I N D U S T R Y S P O N S O R S M E D I A P A R T N E R S

To register visit http://corporate.im-mining.com/imevents.asp


CAVING TECHNOLOGY

Underground
rock flow

In a new underground
development review,
Paul Moore looks at some
of the latest block cave
projects as well as the
application of new draw
point extraction technology
he level of activity in underground mining It is not a new mining method, with the Codelco Andina will see the next major

T continues to be high, partly due to it


representing the best long term solution
for many open pits nearing the end of their lives,
earliest application thought to be in 1895 at the
Pewabic iron mine in Michigan. But these early
applications of block caving are far removed
installation for Caterpillars continuous block
cave extraction technology. This shows a
system at Codelco Salvador, a previous test site

but also because the lead times on these major from todays large scale mechanised block cave
underground developments tend to be quite mines of today. In order to successfully cave, pit, still chose to complete approximately 15,000
long. This is due to the long term investment orebodies typically have to be massive with a m of exploration development during the
commitment, and the many years of studies, sufficiently large footprint; vertical or steeply prefeasibility stage of the Chuquicamata
construction and production ramp-up that are dipping; and with joints and fracturing in the Underground project to provide essential
typically required. An interesting aspect of this mineralisation that has the potential to orebody knowledge. The Chuquicamata
is that equipment and technology first deemed propagate the cave and create a well underground project commenced initial studies
suitable or applicable in the initial plans may be fragmented ore during cave draw. in 2001 and expects to reach the maximum
completely surpassed by more automated and Two case studies cited as a demonstration of production rate of 140,000 t/d of ore by 2026.
efficient options in the time it takes to reach this are Palabora and Chuquicamata. Studies In terms of the project evaluation risks
development. So underground mine plans also into underground mining at Palabora associated with block caving, Ebbels comments:
have to flexible to allow for this. The initial cost commenced in the mid-1980s, culminating into Given the scale of a typical block cave project
estimates also fluctuate significantly over time. the final feasibility in 1996. Ebbels comments: today, there is increased risk in comparison to
The long haul aspect in underground mining The Palabora orebody consists of one of the more traditional mining methods. Major risks for
particularly applies in the case of block caving. most competent rock masses that has been block caving include long lead times to
In a recent paper entitled To cave or not to attempted to cave. The feasibility study constructon; defining a credible project value
cave?, Anne-Marie Ebbels, a Mining Engineer identified that coarse fragmentation and based on the size of investment, typical long
and Consultant with SRK Consulting, comments: sustained caving were major risks to the project mine life and variability of cost inputs over that
Designing and constructing a block cave mine due to an in-situ rockmass that was relatively time; the level of orebody knowledge required;
takes time and there is no fast-track to poorly jointed. Operationally, one of the most the large initial capital outlay for construction;
establishing a block cave mine. Time, challenging aspects has been the handling of the orebody cavability and resultant
commitment from management, and oversize. In support of the load and haul fragmentation; and the production transition,
maintaining a long-term view of the project all activities, a large secondary breaking fleet is particularly if the cave is needed for production
contribute to the success of a block cave mine. required to support the LHDs and reduce draw continuity.
Arguably, the single most important aspect to point rock flow to a manageable size. The These risks if not proactively managed well,
establishing a block cave is the gathering and Palabora mine commenced production in 2000 will have a significant impact on the project
analysis of adequate orebody knowledge. The and reached the targeted production rate in value of the project. A significant control in pre-
quality of this investigation has been shown to 2004 of 30,000 t/d. emptively managing risk is gaining a full and
be a major contributor in firstly analysing the Codelco Chuquicamata, having almost 100 complete understanding of orebody knowledge,
project viability and ultimately in making a years of mining in the open pit and the especially in terms of geology, geotechnical and
success of a new block cave operation. knowledge gained during the mining of the open hydrogeological data gathering and analysis.

74 International Mining | JUNE 2012


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CAVING TECHNOLOGY

Cave extraction automation The RF300 electronic control at


Rock Feeder
Automated ore extraction from block caves is each single dozer
something IM has referred to several times over deede providing
the years, such as in 2011 when Caterpillar automated operation
released more details of its RockFlow and recording of
Feeder and RockFlow Mover system, operational
which are designed to characteristics such as pressures
improve production by and strokes. A server also links all dozer
generating a continuous deeders with a central control room. The control
haulage stream from the room PC itself makes possible remote control
drawpoints. The RockFlow work and remote changing of sequences of the dozer
Feeder takes the rock from completion. Trials feeders; and visualisation of the operational
the drawpoints and the have seen two Rock Feeders data from each dozer feeder. In terms of the
Mover is the main conveyor that they operating alternately with a single draw control it is possible to steer and record
feed onto. In a presentation at Expomin 2012, self-cooling hydraulic unit. It operates at 310 bar the amount of ore taken from each draw point
Caterpillars Markus Frenzel gave an update on with 110 kW power and 150 l/min volume flow. The first system was carried out back in 2007
the system, now referred to as comprising the The RM900 Rock Mover is a chain conveyor, by Bucyrus DBT at Codelco El Salvador. A total
RF300 Rock Feeder and the RM900 Hard Rock with easily changeable wear elements. It can volume extraction of 122,120 t was achieved,
Production Conveyor. convey 900 t/h at a chain speed of 0.15 m/sec, with a mean extraction rate of 260.4 t/h (each
The system consists of the RF300 Rock with a typical conveyor length of 77 m. It is RF300) and a maximum extraction rate of 880
Feeder, which is equipped firstly with a pushing driven by two 90 kW drives and has Pan widths t/h (each RF300). The mine has a porphyritic
device that has two pushing cylinders with a of 1.8 m and lengths of 3 m, The chain length is copper deposit hosted in hard andesite and
1,000 mm stroke: 1,000mm, pressure totalling 156.066 m with the individual chain sizes of 42 x quartz-andesite. The trialled system had a 75 m
5,147 kN and total weight of 13 t. There are also 146 mm. To team with the Rock Mover, chain conveyor, four rock feeders, an impact roll
four dozer plate cylinders, with a stroke of 1,350 Caterpillar is offering an impact crusher for low crusher and a central hydraulic station. The
mm, cycle time of 112.5 sec. and pressure to medium hardness rock, and a sizer for harder chain conveyor capacity was rated at 900 t/h at
totalling 4,021 kN. The dozer plate itself is 4.3 m rock. In both cases they have a compact 0.15 m/sec with two 75 kW engines.
long and 2 m wide. The dozer feeder can be construction and can be installed on top of the The new trial is being conducted at the
removed from draw-point at any time for service RM900 with no foundation or dedicated Andina operation, beginning in July 2013. It will
and hang up removal. It can also be chambers required. have four 75 m chain conveyors and eight Rock
repositioned in the draw-point at any time after Automation is a key part of the system, with Flow feeders per production drift - 32 in total;

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76 International Mining | JUNE 2012


CAVING TECHNOLOGY

teamed with 16 hydraulic stations to produce a Schematic of Caterpillar Rock Flow System and additional skills and abilities that will enable us
volume of 5,000 t/d. The trial will start in July close up of single draw point area to deliver similar projects in the future," said
2013 and last for 18 months. SKMs Mining and Metals Manager, South
Codelco Chile has awarded the EPCM for the approximately 10,000 m2, with which a America, Claudio Lesch.
Andina continuous extraction project to SKM. production of 6 to 7 Mt in approximately 1.5 "This experience adds to the capabilities
SKM states that: The scope of the work years is expected. deployed in the development of conceptual,
includes engineering studies and the Once the development of the technology is basic and detailed engineering, plus
implementation of an innovative system in finalised, the next step will be to apply it to the procurement support for Codelcos El
underground mining. This is a technological operations and possibly to other Codelco Teniente New Mine Level and the
breakthrough, of which a key aspect is the underground structural projects where SKM development of the basic engineering for the
simultaneous and continuous automated ore has previously applied their knowledge and tunnels, primary crusher and material
extraction, in all active sites in a block, which skills. handling of the Andina Expansion 244. This
ultimately can increase the average production "This breakthrough in technology will ensure also consolidates our position as a world-
rate substantially. The technology will be that SKM will remain as leaders in the delivery class service provider in underground
tested in a complete block of exploitation, of of underground mining projects, acquiring mining," concluded Lesch.

JUNE 2012 | International Mining 77


UNDERGROUND TECHNOLOGY

Ore at Cadia East draw-point

Current caving projects concentrate is expected in the second half of two underground block-cave mine at the Hugo
At New Golds New Afton, underground block 2012 and commercial production is projected to North Deposit continued successfully during the
caving was initiated in 2011. The commencement begin in the first half of 2013. In conjunction first quarter of this year. Lateral mine
of caving and continued build-up of the surface with the surface activities, an 85,000-tonne-per- development 1,300 m below surface at Hugo
ore stockpile has positioned New Afton well for day underground block-cave mine also is being North advanced a total of 10,914 m since
its targeted production start in June 2012 with developed at the Hugo North deposit. The tunnelling started in 2008 up to February 2012.
commercial production expected in August. In throughput capacity of the concentrator plant is Underground lateral development was
April 2012, the SAG and ball mill dry expected to be expanded to 160,000 t/d to suspended in February 2012 as planned to
commissioning commenced, following by the process available ore, from both the open pit permit the upgrading of hoisting equipment at
stockpiling of some 900,000 t of ore on surface and underground mines. The underground mine Shaft 1, which is expected to continue until
in May, with the first ore due to be put through is scheduled to commence operations in 2016 August 2012. Underground lateral development
the mill in June. July this year will see 26 draw and the concentrator expansion will need to be is scheduled to resume in September 2012.
bells developed to support the initial required in place by 2018 to meet the increasing tonnage The underground development from Shaft 1 is
6,600 t/d mining rate as well as the first available from underground production. expected to connect with the bottom of Shaft 2
concentrate shipment. Commercial production Construction of Shaft 2 at Hugo North is in 2013 to enable the installation of the ore-
of 6,600 t/d processed should be achieved by progressing well and the head frame has now handling system and production from the first
August then in September the mine will start reached a height of 78.5 m above surface. The lift of the Hugo North block-cave mine. Work to
utilising the gyratory crusher thus enabling the final height of the shaft will be 97 m. The establish the first and second ventilation raise
mining rate to move towards the design capacity headframe and ancillary buildings were 87.4% holes to provide a flow of fresh air from surface
of 11,000 t/d closely followed by the mill. By complete at the end of the first quarter of 2012 to the underground workings will continue from
end-December this year, the mine will have and ahead of schedule. Shaft-sinking activities surface while Shaft #1 is being upgraded.
completed a total of 48 drawbells to support the began in December 2011 and the bottom had The Newcrest Cadia East project also remains
new mining rate. Once in full production, reached 224 m below surface by May 12, 2012.
underground block cave mine and concentrator The development of the first lift of the phase- Chuquicamata underground project timeline
is expected to produce an annual estimated
average of 85,000 oz of gold and 75 Mlb of
copper. The underground mining rate is now
over 4,700 t/d. The underground crusher and
conveyor system to surface has been fully
commissioned and is operating at design
capacity.
The Oyu Tolgoi Project initially is being
developed as an open-pit operation, with the
first phase of mining now underway at the near-
surface Southern Oyu deposits. A copper
concentrator plant, with related facilities and
necessary infrastructure to support an initial
throughput of 100,000 t/d, is being constructed
to process ore mined from the Southern Oyu
open pit. Initial production of copper-gold-silver

78 International Mining | JUNE 2012


CAVING TECHNOLOGY

on schedule and on budget. The project is fully


committed and is 75% complete. The project
remains on track for first commercial production
in the December 2012 quarter. Underground
mine development during the first quarter of
2012 continued to establish panel cave 1 and
underground infrastructure. Development of the
decline toward the deeper panel cave 2 also
continued during the quarter. Preconditioning
blasts continued in panel cave 1 and draw bells
continued to be fired, with ore from the blasted
draw bells and from the undercut being
processed during the quarter. To date, over
300,000 t of ore has been treated through the
process plant. The crushers for the underground
materials handling system remain work in
progress and the conveyor system is largely
complete. An accelerated temporary crushing
capability and a substantially complete
conveyor system provides a level of materials Aerial view of the existing Lace diamond mine
handling capability to enable the ramp up of socket (or slot drive) level, 30 m above the which is to be developed into a major new
block cave
production from Cadia East panel cave 1 albeit at production level, 12 months after development
lower initial rates than expected. On the surface, commences. The anti-socket level tunnels will
the concentrate handling, power, tailings and be developed across the entire pipe by month 15 kimberlite indicated and inferred to a depth 855
water infrastructure were commissioned. The and initially allow final cave footprint m; and approximately 13.291 Mct in both
flotation plant and the regrind Vertimill were delineation, the geotechnical model and grade resource categories.
both completed on schedule and are in the final distribution to be finalised. They are later Morobe Mining Joint Ventures (MMJV) is a
stages of commissioning. The high pressure utilised for physical observation of the blasted partnership between Harmony Gold and
grinding rolls (HPGR) circuit is well advanced slots. The total cost to reach this stage of Newcrest Mining to explore and develop mines
with commissioning scheduled during May 2012. development is estimated at $22.2 million. The in the Morobe Province of Papua New Guinea
DiamondCorp, the South African diamond peak funding requirement (including working (PNG). The MMJV consists of the Hidden Valley
mine development and exploration company has capital) is estimated to be in month 25 at $37.6 Joint Venture, which operates the Hidden Valley
announced the receipt of an independent million when blasting of the slot drive and Mine, the Morobe Exploration Joint venture,
engineering report on the proposed 47 level doming starts to deliver significant tonnage of which operates the exploration activities in the
block cave development at the historic Lace kimberlite The costs of establishing the block Morobe Province and the Wafi-Golpu Joint
mine prepared by SRK Consulting South Africa. cave thereafter are offset by revenues from the Venture, which operates the Wafi-Golpu project.
SRK's key conclusions are that the continuous sale of diamonds recovered from kimberlite The Wafi-Golpu Project is currently conducting a
trough block caving method proposed for the 47 mined and processed during the doming level prefeasibility study and has also commenced
level (470 m depth) mine development is an and production level developments. early exploration access activities. It is
appropriate mining method for the Lace mine to Approximately 600,000 t of kimberlite will be envisaged that the pre-feasibility study will
achieve 1.2 Mt/y of kimberlite production. The extracted and processed during the block cave shortly be completed. Subject to a successful
report states the proposed twin decline access development. Anticipated revenue from this feasibility study, it is expected that Golpu will be
and conveyor system is a sound approach which kimberlite is $54.7 million during the 43 months mined using a block cave bulk underground
will be quicker and cheaper than refurbishing of development before 100,000 t/mth of mining method with an output of up to 30 Mt/y.
the collapsed shaft system and that the existing production is achieved. The deposits 1 billion tonne resource and an
mine engineering infrastructure has been designed, In conjunction with the SRK report, a exploration target of 132 Moz puts it in the same
installed and operated to a high standard. geological resource review was undertaken by league as Grasberg in West Papua, and Harmony
Certain modifications will be required to the VP3 Geoservices which has updated the CEO Graham Briggs has previously described
existing DMS processing plant re-crush circuit to resources statement for the Lace mine in the project as a game-changing asset for the
ensure 200 t/h of kimberlite can be treated accordance with the SAMREC Code of Diamond company. It is expected to produce 600-800,000
without the scrubber section being overloaded. Resource reporting. The review concludes that oz/y of gold and 300-500,000 t/y of copper with
Kimberlite will be accessed first on the anti- the Lace Main Pipe contains 33.121 Mt of mine start-up in 2017. IM

Well Bend Over Backwards


To Improve Your Efciency.
www.twp.co.za

JUNE 2012 | International Mining 79


INNOVATION INTELLIGENCE

Making big changes in small steps


Following on from last months underground communications article, Ryan Siggelkow,
Vice President, HLS Hard-Line Solutions, looks at easy steps to advance remote machine control
and how that infrastructure can help all communications underground
emotely controlled LHDs are widely used is, Can the hazard be removed? Sometimes it

R to extract ore from drawpoints. The


remote control system, although being
made safer all the time, has remained virtually
can, however, other times the hazard cannot be
removed as it is an integral part of the process.
The next discussion would be; How can we
unchanged for many years. The basic guard this hazard? If guarding proves to be
functionality is an operator switching the difficult, the final discussion is; How can we
machine to remote control, getting out of the protect the worker?
cab, walking up a stand, operating remotely, Thinking about remotely-operated machinery,
returning to the cab, switching to manual, Can the hazard be removed? The answer is yes.
driving manually, switching to remote, and The hazard can be removed by simply moving
switching to manual. It seems repetitive, and the operator further from the machine and
time consuming, does it not? keeping him out of the dangerous area. Why
Networking, convergence, video, voice, and would safety discussions jump over the first
data infrastructures, and other technologies are step into guarding or protecting when the option
growing by leaps and bounds in virtually every is available to remove? By making a system to
industry and region, except for mining. A mine Ryan Siggelkow automatically stop the machine if it is within
superintendent must [still] jump through hoops proximity of an operator, the hazard is simply
to have a private conversation with the front line being guarded, but as was already discussed,
supervisor underground. Is there not a better literally had no intended downtime. There would the available guards today are not without
way to handle this? be a stope to draw from and a designated hazards themselves. In a factory, when a
With such a complex industry, it seems as if, orepass, or re-muck to move the material to. A remotely controlled machine or automatically
for the most part, the introduction of new manned machine would then take that material controlled machine is operating, it is usually
technology into mining has either been and load it into a truck or move it further, if contained in a cage that is completely enclosed
overlooked or has been met with some required. The countless hours of operators and cannot be entered without powering the
resistance. It is time to step back, look at the getting in and out of machines today are machine down. In this way, there is no hazard to
process, and see how it can be improved. Key completely wasted. No material is moving and the workers and the machine is free to produce
areas of focus will be safety, productivity, no productivity is being made. all day.
dependability, and cost-effectiveness. Another Question: What is the likelihood that What about productivity? If the operator
Question: Would an operator accomplish an operator would be injured if he was not near could simply be pulling the material from the
more in a day if he never moved from a single the machine? Today, there is much discussion open stope and moving it to a close area, where
location? What if he wasnt required to jump on about warning when the machine is within a it is handled further; could productivity be
and off a machine several times every shift, and certain proximity to the operator. This would improved? The dollars and cents of the
instead, could simply move to his work area, sit prevent the system from accidentally driving too operation are in taking the material from the
down, and move material all day? Imagine, for a close, or even, on top of the operator. But, what blast and moving it out so the area can be
moment, that the remote mining process happens when the braking system fails? What backfilled and a new area can be started. If
happens when the proximity remote machines could do the job of remote
system fails? It seems as if this machines only and manual machines deal with
approach is not a final solution the material in a safe area, the savings would be
to the dangerous nature of astronomical. Today, the machines tram the
remote control machine material down the drift to another area. During
operation. Instead, it would this time, productivity at the drawpoint is
seem to give a false sense of wasted and machines are being beaten up,
security, which amounts to performing a job that they are not really meant
nothing more than hoping that for. Trucks and locomotives are better suited for
nothing goes wrong, rather haulage. Why is the movement of material being
than a proper solution to a done with LHDs?
problem. Hard-Line Solutions has developed the
In safety discussions, if a TELEOP system that allows an operator to
hazard is identified it is operate a machine from a portable remote
discussed by the management, cabin. The required network is very simple to
safety representatives, and install and disassemble as required. When
workers. The first discussion remote control is required, the remote station is

80 International Mining | JUNE 2012


INNOVATION INTELLIGENCE

set up in a safe area that is close to the working The obvious advantages are numerous. Time
area. This cabin includes a remote control chair is saved because the operator is not climbing on
for the machine control, two LCD monitors to and off the machine multiple times every shift.
view the machines forward or reverse cameras Sound and vibration (which are unpleasant and
or any other cameras set up. For example, a hazardous to hearing and the body) are
camera could be set up on the overcut, looking eliminated. The dangers involved with being in
down on the working area. From the chair, close proximity to a remote machine are
pan/tilt/zoom controls are integrated into the eliminated. The operation of these machines can
joysticks so the operator can use this camera to now be achieved by a greater percentage of the
scan around the stope and find loose or large workforce. Being in an ergonomic chair and in
pieces of material that are about to fall. This can an air-conditioned room, the comfort for the
greatly reduce the risk of burying a machine, or operators is improved.
even worse, losing a heading with millions of The obvious question arises: Why not move
dollars of material just sitting there. the operator immediately to surface? Why not
A typical system would include a small cabin make the machines run themselves and jump
set up on the overcut or another area that is over everything today? Obviously, there are
close to the work area. This cabin would be advantages to taking the operator out of
completely self-contained. From the cabin, a underground and moving him to surface to
network would be installed from the cabin to the machine would simply move the material from operate the machine from there. There are even
work area to provide a wireless connection to the drawpoint to a re-muck or to a designated greater advantages to making the machines
the machine. The network is very simple, with dump site. When the drawpoint is completely operate automatically. However, the paradigm
connectors on all parts. Everything would be mucked out, the area can be backfilled and the shift from operating a machine with
pre-configured for that machine. The machine remote machine can move to the next area that conventional remote operation to moving
would already be equipped with Hard-Lines requires the process. If the material is to be directly to surface poses many issues. The leap
Remote Interface Package as well as video loaded into a truck or orepass further down the is too great to take in one giant stride. There has
cameras and wireless access to the network. drift, a manually operated machine would be been very few, if any, real success stories where
Access to the work area is guarded with barriers used for moving the material to the next companies have taken the leap to surface to
that automatically shut the system down if any process. Imagine; machines can be used for the operate mobile machinery. To clarify the point,
machine or person enters the area that is being process that they were designed for. With proper we define success as being cost-effective
tele-operated. mine design around this new concept, enough to be widely deployed and dependable
In this method, the difference is that the productivity will be improved. enough to be trusted to make production
INNOVATION INTELLIGENCE

targets. If a mine cannot trust a remotely complete package will lead to a safer, and
operated machine; why use it at all? Companies ultimately, more cost-effective system.
must be completely confident in a technology Returning to network infrastructure and the
for the concept to succeed. Without this lack of communications available today, it is
confidence the project, and ultimately the entire important to touch briefly on this aspect
concept, will be a dismal failure. because, just as the human body relies so
Would it not make sense to walk successfully heavily on a strong backbone, any new projects
before running? The old adage has proven to be coming in the near future will rely on a
true and has withstood the test of time. A dependable infrastructure, or backbone. The
proposed trial would be to start with operating small, contained, simple network that is
the machine remotely from a close location. installed to control machines can also be used
Once trust in the system by the operators and for mine-wide video, voice, and data. Because it
mine personnel is established, make a simple is based on the Ethernet and WiFi standards,
switch to surface. By approaching the complex wireless VOIP telephones, network video,
overall picture in baby steps, operations and machine and personnel tracking, ventilation
maintenance can easily understand and adapt to control, ore and waste pass levels, oxygen and
the different situations that will arise in tele- CO levels, heading status, as well as many other
operated machine control. It will allow operators applications can be easily implemented.
to become accustomed to operating the With the vast amount of WiFi compatible
machine from a distance, while still having the parts and sensors that are now becoming widely
feeling of being near the machine in case of available, the imagination is the only limiting
breakdown or another situation. The normal could be replaced, but it would prove to be a lot factor to the growth of this technology. This
routine of approaching the work area remains of work. The point is that PLCs and many other infrastructure, if installed mine-wide can
the same with regular circle checks and daily parts are very often made obsolete by the facilitate the control of every piece of machinery
maintenance, greasing, and fuelling. Training manufacturer. In the middle of the project, from surface, and eventually automation. Again,
and safety considerations would be handled in everything looks good until an add-on is this idea is long ahead of the times. However,
this project. required or until a change of direction is many companies today are still relying on, and
After adapting to these changes, then make required by the customer. If the PLC is not even investing in old technology for
the jump to surface. The machine interface is available, they may need upgrading. Or even communications for new mines. New
the same in both scenarios. The operators worse, they may all need to be replaced applications will not work over old technology.
hardware is the same in both scenarios, and the because of protocol changes. The Without implementing technological change
network is the same in both scenarios. The only instrumentation department now requires underground as it is being done at a corporate
difference would be to unplug the network from training and different spare parts again. level, there is no hope for new technology to
the portable cabin and plug it into a fibre pair Another downfall of piecing parts together is make it into the industry. It is time to start
going to surface. Literally, it is that simple. This that everything becomes an unknown. taking steps to implement a new network
step will overcome the maintenance difference Components react differently with other underground. Hard-Line Solutions has
and pre-shift circle checks. components and this could prove to be very developed the MAN (Mine Area Net) digital
Our biggest strength is taking complex unsafe, or even life-threatening. Data sheets are communications solution, which is the
projects and turning them into widely available misleading and sometimes incorrect. Trusted backbone of tele-operation. This system can be
off-the-shelf products. Because of this components and overall knowledge of the installed in small pieces for proof of concept, so
approach, spare parts, troubleshooting, and that the benefits can be quantified to spend
repairs are made to be routine instead of capital.
confusing. This direction has also allowed Typically, the industry has been very reluctant
complex, and previously extremely expensive to change on many fronts. As has happened far
systems to be installed at a very reasonable too often, the company and the supplier plans
price, which will be billed and payable only to climb an entire tower, without focusing on the
upon successful completion of each stage. first step. On the horizon, networking will
Once operators are confident in surface become slightly easier to implement
control and all of the maintenance, training, and underground as maintenance and operations
safety steps are out of the way, take the step become more familiar with the technology. This
over to automated haulage. can be easily accomplished by installing a
More often than not, companies piece network in key areas and working towards
together PLCs (programmable logic controller), implementing new technologies into new
parts from hydraulic suppliers, computers, third- projects that are coming online. Machine control
party software, proprietary networks and over infrastructure will be taken in baby steps
whatever else is needed to stitch together the until everyone is familiar and confident that the
final project (like a quilt where many different technology is cost effective and feasible. Once
swatches are stitched together). What if the the confidence level is raised by maintenance,
entire quilt was almost done, but one fabric was operations, and corporate in this technology, it
discontinued? Another fabric could be used, but will become the new standard of remotely
it wouldnt be uniform anymore. All of the pieces controlled mining. IM

82 International Mining | JUNE 2012


HIGH PROFILE

Another On April 26, the


3DExperience
Company, Dassault

level Systmes
announced its
intention to acquire
mining software
major, Gemcom
Software
International. Paul
Moore spoke to
Gemcom President
and CEO, Rick
Solutions such as
Gemcom's Minex Moignard, to get a
mine schedule
simulation will feel for the deal and
greatly benefit
from Dassault 3D
its implications.
technology

Q: Was it always part of the plan to go public? by all the major aerospace groups, including Q: Despite your acquisitive and organic growth
Boeing and Airbus, by leading automotive in recent years, do you think you will partly lose
A: It is important to remember that we were companies like BMW, Toyota and Honda, by the Gemcom image of being an innovative
already a public company from 1997 to 2008 high-tech companies such as Nokia, LG, and mining software specialist in becoming part of
when we were listed on the Toronto Stock NXP, by consumer packaged goods companies such a large group?
Exchange. With hindsight, however, we were such as P&G, J&J, and Nestle, as well as a range
probably too small to go public at the time, of other industries. They have stated that the A: Our focus on our core products for mineral
when moves by individual shareholders could acquisition of Gemcom, coupled with their exploration, mine design and mine planning will
and did have a significant effect on our share 3DExperience platform capabilities, will further not change this is very much a technology play
price, and this was distracting us from our core their objective to model and simulate the planet, from a Gemcom point of view as it gives us
strategy of business growth and product improving predictability, efficiency, safety and access to resources and capabilities that have
development. As a result, we opted to become sustainability within the natural resources industry the potential to enhance our existing products
part of a private equity grouping (JMI Equity, The and beyond. Gemcom has customers in over significantly. Dassault Systmes is very focused
Carlyle Group, and Pala Investments) and 4,000 locations and over 130 countries, so in on delivering great technology solutions to their
delisted in 2008. We did this to allow us to some cases our existing presence will allow them customers and as
better focus on our long term objectives. Before to have a footprint they would not have otherwise such they
this opportunity to join Dassault Systmes came had in regions such as Asia and Australia. reinvest about
up, we along with our owners were looking at one-third of
staying private for longer, as Gemcom has Q: Will the Gemcom name now disappear or be their revenue
consistently been achieving annual growth rates retained as part of product brands? When will in R&D
of more than 25%. But this deal presented itself, we see a unified front to the market? annually. It will
and it represents a good exit strategy for our also allow us to
investors as well as a unique opportunity for A: Gemcom as a brand will be phased out to be look at new
Gemcom staff and customers. replaced by the new brand GEOVIA, which will offerings,
cover the natural resources interests of Dassault
Q: How did the deal with Dassault Systmes Systmes. However, we expect to maintain our
develop and what is in it for them? eight core product brands as they already have
significant recognition and leadership within the
A: As stated, we had steadily growing sales and mining sector Surpac, GEMS, Minex, Whittle,
in some years growth rates of up to 29%. As MineSched, PCBC, InSite and Hub. In terms of
Rick Moignard
such we began to be approached by a number of unified branding, you can expect to see this
groups, but Dassault Systmes was considered happen later this calendar year. We do have
the prospective acquirer with the greatest some remaining approvals from regulatory
potential. It was not an overnight conversation authorities to receive in July, but we do not see
but we worked together to get to an agreement. potential obstacles, given that there is little
Dassault Systmes software solutions are used direct overlap between the markets served.

84 International Mining | JUNE 2012


HIGH PROFILE

such as virtual and real time mine packages, so also a significant factor? How much new growth growing quickly. There are more than 5,500
our innovation potential will be enhanced not is possible? operating mines worldwide and approximately
diminished. We will retain the customer facing 15,000 mining projects. The associated mining
service that Gemcom has built up and as the A: The mining industry is the software market is experiencing strong growth,
natural resources area is new to Dassault primary user of with analysts estimating a double digit trend for
Systmes, we will operate as a standalone Gemcoms software, the foreseeable future. Becoming GEOVIA
entity but obviously will have access to and it is still under Dassault Systmes will have a very
whatever technology we need from within the significant impact on us in terms of giving us the
group to leverage our existing products and resources to make real functionalities that we
develop new ones. could not have even considered ourselves even
though we may have had
Q: To what extent has this move been the ideas. It will also put
driven by mining groups asking for us on another level to our
more global and comprehensive competitors in terms of the depth of our
solutions from Gemcom across all Aircraft engineering in design relationship globally with the major mining
done in Dassault Systemes
their operations? CATIA software groups. IM

A: Only in the past few years have we been


seeing a genuinely global approach from some
of the mining houses. However, we have now
deepened our relationship with several key
mining companies on a global basis. But more
effective and more real time simulation, whether
in surface or underground mining, will allow for
faster decision making for global miners. They
may even include virtual mines that are updated
with the latest geological, equipment,
production and development data in real time
and could even be hosted on mining companies
intranet systems. New systems will also be able
to deal with the largest operations and the
largest amounts of data; making environmental
impacts of decisions more clear across the
whole operation. Being part of Dassault
Systmes will make much of this a reality.

Q: Are there potential synergies in terms of


Gemcom being able to develop new
functionalities and advanced solutions as part of
Dassault Systmes, especially with access to
their state of the art technology used in
aerospace and other industries?

A: They have some very leading edge


technologies that Gemcom could never have
afforded to adapt to the mining industry. These
include 3D modelling, visualisation, scientific
simulation and 3D lifelike experience. I like to
say that it will make it possible to turn our
dreams for what could be achieved in mining
software, into reality. In addition, we will be able
to improve remote site management for mines,
helping to address the skills shortage issue to
the point where mines will not have to rely as
much on fly in fly out for mining professionals
into remote operations. I truly believe it will
allow us to lead the way in the transformation of
the mining industry.

Q: Is the level of investment that a company like


Dassault Systmes could devote to Gemcom

JUNE 2012 | International Mining 85


HIGH PROFILE

Consolidating mining expertise


Paul Moore spoke to Peter Carter, Global Leader of Mining region where usable water for mining operations
Solutions at GE Energy, about its increasing focus on mining is in short supply. In looking at water
desalination, our offering ranges in both the
and increasing collaboration with EPC groups and partners equipment we provide as well as the chemicals
used in our customers desalination plants. We
supply industry best pumps that can take water
from the ocean and transport the water across
the vast kilometres to remote mine locations.
Once the water arrives, we supply the most
advanced ultrafiltration systems, which act as a
mechanical barrier to algae and other
microorganisms present in sea water. Another
unique offering in our portfolio of solutions are
our factory assembled modular blocks of
desalination plants. Customers that implement
this solution enjoy lower installation costs and
start up times. The combination of our broad GE
portfolio of solutions for the mining industry
and the project expertise brought to the
industry by EPCs makes our partnership an
important facet in the continued evolution of the
mining industry.

Q: In terms of GE Mining as a group, the


solutions mentioned as forming the offering
include Intelligent Platforms, Condition
Q: Can you tell me a bit more about the GE EPC greater value to our current customers. Monitoring & Reliability, Dust Control,
Mining Summit? Is this essentially a realisation Given our significant footprint in the Latin Environmental Technologies, Motors, Inspection,
that given the broad range of solutions GE can American region, Chile stood out as an ideal Power Generation and Water Treatment amongst
provide to mining that you should try to offer a location to bring together customers, EPC others. This involves many different expertise
more unified/comprehensive offering to mining companies and other influencers in the global areas within GE was GE Mining as an entity
groups; are you already working on EPC or mining sector to talk about the top challenges formed to try to present a more unified
EPCM contracts? Will you be marketing GE facing the industry and bring additional approach to the industry?
Mining as more of an EPC/EPCM player in the emphasis on the comprehensive offerings we
future? can bring to our EPC partners. Last year, in Latin A: Yes very much so. GE Mining Solutions is part
America alone, GE won $1 billion in new GE-EPC of GE Global Industries, GE Energys new cross-
A: Over the past 10 years, we have moved from a projects. Continuing to increase collaboration business initiative that takes the best
company that simply provides power generation with EPC companies is a critical element of GE technologies from across GE Energys diverse
products and services to one that can offer a Minings growth strategy for the future. portfolio and interconnects them to increase
broad portfolio of solutions to global industries, efficiency and results for customers in critical
including mining. Over the next three years, Q: Has your success
nearly $6 trillion will be spent on global mining in desalination and
infrastructure investments. With our broad other water related
portfolio of products we are able to provide projects in South
energy, water and productivity solutions to meet America formed an
the demands of mining companies around the important part of
world. By combining our product portfolio and this approach? What
innovative solutions developed by our more can GE offer that
than 40,000 GE technologists around the world other major EPC
and 2,600 global research employees with the groups cannot?
project expertise brought to the market via EPCs
were able to collectively bring to the market A: Overcoming
great new innovations to these pressing challenges related
GE recently acquired
challenges. Given the amount of growth to water the Converteam
expected in the mining space, we see this as a management is a business, which has
great opportunity to partner with companies in big focus for us in been renamed GE
Power Conversion
the EPC space to win some of this and to deliver Latin America a

86 International Mining | JUNE 2012


HIGH PROFILE

business sectors such as mining. Aside from processing water for


mining, additional focus industries include mining needs and
metals, food and beverage, metals, returning clean water to
petrochemicals and unconventional fuels. the earth or processing it
for safe consumption. In
Q: Can you provide any highlights of GE Mining grinding circuits, GE
new contracts, ongoing work or technology Energy has an offering of
development in 2012/2013? high efficient electric
motors as well as
A: At the end of last year, we announced a automation systems and
partnership with Foster Wheeler Chile in which, aims to be present in this
together, we are working to be able to offer area of the plant with
innovative solutions to the mining sector, packaged solutions.
GE Energy itself recently
combining equipment and technology from GE GE Energy itself introduced a new AC
Energy with the technical expertise in mining recently introduced a new excavator solution
and metals and the project execution capability AC excavator solution
of Foster Wheeler Chile. This joint offering which consists of drives,
touches mineral processing, power generation controls and motors designed specifically for greatest footprint in terms of success in
and water desalination facilities, providing challenging surface mine applications and providing a range of mining solutions; where are
solutions to address processing issues, and to environments. We already have a long history of your main focus markets going forward?
improve productivity, water and waste designing, installing and maintaining direct
management and power utilisation. current excavator systems across the globe. The A: Looking at our global footprint, we have a
As an example, the team is designing a co- AC Excavator Solution is a complete electrical significant number of projects in the works in
generation power plant that delivers electricity drive solution comprised of a family of AC Australia, North America and Africa, and South
and heat to remote Chilean mines. Electricity is motors, drives, controls, engineering and field Africa, specifically. If I were to rank the top
generated with the exhaust heat from the services. Heavy equipment original equipment three regions for GE Mining in terms of the areas
engines or turbines used for different processes manufacturers and earth-moving equipment were currently active in, Id name North
at the concentrator plant. These projects have owners can apply this solution in their draglines, America, Australia and Latin America. China and
the potential to significantly reduce carbon shovels and blast-hole drills. Africa follow closely behind as we think there is
emissions and energy costs. Other activity areas a tremendous potential for growth in these
may include wastewater processing - safely Q: Latin America aside, where does GE have its geographies. IM

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JUNE 2012 | International Mining 87


TECHNICAL NOTE

Conclusion
Dust control testing at Pascua Lama Applying water is the most obvious way of dust
management and there are water carts,
Abdul Samad* reports on the recent trial of a customised dust suppression
sprinklers, and nozzles available for this
solution at Barricks high altitude mine on the Chile/Argentina border purpose. However, the extent of dust
suppression achieved is insufficient and the
n the March 2012 issue of IM, the impact of The dust emissions levels after the application effect is short term, as indicated by the high

I dust control in mines and the associated


regulations were covered, as well as the
broad types of dust suppression methods used.
of the dust suppressant were monitored on April
5, 2012, 8 days after the application of the dust
suppressant and again on April 22, 2012, almost
dust concentration measured on wet mine road
(26-43 mg/m3), which usually exceed the usual
dust-emission standards in workplaces. In
Customised solutions for dust suppression were a month (25 days) after the application. addition, with water shortages in some areas
referred to, which are part of the latest trend in Between these two dates, no maintenance and and the expense involved in frequent application
haul road dust treatment. There is no off the measurements could be done because of severe of water on roads, customised dust
shelf solution, however, and in developing weather conditions. suppressants such as those offered by Earth
customised dust suppression solutions, the soil Alive can represent an effective dust control
is tested in the lab and the soil characteristics Equipment and method used alternative that is effective and economical.
closely studied before a suitable solution is Real-time dust monitoring was performed using Controlling dust emissions in this way may
designed and tested to check whether all the a DUSTTRAK DRX Aerosol Monitor 8533 which help to minimise the dust concentration in the
objectives of the test have been met, otherwise can simultaneously measure size-segregated air and mitigate the associated risk of increased
modifications may be required. mass fraction concentrations corresponding to melting of Andean glaciers straddling the
The following outlines a case study of a PM1 (particulate matter of diameter 1 micron), Argentine-Chilean border, which are hugely
customised dust suppression trial at the Barrick PM2.5, respirable (PM10) and total PM size important water sources for thousands of small
Pascua Lame operation, located between 3,800 fractions. The aerosol concentration range of the farms in the Huasco Valley. The use of the Earth
and 5,200 m on the Chile-Argentina border. It is monitor is 0.001 to 150 mg/m3 (or ppm). Dust Alive dust suppressant may also help to
well known that mines in this region face water emissions were measured using two different increase productivity and cost savings in mining
shortages and any solutions to dust that can types of measurement: operations. High levels of dust can undermine
reduce water consumption are a major priority. 1. Mobile monitoring: Having the monitor operation profitability and productivity by
During the test, Chiles HSEC (Health, Safety, installed at the back of a pick-up truck posing a threat to the moving parts of mining
Environment, and Community) targets were 2. Static monitoring: A Komatsu 930E mine equipment required to operate the mine, which
used as a basis for establishing key truck passing at about 1.5 to 2.5 m of the can lead to expensive repairs and downtime, or
performance indicators (KPIs) such as: monitor located on side of the road. by reducing the visibility for workers which
Average Dust Concentrations Maximum Dust Concentrations

Figure 1 Figure 2 Figure 3 Figure 4

Reduction of dust emissions The most important results can be forces vehicles travelling on dusty haul roads to
Cut back of water usage summarised through the average (Figures 1 and drive much slower.
Decrease of operating cost through 2) and maximum (Figures 3 and 4) The microbial technology component of the
cost/benefit analysis concentrations of dust measured as PM 2.5, PM Earth Alive dust suppressant formulation offers
Reduction of occupational health exposures 10, and Total PM for each road monitored. The additional expected benefits over a longer term
(eg silica) results clearly indicate that although the dust such as bioremediation, soil regeneration,
Reduction of soil and water contamination emission is reduced by about 50% by the vegetation regrowth and improved stickiness
resulting from the use of outdated and toxic application of water on road, the application of providing stronger and better binding of roads.
dust suppressants. Earth Alive dust suppressant is more efficient, The dust suppressant is an environmentally
The field test was performed from March 26, the average concentrations were calculated as respectful formulation of agriculturally derived
2012 to April 5, 2012 to evaluate the ability of 0.2, 0.2, and 0.1 respectively for Total PM, PM complex organic polymers, with an added
the Earth Alive dust suppressant to control dust 10, and PM2.5. hydrocarbon-degrading microbial technology. IM
emission at Pascua Lama. The dust suppressant
was applied on March 28, 2012 on a 200 m x 33 Types of roads monitored
m surface of a mine haul road located in Sector Types of Roads Monitored
KL "Superior of the operation at about 5,100 m. Dry Mine Road Dust emission monitored using static monitoring
Wet Mine Road Sprayed with water, some hours prior to dust measurement
* Research Analyst, Beroe,mohammed.abdul@beroe-inc.com Dust emission monitored using static and mobile monitoring
This article is an edited summary of a 2012 report by entitled Treated Mine Road Treated with the Earth Alive dust suppressant
Evaluation of the Earth Alive Dust Suppressant by Viviane Dust emission monitored using static and mobile monitoring
Yargeau, Associate Professor at McGill University

88 International Mining | JUNE 2012


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Mining technology updates the separation size. Oversize material is recycled via a
cone crusher to the machines thus increasing the feed

Every month IM posts around waste water treatment systems. Instead of sinking or rate by an estimated 50%. Each sizer is driven by two
forming as sediment, the paint is suspended in the water counter-rotating Invicta BL50-75/6 rotary electric
100 news items to its website, and pumped to a waste treatment tank. vibrators delivering a linear vibration.

mainly technology related.


Honeywell has announced the global launch of Booyco Electronics has entered the arena of centralised
Here are some recent highlights Intuition Executive, the flagship product of its new blasting systems (CBS), becoming one of the first
Intuition software portfolio. Intuition Executive delivers South African manufacturers to be granted an
Joy has shipped its 6,000th continuous miner, a model enterprise-wide information management, decision Inspection Authority (IA) number shortly to be required
12CM12, to Patriot Coal in West Virginia, USA, which support and collaboration tools to help companies by law for all CBS products. The IA
currently operates more than 90 Joy continuous miners. achieve operational excellence, says the group. The number was awarded by a
This marks yet another milestone in Joys development launch comes some two years after Honeywell acquired SANAS Accredited and
of continuous mining machines for the global Matrikon along with its Mobile Equipment Monitoring Approved Test Laboratory
underground mining industry. Joy produced its first and Mine to Port offerings, and incorporates these (ATL) for Booyco Electronics
continuous miner unit (the model 3JCM) in 1948. Since solutions but as part of a much wider data analysis and C3 CBS, making it the only
then, it has pioneered many continuous miner integration package. The group states: Companies in approved alternative to
innovations that allow mining operations to increase the process industries often use dozens of electronic detonator driven
productivity, lower costs per tonne, and most applications and hundreds of spreadsheets to centralised blasting technology. The C3 is a simple
importantly, improve operator safety with the manage complex production operations, workhorse system that can be configured to fire any
mission of achieving zero harm. monitor processes and make operating non-proprietary initiator or detonator with precision
Joys says its ongoing decisions. These systems are usually either from a remote location, Anton Lourens, Managing
commitment to improving completely isolated or are connected with Director of Booyco Electronics, explains. It is now the
underground mine working conditions complex, custom-designed interfaces that make it only approved open system on the South African
is illustrated by its leadership in safety-focused difficult to use the data effectively and maintain data market. The C3 is unique in that it allows for a single
continuous miner design features. Early improvements integrity. With its sophisticated data processing and power point on surface and draws an extremely low
were marked by the transition from on-board operation analytics capabilities, Intuition Executive solves this current, while delivering a guaranteed output. Booyco
to operation via radio remote control, reducing critical challenge. The software anticipates problems Electronics C3 CBS was originally designed for the safe
exposure to dust, vibration, and an unsupported roof. and identifies opportunities. Its collaboration tools electric blasting of Shurstart Instantaneous Electronic
Current innovations include improvements in operator highlight and capture expert knowledge, share Detonators (IEDs), but as the electronic detonator
interface ergonomics. information and help users to make more agile market grew the system was increasingly used to fire
decisions and take action in order to drive intelligent electric detonators such as Shock Tube Starters
Hitachi Construction Machinery (Europe) has operations and solve key challenges. For the mining (Handistarts) and Statsafe Carricks.
implemented what it industry, Honeywell believes that this can result in
believes to be a unique increased efficiency and ability to manage and respond Neptune Chemical Pump, a leading
process to reduce to volatile energy costs, complex regulatory changes, manufacturer of chemical metering
chemical waste from the and real-world safety challenges. pumps, has designed the Neptune
painting process at its 500-D Series (Duplex) Diaphragm
factory in Amsterdam. Developed in cooperation with Mogensen has received an order for a further type Metering Pumps for frother
Advantage Chemicals, the process will save an S2056 sizer from the El applications found in coal mine prep
estimated 60,000 per year on labour and energy costs, Nasr phosphate rock plants. In the preparation plant, the
as well as disposal costs for waste water and sludge. processing plant in Neptune 500-D Series pumps diesel fuel from one
Before the new system was introduced in December Egypt, part of EL Nasr pump head to coat the coal and feeds frother (alcohol)
2011, the painting process produced approximately 260 Mining. The new from the other pump head, which makes the coal float
t of waste per year. It used a classic sinking system, in machine, scheduled to on top of the slurry so it can be extracted. The 500-D
which the paint would sink or form a sediment at the be delivered in early Series pumps are designed with features that the
bottom of the pool of water beneath the paint facility. August 2012, is to be company believes set the standard in the industry. Its
Twice a year, the pool had to be cleaned, and the water used to supplement the two machines currently in EZE-CLEAN valve cartridges can be removed from the
and paint had to be removed, which was costly in terms operation and increase capacity. Mogensens pump heads without having to disturb the pumps
of labour, energy, water and waste removal. The new connection with the El Nasr plant goes back 28 years. piping. Neptunes Variable Oil By-pass stroke
system has reduced the amount of waste by 88% per Two S2056 sizers lined with wear-resistant vulcanised adjustment provides better valve performance than
year. HCME Production Engineering Manager Robin rubber were delivered in 1984; they operated variable-linkage designs. Other standard features of
Huijsman, who is also Compliance Officer for successfully under very arduous conditions meeting all Neptune pumps include double ball-check valves,
Environmental Regulation, explains: Cleaning the pool specified requirements for 17 years. In 2001, they were internal relief valve, and a hydraulically balanced Teflon
beneath the paint facility twice a year was a difficult replaced by two identical machines, which have diaphragm for extended life. Optional features
and dirty job. With the new system, we are able to maintained the previous levels of performance. The available are automatic flow rate adjustment using an
remove the overspray paint from the water and reuse feed to the sizers is an abrasive phosphate rock slurry electronic stroke controller and variable frequency
the water. Thanks to the new system, the facility is delivered from a rotary crusher via a trommel fitted drives.
cleaner and the filtering system that removes paint with 30 mm aperture screen panels. Each sizer takes
particles from the air functions better. The new process 150 t/h of <30 mm rock in 150 t/h water and makes a To keep up with this news in detail,
combines real-time CoAg (coagulation) systems with separation at 1.5 mm, 60% of the feed being less than go to www.im-mining.com

90 International Mining | JUNE 2012


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PREFEAbe in the mar and in the
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MEXICO .............. pme rts from Contact ks
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industries PAPUA - Tyle around - update


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information incorporating the latest news as they get closer to production. key project personnel, subscribe now
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FOR A FREE TRIAL!


..............
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existing mines.
Resource
ADA - GeoLVE ..............
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mineral processing industries


AUSTRA dex Mine ....... LYBDEN .......LVE
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It is specifically about projects


pendence
Polymeta D/SILVE ..............
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American - EastLITY STAGE
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DESIGN ENGINEERS
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....... ....... .............. ..8 .............. .5
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(not speculative exploration reports)


ican

At any one time there can be 8,000 Contact: emma@im-mining.com


AUSTRA PER tern Cop....... ....... .............. ..............
.............. .............. Coal
....7
Nort LIA /CO .............. .....................
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Experience in the design NC/s - GOL....... .............. .............. .............. ......7


Corp
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