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Cultura Documentos
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Contents
Contents
03 Comment Engines & Emissions Control
05 News 32 A New Beginning
Sarah Lispet (Australia) and Naoto Sannomiya (Australia), Global
10 Industry View Mining Division of Hitachi Construction Machinery, discuss how
autonomous technologies are marking the dawn of a new era for
the mining industry.
Regional Report
12 Predicting Trends Dust Control
Alexander A. Ignatov, Ignatov & Company Group, UK, provides 36 Fighting Fire
an insight into Russia and Central Asia’s current coal mining Clean conveyor systems, good firefighting capabilities and
industry. ongoing maintenance are the best defence against fires, explain
Dan Marshall and Todd Swinderman, Martin Engineering, USA.
Longwall Mining Equipment
41 Washing Away
18 A Competitive Advantage Eric Tomicek, Australian Diversified Engineering, Australia,
Andreas Westphalen, Caterpillar Global Mining, Germany, discusses the importance of developing innovative ways to
discusses the advantages of variable frequency drive technology combat dust emissions in coal mining, and details two new water-
for face conveyors and plow systems in longwall mining. based dust control solutions for the coal industry.
23 Safe And Sound Coal Washing & Dewatering
Andrzej Kret, FAMUR SA, Poland, provides an overview of
a range of powered roof supports and discusses how their 43 Times Are Changing
implementation can improve the safety of new longwall projects Ernst Bekker and Brent Combrink, Multotec, South Africa, discuss
in underground mines. coal washing and dewatering processes.
Underground Mine Safety Mining Software
27 Extinguished! 47 Adapting To Change
Al Ozment, US Foam Technologies, discusses the prevalence Frank Grima, RPMGlobal, Australia, talks about closing the gap
of underground mine fires in the USA, and details how in mine planning and scheduling solutions.
gas-enhanced foam and direction drilling can increase the
effectiveness of current mine fire suppression technologies. 51 The Significance Of Software
The World Coal team talks to RCT about the introduction of
mining software and how it has benefited the coal industry.
Cover Story
54 A New Era For Mining Maintenance
Domitila Moreno, Cummins Inc., USA, discusses the evolution
of a number of filtration optimisation solutions that can extend
service intervals in coal mining.
Mine Productivity
61 Boosting Process Stability And Output
Nathan Flesher (USA) and Eben van Niekerk (Australia), McKinsey
& Company, describe a data analytics-based approach to improve
the stability of coal mining processes and raise productivity.
This m
month's mining operations. That’s why Cummins is working with mining
front cover customers around the globe on holistic maintenance plans that lead to
longer intervals and more strategic scheduling of service events. The
Coal News
DIARY DATES RUSSIA Maly Port promoting environmental protection
M
25th World Mining Congress 2018
19 June - 22 June 2018 aly Port Stevedoring Company Administration. As part of the
Astana, Kazakhstan has entered into an agreement comprehensive investment and
https://wmc2018.org/en
to promote the environmental environmental programmes, the terminal
protection of the city of Nakhodka has been equipped with unique 4 m
Hillhead 2018 (Russia) and RUB 228 million of its protective walls along the entire perimeter
26 - 28 June 2018 overall RUB 2.1 billion investment will of the production site, which completely
Derbyshire, UK
https://www.hillhead.com/welcome#/ be aimed at minimising the negative shields the coal storage from the wind.
effects of coal transhipment on the local According to the experts, the use of new
population. portal cranes has reduced the number of
Conveying and Handling of Particulate
Solids Conference 2018 At the St. Petersburg International coal transhipment operations, along with
10 - 14 September 2018 Economic Forum, the Ministry of dust emissions, by 20 times.
London, UK Transport of Russia, Rosprirodnadzor, The main upgrade measures deal with
http://www.constableandsmith.com/events/
chops-2018/ Primorsky Regional Administration, the dust suppression system. Loading and
Rosmorport and LLC Maly Port unloading operations involve cranes that
Stevedoring Company signed a prevent spills, which means no dust
Electra Mining Africa 2018 co-operation agreement aimed at formation. The pile spraying system
10 - 14 September 2018
Johannesburg, South Africa completing the transition of Maly Port to includes four mobile fog-generating units,
https://www.electramining.co.za/ shielded coal transhipment and ensuring spraying fog and snow within a radius of
favourable environmental conditions for 80 m. Their capacity is 2400 l/hr.
the population of the city of Nakhodka. As part of the new agreement, four
ACPS Conference and Exhibition 2018
11 - 14 September 2018 In accordance with the agreement, more stationary units will be installed on
Brisbane, Australia Maly Port plans to invest more than 12 m masts. In addition, in
https://www.acps.com.au/
RUB 730 million, including November 2018, a video surveillance
conference-2018/
RUB 127 million in environmental system and automatic dust analysers will
programmes this year. be put into operation. These measures,
Coal Association of Canada 2018 It is significant to note that in along with a climate monitoring system,
Conference
12 - 14 September 2018 September 2016, Maly Port SC concluded operated together with Roshydromet, will
Vancouver, Canada a co-operation agreement with the regulate the humidity of the coal and
http://www.cvent.com/events/2018-cac- Ministry of Natural Resources, prevent dust in the course of loading and
conference/event-summary-937bd414f3df4
07b8f0ece3d5e53894b.aspx Rosprirodnadzor and Primorsky Regional unloading operations.
O
Barcelona, Spain
http://www.coaltrans.com/world-coal- n 29 May, Britain’s Royal Bank It also said it would stop lending money
conference/details.html of Scotland (RBS) announced to mining companies that generate over
that it had tightened restrictions on 40% of their revenues from thermal coal, or
BULKEX18 project finance and general lending power companies that generate more than
17 - 19 October 2018 for high carbon energy projects and 40% of their electricity from coal; the
Nottingham, UK
companies. previous threshold for both was 65%.
https://bulkex.co.uk/
RBS said it would cease directly In April, HSBC also said it would stop
financing new coal-fired power plants or funding new coal power plants, oilsands
IMARC thermal coal mines, as well as oilsands or and Arctic drilling, following on from
29 October - 1 November 2018
Melbourne, Australia Arctic oil projects and unsustainable other large banks such as ING and BNP
https://imarcmelbourne.com/ vegetation or peatland clearance projects. Paribas.
CONTINUING
THE WINNING STREAK!
CHINESE
RUSSIAN RECORD
RECORD SL 1000
AUSTRALIAN
EUROPEAN RECORD SL 900
RECORD SL 750
SL 300
CONGRATULATIONS
TO OUR GLOBAL CUSTOMERS
FOR ANOTHER SERIES
OF PRODUCTION RECORDS.
Coal News
USA San Juan coal mine area to be expanded
© 2018 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos,
“Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission.
Industry View
Industry View
The energy-water nexus
Anne Carpenter, IEA Clean Coal Centre, UK
Surface Miner =
Mining made easy.
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4200 SM: WIRTGEN Surface Miners cut, crush and load material in a single operation. WIRTGEN is the only
manufacturer to cover a performance spectrum of up to 3,000 tons per hour with direct loading by conveyor
belt. This high output is based on high-performance cutting technology and a wealth of experience acquired in
three decades of application technology. Take advantage of innovative solutions from the technology leader.
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Other FSUs
Coal mines in Kyrgyzstan produce about 550 000 tpy of coal,
mainly lignite. 100% of thermal coal is used inside the
country. As many of the country’s power plants still utilise
coal, the demand for thermal coal counts for 1.6 million tpy;
domestic supply (0.55 million tpy) counts for only 34% of
the demand, while the country imports about 1 million tpy
of thermal coal, mainly from Kazakhstan.
Mines in Tajikistan produce about 100 000 tpy of lignite
and sub-bituminous coal, with 100% of thermal coal being
used inside the country. As most of the electricity in the
country is produced with its hydropower plants, Tajikistan
consumes no more than 200 000 tpy of thermal coal. With
100 000 tpy of domestic supply, the country imports about
100 000 tpy of coal, mainly from Kazakhstan.
Georgia’s single coal miner, GIG Group, produces about
350 000 tpy of thermal coal. Georgia also imports thermal
coal for its power plants and boilers, mainly from
Kazakhstan. As the country’s power plants work chiefly
with natural gas, the thermal coal import is low and
accounts for only 100 000 tpy. In 2017, GIG Group won the
tender for the supply of 700 000 t of coal to Ukraine.
There is no coal production in countries such as Belarus,
Armenia, Azerbaijan, Moldova and Turkmenistan.
Figure 1. Cat longwall plow system.
“I thought the recovery they said they were going to get was too good to be true, and then
we tested it, and it was what they said.” ALLEN LEGRAND, Plant Manager, Robindale Energy Services
Coal preparation plants are now achieving fine coal recovery system. Our innovative
fine coal recovery they once thought to be technology is capturing up to 95% of minus
impossible. And the proof is in the plants, 325 mesh coal at a marketable moisture level
where managers and operators are seeing that had previously been forced to recirculation
an increase in their recovery as well as their or washed away to refuse. And the best part —
profits after adopting Somerset Coal’s Sub325® there’s no cost for the plant.
Conclusion
The technology of plow systems equipped with Cat UEL
gearboxes and that of conveyors operated with CST
technology in combination with asynchronous motors
connected directly to the mains has proven itself under a
wide range of operating conditions. The examples presented
here show that this technology provides robust load
balancing and offers appropriate protection against
unexpected load situations. In this way, the service life of
these systems is extended and chain failures, with the
Figure 7. Cat intelligent CST (controlled start technology) associated costly loss of production, are minimised.
longwall conveyor drive system.
Drives equipped with frequency inverter technology offer
even more advantages. Being able to specify a variable speed
than what may be required is then available. A plow system and/or a defined torque permits new control approaches for
with inverter-fed drives does not have this limitation. the entire system, such as controlling the plow and conveyor
for optimal loading or improved load balancing between the
Face conveyor applications drives. Having the ability to brake the plow by actively
A conventional Cat longwall face conveyor uses CST feeding electrical energy back into the grid also protects the
gearboxes with a 33:1 or 39:1 ratio and asynchronous motors system components. Additionally, when the drives are
connected directly to the mains. The starting process proceeds started, the electrical system of the mine is not subjected to
first with the electric motors accelerating to their nominal even greater loads. Even weaker electrical supply systems can
speed with the CST clutch open, and then the conveyor is increase performance with inverter technology.
ROLLER CHAINS • ENGINEERING CLASS CHAINS • BACKSTOPS • SPROCKETS • CABLE & HOSE CARRIERS • POWER TRANSMISSION PRODUCTS
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USTSUBAKI.COM
Table 1. Technical parameters of line sections changed, practically by 1.5 m
No. Parameter Unit of FRS GLINIK- FRS GLINIK- FRS-18/41- FRS-GLINIK without the need for installing
measurement 10/21-2x3848 12/26-2x5655 2x4775 25/55-2x4775 another section. All sections
1 Minimum support m 1.0 1.2 1.8 2.5 enable position correction
height equipment to be installed; this
2 Maximum support m 2.1 2.6 4.1 5.5 equipment offers the
height
possibility of work
3 Range of operation m 1.2 ÷1.8 1.4 ÷ 2.5 2.0 ÷ 4.0 2.7 ÷ 5.4
mechanisation when the
4 Longitudinal longwall degrees (˚) ±35 ±10 ±28 ±15
inclination section width is changed.
Once stabilisation
5 Transverse longwall degrees (˚) ±15 ±15 ±20 ±10
inclination equipment is installed, the
6 Support centre m 1.75 1.75 1.75 1.75 support may operate at
spacing longitudinal inclinations of up
7 Number of hydraulic pcs 2 2 2 2 to 25˚.
legs
What makes the FRS
8 Internal diameter mm 350 400 400 400
GLINIK-12/26-2x5655 support
of leg
special is the fact that it may
9 Section pitch m 0.8 1.0 0.8 0.8
be used in high performance
10 Operational yield of kN/m2 690 ÷ 784 995 ÷1118 924 ÷ 1100 1105 ÷ 1131
systems. This is a direct
section
consequence of the fact that
11 Operational yield kN 3848 5655 4775 4775
of leg the support is adapted to the
12 Advancing force of kN 643 726 726 726 advance of the 1000 mm
section shearer and uses the
13 Advancing force of kN 392 934 394 394 electrohydraulic control
conveyor system in such a version that
14 Service life Number of 30 000 45 000 30000 60 000 allows for unmanned longwall
cycles
mining with the use of a
longwall control system
operated from the station located in the gallery. The station
features complete monitoring of the support state and HD
video transmission of any longwall area selected. Ergonomic
solutions used in the support ensure trouble-free operation
and maintenance.
The longwall system with the FRS-18/41-2x4775 support,
which is shown in Figure 1, was delivered completely by
FAMUR. Apart from the support, the system features an
FFC-9DM armoured face conveyor, an FSL 10 beam stage
loader with an FLB-10B coal crusher and an FSBE 1200
bootend, plus an FS400 shearer.
Due to similar heights of the longwall in relation to the
support gallery, the system was equipped with one type of
powered roof support, while gallery sections have longer
canopy that allow for the space above the conveyor drives to
be installed and deflectable side shields that protect gallery
sidewalls.
The longwall system with the FRS GLINIK-10/21-2x3848
support is designed for mining low seams and, depending on
the type of shearer used, offers the possibility of driving
seams with a minimum height of 1.25 - 1.4 m. The FRS
GLINIK-10/21-2x3848 support is a two-prop support and
features a centre spacing of 1.75 m; its props have an internal
Figure 3. The FRS GLINIK-25/55-2x4775 roof support for the
W.D. Yalevskogo mine AO SUEK-Kuzbass. diameter of 350 mm and a yield of 3848 kN each.
The delivery of these powered roof supports, which are
Furthermore, all transition and gate sections have side shields highly advanced in terms of technology, serve as confirmation
that are extendable on both sides, allowing for the section of FAMUR’s position as a leading supplier of both supports
width to be changed within the range of 1.7 - 2.0 m. In and entire longwall systems for the needs of international
combination with sliding clevis on the conveyor, the longwall markets and constitutes a good showcase of FAMUR’s ability
may be completely protected when the longwall length is to expand into other markets.
www.acps.com.au/conference-2018
www.acps
p .com.au/
/conference
f -201
2018
SCHEDULE
Tuesday 11th Wednesday 12th Thursday 13th Friday 14th
10am Golf & Technical Tour (CSIRO/QCAT) Opening Ceremony Technical Sessions Technical Sessions
- Dewatering (I²FLHQF\DQG2SWLPLVDWLRQ
3pm Registration & Exhibition Open Technical Sessions - A Le Page Lecture: Column - General Mine Site Papers
- New Plants and Upgrades Flotation by Prof J Rubinstein
5pm Arrival Function - Dense Medium Separation Conference Concludes 2pm
- Poster Session
- Improved Fine Coal Processing - Fine Coal Treatment
Evening Welcome Function Evening Conference Dinner
voith.com
www.Derrick.com
rolling equipment from fouling and seizure. The decrease in
spillage mitigates the collection of potential fuel around the
conveyor and requires considerably less labour for cleanup.
Modern belt trackers with troughed idlers or gripping
return idlers are so sensitive that they detect mistracking the
moment it happens and correct the belt path immediately,
significantly reducing the chance of a friction fire due to belt
drift. This also reduces spillage along the belt path from
uneven cargo loads.
A heavy-duty belt cleaner system, featuring modern primary
and secondary cleaners with an effective tensioner, increases the
volume of discharge and limits the amount of carryback and
Figure 3. Dust explosion pentagon. fugitive dust. Along with limiting spillage, tail pulley health is
improved and there is less fouling of rolling components.
the chute is not adequately cleaned, this task could pose a
serious hazard. Conclusion
Improving the fire retardance of its belting is just one of the ways
Think like an inspector that an operation can reduce the risk of conveyor fires. The
When examining conveyor equipment, one should approach the development of fire-retardant conveyor belting has made an
task with the same critical mindset as an inspector from OSHA, important contribution to safety, but even fire-retardant belts can
MSHA, or the local fire department. Prior to concentrating on burn in the presence of another fuel. These potential fire hazards
specific components of the conveyor, safety professionals can only be minimised through high standards of conveyor
recommend a holistic view of the system, taking into account the installation, maintenance and cleanliness.
combustibility of the material being conveyed and how the areas Operators should regularly contain airborne dust at transfer
around the conveyor could be impacted. The following should points and remove accumulated dust from beams, pipes,
also be assessed: conduits, equipment and fixtures; and minimise spillage from
Spillage levels and cleaning schedules. belts. Damaged rollers must be identified so that they can be
The conveyor’s proximity to work stations. replaced as soon as possible before the damage leads to frictional
How the conveyor design (enclosures, narrow walkways heating that can result in a fire. Operators should use flame
etc.) could create a hazard for employees. resistant grease and other lubricants. Fire detection and
Safe storage of flammable liquids. suppression systems and equipment must be tested in
Compliant signage. accordance to industry and regulatory standards.
Conveyor belt alignment is also an essential prerequisite to
Finally, take a common sense look at the current state of fire belt safety. Belts must be aligned and trained to prevent frictional
suppression apparatus. Conveyor designs are ever-evolving and heating where the belt rubs against the conveyor structure.
often retrofitted with new equipment based upon changes in Another significant fire-prevention measure is control of ‘hot
production and volume. In older facilities, fire suppression work’ permits and procedures (for employees and outside
systems were most likely designed for the conveyor that was in contractors), and restrictions on the placement of flammable
place years, if not decades, prior and may no longer be effective liquids and gases.
in the event of a fire on the current system. It is incumbent upon employers to protect workers from one
of the most potentially hazardous pieces of mechanical
Considerations for conveyor fire equipment at any facility: conveyors. Knowing the risks of fire,
prevention facilitating periodic inspections, and striving to implement the
Often, the potential return on investment (ROI) for prevention steps and equipment needed for a safer workplace should be the
equipment is not recognised until managers are inspecting burnt goal of every operation.
rubble and negotiating with insurance adjustors. However, Experience has shown that clean conveyor systems, good
safety-minded operators understand that the same equipment firefighting capabilities, and ongoing maintenance form the best
they would implement for increased efficiency, such as belt defence against fire.
cleaners and impact cradles, can also help prevent fires.
Impact cradles and support cradles help reduce fugitive References
material by providing a flat, stable belt surface that facilitates 1. CHEREMUSHKINA, M. S. and PODDUBNIY, D. A., 'Reducing The
effective sealing. Risk Of Fires In Conveyor Transport', Institute of Physics Conference
Transfer chute design is a critical element of fugitive material Series, Earth Environ, Sci. 50 012043, 2017.
control, with sufficient settling zones and confinement. New 2. ROWLAND III, J. H. and SMITH, A. C., 'Flammability of wider
conveyor belts using large-scale fire tests', National Institute for
raised chute designs also allow for external wear liners that
Occupational Safety and Health (NIOSH), Pittsburgh, PA, 2010.
eliminate the need for confined space entry or torch removal.
3. FERNÁNDEZ, M. and RODRIGUEZ, Á., 'Early Detection and
When paired with improved skirt seal designs, fugitive spillage Fighting of Fires in Conveyor Belt', Edaffic, Publications Office of the
and dust emissions are drastically reduced, which protects European Union, EUR 25364, Luxembourg, 2013.
T
Ernst Bekker and
substantially over the years, from manual sorting
Brent Combrink, to advanced processes such as dense medium
Multotec, South Africa, separation and fines beneficiation. With the
associated increase in complexity of the operations, a proper
discuss coal washing and understanding of these modern processes has become a
dewatering processes. prerequisite. To add to the complexity of coal washing,
dewatering processes are also becoming prime focus areas
due to water availability, which is becoming more critical to
the mining industry every year. The coal industry is,
therefore, torn between two extremes: improving washing
technology to handle lower quality coal, or reducing water
consumption as far as possible and cleaning their water for
safe discharge.
Coal washing
Coal washing has progressed over the years from multi-
module operations treating separate size fractions, to less
complex designs sometimes treating complete size fractions
and consisting of one or two modules at most. These types
of designs allow for better operational control which, in
turn, lead to higher separation efficiencies or more
consistent operations over a longer period.
With deteriorating run of mine (ROM) coal qualities
becoming ever more a reality, the standard approach to coal
washing requires some rethinking. The type of equipment
used may have to change to increase the capacity per
footprint in order to allow for the process to stay profitable.
A change from the older design bath washers to centrifugal
washers, such as cyclones, is becoming standard practice.
Depending on the coal washability characteristics, it may be
coaltrans.com/socox
The World Coal team talks to RCT
about the introduction of mining software
and how it has benefited the coal industry.
Why mining
software?
The mining industry is very
much turning into a paper-free
industry with the majority of
information being documented
on a computer now – mining
software was the logical step
forward. It is being used to
significantly improve several
aspects of opencast coal
mining, including mine
Figure 3. Mining software systems are helping the opencast coal industry to improve bottom planning, fleet management,
line profit. data analytics and machine
Availability
By implementing site assessment check sheets, Cummins
engineers are able to obtain baseline data and identify
areas for potential improvements to enhance TCO. Once
common issues are identified, new product designs can
be created and existing products given fixes.
Cummins provides TCO savings. These include
optimised service intervals, reduced equipment
downtime through condition-based maintenance, better
consumable product life use, monitored, extended and
synchronised service events through predictive analysis,
effective inventory management and oil life monitoring.
Supporting documents, which range from marketing
literature to installation instructions, are all easily
accessible from their site. This allows information to be
readily available to consumers worldwide.
“Cummins filter optimisation programme provides
Figure 1. Cummins QSK60 HPI mining engine. additional availability of the equipment to miners
through extended intervals as demonstrated around the
world,” according to Johansen.
Cummins field tests took place in Australia, Brazil,
Canada, Chile, Colombia, Peru, Russia, South Africa and
the US, with miners including Anglo American, BHP
Billiton, Cleveland-Cliffs, Glencore, Goldcorp, Rio Tinto,
Suncor, Teck Resources, Vale and others.
The first task in one of the company's Australian coal
mine case studies was to move the miner to the newly
released NanoForce® air filtration products. Once in
place, the NanoForce air filters delivered up to three
times more protection, enabling the site to extend service
intervals and increase operation of the equipment. The
availability of the product, though, means nothing if it
Figure 2. Cummins NanoForce filter. does not work well.
reprints@worldcoal.com
Efficiency because the filter becomes full faster, which decreases
the life of the filter.
Innovation in filter media In addition to the laboratory tests, Cummins
Traditional filter media use a blend of coarse (15 - 30 μm) NanoForce and NanoNet® filters have been extensively
cellulose fibres and varying amounts of sub-micron subjected to real world trials around the globe in a broad
synthetic, glass and polyester fibres. This method for range of mining equipment. Even in the most severe
developing filter media results in inconsistency with environments in coal, copper, iron ore and platinum
filtering out different sized particles and enables those mines, with temperatures ranging from -45˚C to 50˚C,
trapped particles to pass through the filter through these filters have proven able to reduce maintenance
vibrations consistent with equipment operations. With intervals and reduce overall cost for the miners.
the advanced emissions regulations being adopted For example, if 100 000, 4 μm sized particles enter the
globally, operating tolerances on equipment are much filter and 1333 make it through, then the filter’s efficiency
tighter, thus making them less tolerant to debris. is 98.7% with a Beta ratio of 75. The best traditional
Typically, improvements in traditional media filters media filters available today would offer this type of
focus on either filter efficiency or capacity. By performance. However, nanofibre media can remove the
improving efficiency, the filter will need to capture same four micron sized particles 99.9% of the time. While
more of the smaller particles. Flow restrictions increase that is only a 1.2% improvement, in reality it means that
of the same 100 000 particles flowing
into the filter, only 100 particles are
able to get through the media. A 1.2%
improvement in efficiency is actually
a 13 times improvement over
traditional filtration.
LESS DOWNTIME
involved.
In these extensive field tests,
Cummins identified a number of
IS MORE UPTIME
critical factors and control criteria
to achieve improved
performance. The different
systems on the equipment, with CleanScrape® Belt Cleaner
including air, fuel, lube, coolant
and hydraulics, were taken into
consideration together. This
holistic approach to smarter
maintenance management,
coupled with Cummins
innovative filtration technology,
realised increased productivity
with minimal investment.
Productivity
Productivity is often a result of a
well-oiled machine. Yet, some
machines lack systems that
increase filtration in common
lubricants.
Consider that contaminants
found in today’s lubricants are
generally measured in microns.
A micron, which is a metric
term, refers to 1 millionth of a
metre, or 39 millionths of an inch.
A human hair, which is in the LESS IS MORE WITH
range of 50 - 70 μm, is CLEANSCRAPE® BELT CLEANER.
significantly larger than pollen,
Less Blade Replacements / More Blade Life
which is in the 30 - 50 μm range.
– lasts up to 4x as long as traditional cleaners
Inorganic contamination, often
referred to as dust, which causes Less Maintenance / More Performance
the most wear of vital – only one tensioner adjustment ever
components is in the 5 - 15 μm
/HVV&RQFHUQ0RUH&RQ¿GHQFH
size.
– safe for vulcanized and mechanical splices
By increasing the size of the
filter, you can improve the flow
through the filter, but run into visit martin-eng.com
800.544.2947 / 309.852.2384
cleanscrape@martin-eng.com
® Registered trademark of Martin Engineering Company in the US and other select locations. © 2018 Martin Engineering
A GLOBAL FAMILY
Company. Additional information can be obtained at www.martin-eng.com/trademarks and www.martin-eng.com/patents.
micron and eight-tenths of one micron, whereas Sustainability
traditional synthetic fibres could be in the 5 - 20 μm dia.
size range. Proven capability through testing
Prior to the upfit of the new air filters in an Australia Its commitment to protecting and enhancing equipment
coal mine, the site requirement for air filter changes was performance means Cummins Filtration is dedicated to
250 hr, resulting in the company’s use of over 190 filters creating sustainable products. Therefore, proprietary
per year. Once fitted with NanoForce air filters, the tests were developed in addition to industry standard
equipment sustained 1645 operating hours before testing to evaluate filtration. Beta ratio is an industry
requiring the air filters to be changed. Considering safe measure of particles of contamination introduced to the
operating margins, the site released a newly revised filter to the number of particles of contamination that
service interval of 1000 hr that resulted in a reduction of pass through the filter. The beta ratio gives us a true
annual filter use from 190 filters to 48 filters. A 75% indication of a filter’s efficiency for a given size particle.
reduction in filter services (from 24 to six) and The NanoForce media used in Cummins air cleaners
maintenance hours (from 48 to 12) was also achieved and the NanoNet media used in fluid filtration has been
due to the lengthened change intervals. tested and proven in controlled laboratories using ISO
A global mining customer requested support to 5011 and proprietary test methods to ensure an optimum
reduce operating and maintenance costs while balance of engine protection, performance and life.
increasing production. The customer selected a coal
mine in Australia with 16 Komatsu 830E haul trucks Connectivity ensures uptime
powered by Cummins QSK60 engines as one of three In this digital age, some miners are finding even greater
demonstration sites for a global pilot. savings by turning to electronic solutions to make
A fuel and site assessment was conducted jointly on smarter maintenance choices. Recently released Cummins
the operation and opportunities were identified to FleetguardFIT™ – Filtration Intelligence Technology –
improve site bulk filtration and specific equipment revolutionises conventional maintenance by enabling the
filtration upgrades. The customer implemented key decision makers to better predict downtime,
Cummins NanoForce air filters, NanoNet fuel filters, synchronise service events and optimise maintenance
improved oil filtration rotors for Eliminator units, long spend.
life coolant filters, and fuel tank vent filtration FleetguardFIT is a real time filtration monitoring
upgrades. system that provides full visibility to filter (fuel, lube and
Service intervals on the truck fleet were extended air) and oil life enabling proactive problem detection
from 500/1000 hr to 1000/2000 hr, delivering increased through the use of intelligent sensing and advanced data
productivity and operational savings with lower filter analytics. Cummins FleetguardFIT is part of Cummins
consumption, lower oil consumption and lower Electronic Service Tools that provide customers with
consumables. software, mobile applications and digital hardware to
The Peruvian copper mine customer implemented an provide real time connectivity, monitoring and service
extended interval package for the Hitachi shovels on support that optimise the performance and reliability of
their fleet. As a result, it achieved an extended air filter engines and fleets.
interval from 500 hr to 750 hr using NanoForce air At one Australian coal mine, a follow-up study was
filters. The switch to extended interval filters resulted in conducted a year later, jointly between the customer, the
a lower cost per hour or 45% savings. OEM and Cummins. This study found no negative
The customer was able to extend oil drain intervals impact on engine wear from the oil drain and service
from 250 - 350 hr while increasing the protection to the interval extensions. The results and improvements are
engine, using a Fleetguard remote centrifuge being replicated at the miner’s other operations around
supplementing the Fleetguard on-engine lube filters. the world.
The Fleetguard remote centrifuge helps in the The continuous work to optimise maintenance
elimination of large particles lowering the engine wear. practices while reducing costs is dependent on
The oil drain extension represented a savings of 28% in implementing innovative filtration products. Nanofibre
oil consumption. media has proven its way to become the filter media of
The customer was satisfied with the test, modified choice for miners looking to align and expand
the rest of the shovel fleet, and has begun using air maintenance intervals.
filters, centrifuge rotors and lube filters following the Johansen concluded: “The field testing has shown that
modifications made. new technology filters combined with a holistic approach
Filter optimisation lowers the TCO by providing to smarter maintenance management provides exceptional
holistic solutions that optimise productivity: enhancements and long-term sustainability. Some of these
Up to 13 times enhanced engine protection. trials have delivered results beyond our service interval
Up to three times longer service intervals. target and miners have seen the benefit of a significant
Up to 30% less annual commodity costs. reduction in total operational costs through increased
Up to 50% less annual maintenance hours. equipment availability and lower consumable costs.”
First
A fleet management system (FMS) – common at most
mines – provides the foundation mechanism to generate
Figure 3. Detailed fleet management opens the way to continuous data on location, payload, speed and often additional
improvement (haul cycle example). information such as engine temperature, tyre pressure,
Fifth
Using this approach, it is possible for a
mine to continuously work on improving Figure 4. Using Weibull analysis identifies losses and points to ways to improve
its performance, so that cycle times performance.
converge to the planned, ideal time.
Advertiser’s Index
ACPS 30 Komatsu 11
Caterpillar 9 Martin Engineering 59
Coaltrans Conferences 50 Sandvik Mining OBC
Cummins OFC, 45 Somerset Coal International 21
Derrick Corp 39 Standard Industrie 17
Eickhoff 7 U.S. Tsubaki 25
FAMUR 2 Voith Turbo GmbH 39
Geometrica, Inc. IFC WIRTGEN GmbH 15
Global Mining Review 4 World Coal 57
Jennmar Corp. IBC
GLOBAL HEADQUARTERS
Pittsburgh, PA USA • (412) 963-9071 • www.jennmar.com
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What do you get when you combine 150 years of innovation with unparalleled success in underground mining and
a passionate commitment to innovating for the future? A suite of scalable automation products that can completely
transform your drilling operation.
Our AutoMine® solution works in concert with our analytics and process optimization platform, OptiMine®, to improve
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Automated Functions: Tele-Remote Operation: Fully Autonomous:
Achieve consistent and Operator controls equipment at Equipment is controlled via
reliable results with features a remote location with the use of programmed machine operations
such as auto level, auto drill, cameras, sensors, software and and only requires human
and auto pipe handling. vehicle telemetry. intervention to handle exceptions.