File 1

OCTOBER 2011
Informed and in-depth editorial on the world mining industry

www.im-mining.com
SIMULATORS
PROMOTE
SAFETY
BETTER
CONVEYOR
SYSTEMS
NEW TECHNOLOGY
FOR DEEP MINES
NORDIC
FOCUS
CONTINUOUS
IMPROVEMENT OF
UNDERGROUND MINING
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CONTENTS
OCTOBER 2011
AROUND THE WORLD 3 The Leader 4 World Prospects 79 Classifieds 80 Forthcoming events
COVER: Weir Minerals
Multiflo
dewatering units are custom designed for the harsh, arduous conditions in the mining and
related industries providing maximum reliability and performance. Weir Minerals Multiflo provides
the widest product portfolio in the industry including, self priming pumps, submersible pumps,
centrifugal pumps & fuel valves.
Keeping a mine dry is more than supplying a pump unit; it is about improving the productivity
of the site. Weir Minerals Multiflo custom design and purpose build; open-pit dewatering pumping
systems, dewatering pontoons and a proprietary fuel filling system.
The Weir Minerals Multiflo team based in Coolum develops innovative new products to fill the
gaps in the market. This year it has released two new Heavy Duty pump range units. First was the
MF-90HV (High Flow Pump) and recently released was the MF-210 MV (High Head Pump). The MF-210MV provides 210 m max
head and up to 140 litres/s flow rate. The MF-90HV provides 105 m max head and up to 350 litres/s. Since the units are exactly
the same except for the bare shaft pump, versatility is a key feature. Customers can therefore get two different duties by just
interchanging minimal components. www.weirminerals.com
8
8 OPERATION FOCUS: Chelopech
John Chadwick returned to this highly advanced
mechanised copper-gold underground mine in
Bulgaria to find world leading operating practices,
including extremely well-organised maintenance
and training, all aimed at better utilisation and
doubling ore production and reducing cost/tonne.
All this is being achieved without any increase in
personnel or the mining fleet
22 SIMULATE AND SAVE
Save accidents and training costs. Using simulators
can create training and refresher course
applications, serious situation exercises that allow
operators to build skills in a practical and cost
effective way, and can also prove process designs,
as John Chadwick discovers
48 NORDIC FOCUS
IMs undertakes its annual examination of
technologies and services from the region.
Suppliers in Finland, Sweden and elsewhere are
world leaders in underground hard rock mining
machines and mineral processing, and a lot more
70 NICKEL FUTURE
Closing our series of Great Mines articles on First
Quantum Minerals, Paul Moore looks at two
worldclass nickel mines about to be commissioned
Kevitsa in Finland and Ravensthorpe in Australia
though in the latter case it is a reopening after a
long and difficult road for the former operator
76 HIGH PROFILE: The case for contracting
In an exclusive interview with Bruce Munro,
Managing Director of Thiess, the worlds leading
surface contract miner, Paul Moore explores some
of the issues unique to contract mining, as well as
the Thiess approach to equipment and technology
78 MINING TECHNOLOGY UPDATES
Every month IM posts around 100 news items to its
website, mainly technology related. In a new
monthly feature, here are some recent highlights
34
60 CONVEYORS
Paul Moore has just reported
back from Belo Horizonte that
our first In-Pit Crushing and
Conveying conference was a
great success; more news from
that event next month. But in
this article, John Chadwick looks
at gearless drives, grasshopper
conveyor advances, cleaning
belts and around them, and
much more
34 DEEP MINING
Including a look at some major
Canadian deep mining research
programs, John Chadwick looks
at progress in deep mining
research, advances in ventilation
and cooling, hoist rope
monitoring, mine support and
development and ore haulage
OCTOBER 2011
Informed and in-depth editorial on the world mining industry
www.im-mining.com
SIMULATORS PROMOTE
SAFETY
BETTER
CONVEYOR
SYSTEMS
NEW TECHNOLOGY FOR DEEP MINES
NORDIC
FOCUS
CONTINUOUS
IMPROVEMENT OF
UNDERGROUND MINING
OCTOBER 2011 | International Mining 1
60
22
48/70
Single-point throatbush
adjustment for rotational and
axial movement while the pump
is running.
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The new Warman
WBH

pump. With non-stop improvements.
The single-point throatbush adjustment is just one of the many improved features offered
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Other high-performance features include a new bearing frame design for truer alignment,
larger capacity bearings designed to handle higher loads and provide longer life, encapsulated
rubber or hard metal liners, and the Warman HI-SEAL
expeller for better sealing and

improved efciency. Theres also an optimized impeller and liner design for lower ow
turbulence and enhanced operation.
For more information on the new WBH

pump, please contact a Weir Minerals
representative or visit www.weirminerals.com/WBH
Weir Minerals. Expertise where it counts.
Copyright 2011, Weir Slurry Group, Inc. All rights reserved.
WARMAN, WBH, AH and WARMAN HI-SEAL are registered trademarks of Weir Minerals Australia Ltd.
Excellent
Minerals
Solutions
turbulence and enhanc
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rubber or hard metal li
larger capacity bearings
formanc Other high-per
ARMAN in the new W WA

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ced operation.
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arman HI-SEA iners, and the W
designed to handle higher load
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ARMAN ARMAN, WBH, AH and W WWA
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A
s mining organisations pursue growth
opportunities outside their home countries,
they are challenged by a number of new
and emerging exposures.
Mining companies have an impressive track
record for delivering continuous improvements in
safety and risk governance standards. This
professionalism and expertise will ensure that any
new and emerging risk challenges are dealt with in
an equally determined fashion.
Insurers have recognised the approach and
achievements of mining companies in identifying,
mitigating and retaining their risks. Many mining
companies have long-standing relationships with
their insurers built through regular dialogue and
site visits.
The very nature of mining natural resources means
that many businesses have operations in remote and
inhospitable parts of the world, very often coupled
with a high susceptibility to natural catastrophe.
In addition to traditional risks, the mining
industry now faces an even wider range of
challenges. Climate change, economic
uncertainties and the secure supply of key
consumables like electricity, water, and gas, as
well as rubber for truck tyres, are difficult to
predict and bring additional complications to
securing appropriate balance sheet protection.
As a number of mining companies were financing
operational expansion on the back of debt, many
have been affected by the global financial crisis.
Balance sheets were shored up to prevent a
funding crisis and drastic measures to protect
earnings had to be taken, including suspending
operations and the divestment of non-core assets.
These strategies have, broadly speaking, paid off.
Operational efficiencies have increased and, as
many countries demand more and more commodities
to underpin the expansion of their infrastructure,
the mining industry is once again thriving.
Additionally, the rapid expansion of a middle
class in China, India, other parts of Asia, Latin
America and Eastern Europe, continues to fuel the
voracious demand for these commodities.
To satisfy this demand, heavy investment has
been seen in mining assets in Canada, South
America, Australia, Africa, Asia and Central Europe
amongst others. In addition, some mining
companies are looking at ways to access reserves
in non-traditional locations, including Mongolia,
the Democratic Republic of the Congo, Afghanistan
and Mauritania. Safety and environmental control
remain key drivers, but expectations of sustainable
development require the provision of electricity,
water, healthcare and education to the local
communities where mining operations are based.
Companies are also more
exposed to political risks
and kidnap and ransom
than had previously been
the case.
The creation of new
mining techniques, such
as the ability to secure
minerals from beneath ice,
lakes, and inside volcanic sulphur mines, requires
the development and use of advanced extractive
technologies, which can create additional risks.
Also the expanding geographical reach of mining
companies brings greater exposure to host
government actions such intervention has
increased substantially in recent years.
Mining owners and operators face many
significant environmental risks throughout the mining
cycle including groundwork, handling hazardous
substances, waste disposal and control. These
include risks arising from new regulatory structures
designed to address the potential impacts of mining
activities on the environment, and to ensure the
local community doesnt become financially liable
for the reclamation of abandoned sites.
Companies face a risk of civil fines, penalties and
sanctions being imposed on those who fail to satisfy
the authorities, as well as growing pressure from
shareholders to disclose environmental performance.
In April this year, Marshs Global Mining Practice
published its Mining Industry Risk Analysis Report,
which identified many of the risks that challenge
the industry around the world today.
As the report made clear, mining companies face
a growing array of risks across a range of areas,
including construction, operational and
environmental risks, liability, marine cargo,
directors and officers liability, political violence
and terrorism, and the insurance of valuable
commodities in transit or at rest.
It is important that mining companies, especially
those looking to grow beyond their traditional
geographies, work with a trusted advisor to ensure
that they have appropriate local and global
insurance solutions to meet these new challenges.
As risks become more complex, so does the
vulnerability of company balance sheets. By
tackling them proactively, mining companies will
be able to grow and thrive with greater confidence.
Andrew Chester
Chairman
Marshs Global Mining Practice
The Mining Practice Industry Risk Challenges & Solutions
report is available on request. Please contact Roy Nott at
Marsh: roy.s.nott@marsh.com for further details.
THE LEADER
VOLUME 7 NUMBER 10
Risk challenges and insurance solutions
Publisher
John Chadwick
Email: john@im-mining.com
Editor
Paul Moore
Email: paul@im-mining.com
Associate Editor
Chris Cann
Email: chris@im-mining.com
Editorial Board
Professor Malcolm Scoble
Robert E. Hallbauer
Chair in Mining
Engineering.,
University of BC,
Vancouver
Jeff Roschyk
Vice President of
Product Management
& Marketing, P&H Mining, USA
Peter Knights
BMA Chair & Prof. of Mining
Engineering University
of Queensland
Stephen Stone
West One Management
Perth, Western Australia
Dr. Andrew M. Robertson
President, Robertson
GeoConsultants
Vancouver, Canada.
Ed McCord
Project Consultant
Caterpillar Global Mining, USA
Jason Nitz
Mining Systems Strategist
Newcrest Mining Ltd, Australia
Dr Terry Mudder
Managing Director
TIMES Ltd, USA
Simon Tarbutt
Consultant, Santiago, Chile
Dr. Mike Daniel
Comminution Process Consultant
Ausenco Minerals & Metals, Australia
Editorial Enquiries:
Tel: +44 (0)1442 870 829
Fax +44 (0)1442 870 617
Advertising Sales:
Phil Playle
Email: phil@im-mining.com
+44 1442 87 77 77
Advertising Production
Emma Smith
Email: emma@im-mining.com
Publishing Consultant
Robin Peach
Design & Production
Trevor Sheldon
Email: sheldonmann@gmail.com
Website:
www.im-mining.com
Annual Subscription Enquiries:
Emma Smith
Email: emma@im-mining.com
Annual Subscription
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International Mining is published
monthly by Team Publishing Ltd,
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Berkhamsted, Herts. HP4 2AF, UK
Printed by The Manson Group, St Albans
Team Publishing Ltd 2011
ISSN 1747 -146X
WORLD PROSPECTS
S
EI Industries King series (Arctic, Desert
and Jungle) of tanks are all well suited for
remote mining operations. SEI has
cultivated a unique, innovative capability not
readily found elsewhere in the world by
designing, engineering and manufacturing
products from industrial fabrics. These fabrics
provide advantages not available with products
made from traditional rigid materials. With an
emphasis on customer-driven features such as
collapsibility, transportability and quick set-up,
it has found itself at the forefront of product
design for a variety of applications related to
liquids containment and handling.
The company manufactured a turnkey
temporary fuel farm and deployed it on Baffin
Island, Nunavut, Canada. The system was
designed to store 8 million litres of fuel. The
system was filled via a barge through a pipeline
that extended from the fuel farm to the shore.
Two types of fuel were pumped in to 76 114,000-
litre Arctic-KingTM Collapsible Fuel Tanks. The
tanks sit inside an above ground earth in
secondary containment berm with an oil water
separator to prevent ground contamination in
the event of a spill. Four 1,000 litre/min trailer
mounted fuel pumps provide bulk fuel transfer
for site tanker trucks
that shuttle the fuel to
various sites at the
mine. Two vehicle
refuelling systems
provide service to other
mine vehicles. This fuel
farm was used to
support the construction
of an iron ore mine.
The Arctic King
collapsible tank is
specifically designed for
liquid fuel storage in
sub-zero climates.
Constructed from a
proprietary high-
durability fabric unique
to SEI, it has excellent UV and hydrolysis
resistance for a longer life expectancy than any
other urethane collapsible fabric tank in the
arctic. With all these features plus its one way
vent system to handle deep snowfalls, the Arctic
King is ideally suited for even the most extreme
arctic conditions. These tanks combine
portability and versatility with economy.
SEI supplies the Arctic King as a standalone
product or as part of a complete turnkey arctic
fuel system which includes:
Primary storage tank with arctic vent and
fill/drain connections
Secondary containment berm
Rainwater filter system
Fuel transfer, metering and filtration
equipment.
www.sei-ind.com
FUEL FARM FOR A REMOTE ARCTIC MINE
Mine dewatering downflow beats upflow, says Feluwa
4 International Mining | OCTOBER 2011
P
umping of slurries and fluids containing
coarse contaminants requires custom-
tailored solutions to ensure permanently
trouble-free operation. FELUWA says its
MULTISAFE double hose-diaphragm pumps
allow for economic pumping of dirty mine
water or sludge from underground to surface in
a single stage. Unlike traditional diaphragm
piston pumps they are not designed with
circular flat diaphragms but with two
redundant hose-diaphragms, which are
arranged one inside the other. This allows for
relatively narrow cylindrically shaped pump
heads and contributes to considerably reduced
excavation costs as a result of the small
footprint.
A distinct advantage of the MULTISAFE pump
is its linear flow path, making it especially
conducive to the handling of aggressive,
abrasive and solids carrying fluids and slurries,
even at high viscosity. Hose-diaphragms do not
require a clamping ring that allows for settling of
solids, which results in early diaphragm failure.
The pump offers high operational reliability.
Even in the event that one of the hose-
diaphragms leaks or fails, the second hose-
diaphragm will ensure that pump operation can
be maintained until the next planned shutdown
of the unit. Any internal loss of hydraulic fluid is
automatically compensated by the incorporated
leakage compensation valve. External
compensation systems are not required.
In order to avoid disadvantageous
sedimentation, MULTISAFE double hose-
diaphragm pumps literally turn the traditional
pumping principle upside down, which means
that the flow is directed from the top to the
bottom of the unit. The cylindrical shape of the
diaphragm with a maximum of linear flow lines
accommodates the flow behaviour and avoids
the settling of solids.
Handling of fluids carrying large solids
moreover requires special and custom-tailored
check valves. MULTISAFE pumps are
characterised by easily removable check valves
of wafer design. This valve design not only
ensures linear flow through the pump and
valves, but also allows for easy withdrawal of
the complete valve assembly without prior
removal of adjacent elements.
Various design options, which assist the
passage of entrained solids, are available for
downflow configuration, such as spring-loaded
ball valves, spherical cap ball valves or special
floating ball valves with hollow steel balls. For
critical applications, such as single-stage
underground mine dewatering, double hose-
diaphragm pumps are designed with double
valves to avoid backflow leaks resulting from
jammed solids. Large-size double check valves
of high-pressure pumps are additionally
provided with customised hydraulically
activated FELUWA Quick Change Systems.
www.feluwa.com
Three sets of
high-pressure
FELUWA
MULTISAFE
downflow pumps
for single-stage
underground
mine dewatering
WORLD PROSPECTS
I
n the first moments after a mine accident,
first responders work against the clock to
assess the situation and save the miners. But
countless dangers lurk: poisonous gases,
flooded tunnels, explosive vapours and unstable
walls and roofs. Such potentially deadly
conditions and unknown obstacles can slow
rescue efforts to a frustrating pace.
To speed rescue efforts, engineers at Sandia
National Laboratories have developed a robot
that would eliminate some of the unknowns of
mine rescue operations and arm first responders
with the most valuable tool: information.
Sandia robotics engineers have designed the
Gemini-Scout Mine Rescue Robot, which finds
dangers and can provide relief to trapped min-
ers. Its able to navigate through 460 mm of
water, crawl over boulders and rubble piles, and
move in ahead of rescuers to evaluate precarious
environments and help plan operations.
We have designed this robot to go in ahead
of its handlers, to assess the situation and
potential hazards and allow operations to move
more quickly, said Jon Salton, Sandia engineer
and project manager. The robot is guided by
remote control and is equipped with gas sensors,
a thermal camera to locate survivors and another
pan-and-tilt camera mounted several feet up to
see the obstacles were facing.
Less than 1.2 m long and 609 mm tall,
Gemini-Scout is nimble enough to navigate
around tight corners and obstacles300 mm high.
In addition to giving rescuers an idea of what
theyre headed into, the robotic scout can haul
food, air packs and medicine to those trapped
underground. It is equipped with two-way radios
and can be configured to drag survivors to safety.
Designers built the Gemini-Scout to negotiate
nearly every known mine hazard. Methane and
other gases can ignite if exposed to sparks, so
the electronics are housed in casings designed
to withstand an explosion. Such measures
would prevent a spark from causing further
destruction. While it might harm the robot, it
wouldnt create another dangerous situation for
the miners or rescuers, Salton said.
Gemini-Scouts controls and equipment need-
ed to be waterproof. When we were designing
a robot that could provide this level of assis-
tance, we had to be aware of the pressures and
gases that are often found in that environment,
said Sandia engineer Clint Hobart, who was
responsible for the mechanical design and sys-
tem integration. So we had to make sure the
strength of materials matched what our goals
were, and we had to keep everything light-
weight enough so it could navigate easily.
In addition, engineers had to build something
intuitive for new operators who need to learn
the system quickly. To overcome that challenge,
they used an Xbox 360 game controller to direct
Gemini-Scout. We focused a lot on usability
and copied a lot of gamer interfaces so that
users can pick it up pretty quickly, explained
Sandia engineer Justin Garretson, the lead soft-
ware developer.
The National Institute for Occupational Safety
and Health (NIOSH) provided funding for the
efforts, which have been underway for the last
three years. If all goes well, the Gemini-Scout
could be ready to head underground by the end
of next year. The team is in the final stages of
licensing Gemini-Scout to a commercial robotics
company, but for now, the Mine Safety and
Health Administration (MSHA) will be the pri-
mary customer. www.sandia.gov
M
ine refuge stations (static and mobile)
play a very important role, both in the
immediate safety of an underground
mine worker in the event of an emergency, fire
or hazardous gas release, and in the overall
planning of a mine rescue strategy. Having the
ability to thoroughly plan a rescue, with
adequate time for implementation and then
execution, greatly ensures the safety of both the
rescue team and the trapped miners.
Simple human breathing within a closed
space disperses carbon dioxide (CO2) into the
air and lowers the oxygen level. Overtime, critical
breathable air levels must be maintained in
these spaces to ensure safety and sustain life,
giving the mine rescue team a chance to execute
well trained practices. Sources of breathable air
considered by the mine typically include:
Mine compressed air supply
Oxygen candles
High pressure oxygen cylinders
Natural mine ventilation
Each of these only deals with a portion of the
solution when all safety factors are considered
to ensure respirable air is in sufficient supply.
The ability to supply oxygen that is consumed is
a relatively simple process. What is significantly
more difficult is the ability to remove the CO2.
With each exhaled breath, the CO2
dissipates to every corner of the refuge station.
Any system that does not address the proper
control of CO2 levels should not be considered.
Therefore, according to RANA, the use of just oxygen
candles, oxygen cylinders or mine compressed
air is not appropriate, especially if the design of
the refuge station or chamber is to be air tight.
RANA Mine Refuge Systems manufactures
the Refuge One Breathable Air Centre which is
used to maintain the safe levels of both CO2 and
O2 for a specified period of time corresponding to
the mines rescue strategy. The Refuge One air
centres have been developed to both remove
CO2 and replenish the oxygen at carefully measured
levels, depending on the number of people inside
the refuge station, its size and the duration of
protection time (typically 36, 48 or 72 hours).
The Refuge One is an independently run system
with its own back-up power system (DC batteries)
that can maintain safe breathable air levels. It
has been carefully tested and specifically devel-
oped for this
application. With
easy to use
instructions, the
Refuge One is
used as either a
primary or
secondary
breathable air source to
ensure all kinds of emergency
possibilities are covered.
RANA recommends that strategy reviews
should be done on each refuge station within
the mine on an ongoing basis. Given that the
activity in mines is continuously developing and
moving, the location and number of people in
certain areas also changes.
Irrespective of the method used to provide
respirable air, all personnel working under-
ground should be well trained on the effective
use of the respirable air source being supplied
to refuge stations and chambers. Ongoing service
and training on these systems is critical to the
mine safety plan.
www.ranacaregroup.com/minerefuge
Sandia Labs Gemini-Scout robot likely to
reach trapped miners ahead of rescuers
Respirable air for underground mine refuge stations
Sandias Gemini-Scout is equipped to handle
any number of obstacles, including rubble piles
and flooded rooms, to help rescuers reach
trapped miners safely and efficiently
(Photo by Randy Montoya)
Improve process
Boost business
Sandvik DPi rigs with TIM3D system bring surface drilling into the realm of GPS-based
navigation. With these machines, your drilling accuracy will be second to none - which means
excellent fragmentation and thus decreased costs further in the process. Combine this with the
DPi rigs high productivity, excellent fuel economy and advanced usability - and you can not fnd
a better solution for surface drilling in mining applications.
www.sandvik.com
Simplicity of use
Absolute accuracy Absolute accuracy
Simplicity of use
fragmentation excellent
these ith WW navigation.
with rigs DPi Sandvik
Bo
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furth costs decreased thus and n
accurac drilling your machines,
surface bring system TIM3D h
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A
ttention to detail, reliable and innovative
communications, some of the latest
trackless mining technology, commitment
and passion are all coming together at the
Chelopech copper-gold mine in Bulgaria
(IM, October 2006). The specific goals are to
double ore production to 2 Mt/y and to reduce
cost/tonne from $52.2/t in 2010 to $29.8/t after
the expansion, all without any increase in
personnel or the mining fleet. The concomitant
benefits will be as reported by Dundee Precious
Metals (DPM) Executive Vice President and
Chief Operating Officer, Rick Howes, at the
Mining Americas Summit in Denver in June
1
:
Howes describes what is being done at
Chelopech as taking the lid off, i.e. making
underground operations as visible and well-
controlled as those of open-pit mines. He
estimates the quantifiable benefits of this
program to be 10-30% improvement. This will be
achieved using an Integrated Mine Management
approach with Continuous Improvement
becoming a standard way of working within the
operations.
Howes has over 30 years experience in the
mining industry, and has been closely
associated with the practices that make for
worldclass mining operations, including Incos
North mine which won the 2006 Ryan Award as
the safest mine in Canada. He has much
experience of preferred supplier agreements
and the like and says this relationship with
Sandvik is the best example of a partnership I
have seen. The collaboration is much closer than
I have seen anywhere and there are none of the
disagreements about machine performance that
are so common, allowing us to move forward with
achieving our common goals, unencumbered.
Equally, Nikolay Hristov, Chelopechs
Executive Director says the mine is thankful to
Sandvik for being so open and being so
amenable to make changes to suit our needs.
There is something for everyone in this journey.
This article will focus on the mine and the
great work being done there, including new
projects to install a Sandvik underground
crusher and a new conveyor system and decline
to haul ore to surface. A second part next month
will examine the updated concentrator at
Chelopech and the greater DPM world that is
directed from Sofia, Bulgaria and currently has
production or near-production facilities in
Armenia and Namibia.
There is a strong partnership at Chelopech
between Sandvik and the mine. The mining fleet
is predominantly of Sandvik manufacture with
seven 50 t trucks (Toro 50s and one TH550),
seven LHDs three Axera D07 development drills
and four Solo production drills.
For the trucks and LHDs Chelopech has
implemented Sandviks OptiMine - real time
monitoring of operating performance and equipment
health, which will increase the safety and efficiency
of operations and maintenance. OptiMine has
the system elements required to assist in onboard
data gathering that can serve as an enabler for
fleet management. The unit monitoring includes
onboard devices, which monitor mobile equipment
health, status and production output and transmit
this data to the central computer applications.
In less than a year from now Chelopech
aims to break the mould in continuous
improvement of underground mining by
bringing world-leading underground
operating practice to Bulgaria
OLD WAY NEW WAY
Paper reporting at end of shift Real time display of information
Supervisor interaction one or twice per shift Supervisor dispatched to critical shift problems
Limited knowledge of shift delays Delays identified in real time
Slow response time to process interruptions Problems identified immediately
Reactive maintenance Real time equipment health monitoring
Small picture view See activities in whole mine in real time
Poor co-ordination Co-ordination through CCR with big picture
Poor use of resources Resources used to optimise shift results
Lost time locating equipment/materials, etc. Real time equipment and materials tracking
from shift to shift.
OPERATION FOCUS Bulgaria
The new Haver Scarabaeus Pelletizing Disc converts up to
150 tph of fnes into transportable pellets that can be sold
for proft. This revolutionary technology is designed with a
low-maintenance, energy-effcient direct drive. The variable
adjustment inclination, rotation and side wall height of the
Haver Scarabaeus have the ability to control size and consistency
of your pellet and reduce recirculation. Improving recirculation
loads by even a few percentage points is an opportunity for you
to generate millions.
The Haver Scarabaeus redefnes your fnes into something
precious.
REDEFININGPRECIOUS
HAVER SCARABAEUS
PELLETIZING DISC
www.haverscreeninggroup.com
North America:
W.S. Tyler
+1-800-325-5993
South America:
Haver & Boecker Latinoamericana
+55-19-3879-9100
Europe, Africa & Asia:
Haver & Boecker
+49-251-97930
F E D E R E R P G N I N I F S U O I C E
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OptiMine Remote Monitoring System enables
flow of data and information, stores the data,
makes it accessible for other applications and
offers some basic reporting capability. As part of
the Integrated Mine Management System
(IMMS), the OptiMine Process Control System is
to be commissioned in the first quarter of 2012.
Sandvik has a number of roles in this mine
improvement program, here and in other mines:
1. To support customers in defining and
selecting the best systems, and in this way to
develop and establish the Integrated Mine
Management System (IMMS)
2. With OptiMine process control to enable real
time remote monitoring of all underground
fleets with applicable central control room
functions as well as a new way of work
management with short interval process
control of production, service and support
processes during the shift
3. To entrench the Trans4mine continuous
productivity improvement way of working to
ensure optimal utilisation of equipment,
personnel and mine assets in totality.
Chelopech was embarked on an extensive
Trans4mine program when I visited the mine in
2006. Its successes and audits carried out under
the program have helped bring the mine to the
cutting edge position it is in today.
The Sandvik/Chelopech partnership has also
fostered networking and exchange of ideas with
other key Sandvik partners. Gemcom is the
third, very important, member of this
groundbreaking underground mine management
team. Chelopech has selected Gemcom InSite
as its mine production management solution.
InSite is used as an integrated production
management solution, as a platform for
common production reporting and analysis, as
well as for shift monitoring and management
(Central Monitoring and Control System for the
mine). In addition it is used for metal balance
and accounting for the site and has an option to
be used for the smelter in Namibia.
"We selected InSite as our mine production
management solution because of Gemcom's
partnership approach to understanding our
goals and objectives as we seek to expand
production," said Howes. "InSite provides the
tools that will help us improve efficiencies
across the operation, including metal balance
from the block model through to final product.
This will create synergies between the mine and
the mill, resulting in productivity gains such as
improved equipment utilisation and greater
throughput."
The InSite deployment at Chelopech is also
being integrated with technology developed in
collaboration between Gemcom and Sandvik
which provides a system and interface for
monitoring underground mobile equipment. This
will enable the tracking of production,
equipment and personnel metrics in a simple
and effective manner and provide hard data to
inform business decisions for things like capital
equipment expenditures.
With InSite, mining operations are able to link
production data, costs, and planned versus
actual production. The result is greater
efficiency, lower costs, and the ability to
continuously improve performance of all
processes, activities, and equipment.
Sandvik has developed an in-depth
understanding of the demands of modern
mining operations and how automation of
loading and hauling processes in the mining
cycle can contribute to the improvement of
safety and efficiency of ore transportation,
explains Allen Vaughn, Executive Vice President
of Gemcom. Sandviks desire to provide
customers with more in-depth knowledge on the
condition of the equipment for maintenance
purposes, as well as production monitoring to
more effectively manage draw and production
control, creates the opportunity to leverage
InSite.
Cream of Bulgaria
Chelopech remains Bulgarias most mechanised
underground mine. The deposit lies in the
northern part of the Panagyurishte mining
district hosting a number of copper-bearing
massive sulphide and porphyry copper deposits.
The Mining License covers an area of 266 ha and
includes the area of the Chelopech mining
operation and its immediate surroundings. The
mine has operated since the early 1950s, was
acquired by DPM in 2003 and is operated by
DPM subsidiary Chelopech Mining.
Each year the mine currently produces some
A great deal of attention and effort has gone
into improving maintenance procedures, with
excellent results
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75,000 oz of gold and 12,000 t of copper in a
high arsenic concentrate grading about 16.5%
Cu and 30 g/t Au. All concentrates produced are
processed through the Tsumeb Smelter. In
March 2010 DPM purchased the Tsumeb Smelter
in Namibia.
Todays mining operation uses conventional
longhole open stoping (LHOS) with paste fill.
The mine is developed beneath the existing
sublevel caving operations and will use a
conveyor from the underground workings to
surface for ore transport. The change in mining
method from sublevel caving to LHOS in 2005
has proven beneficial, with improved
geotechnical and geological controls and
reduced dilution. Commissioning of the paste
plant in late 2010 has allowed the full
implementation and realisation of the benefits
of the LHOS method. A 0.5 Mt stope 100 m long,
100 m deep and 20 m wide is the mines largest
stope excavated so far, in 151 Block.
Gemcom and MineMax software are used to
produce the mining development and
production schedule. A focus in the scheduling
is to maintain a blend from the blocks
approximating the proportion in the Mineral
Reserves so that multiple mining areas can be
maintained for as long as possible to minimise
congestion and maximise production.
The main features of the mine schedule are as
follows:
Production ramps up slowly during 2011 until
the crusher/conveyor project is complete and
then continues to ramp up in the first half of
2012 until the 2 Mt/y rate is reached
Total development peaks at an average 460
m/ month advance in 2012, with the
continuation of development to the bottom of
the Western Decline. Development is required
to access the 149, 147 and 145 Blocks in 2012
but, then decreases as only development to
and through secondaries is required after 2013.
With the operation reaching its estimated
design rate of 2 Mt/y in mid-2012, it will
produce in concentrate, a total of 1.28 Moz of
gold, 2.19 Moz of silver and 207,000 t of copper
metal for the years of 2012 through 2021.
Maintenance pays
Extremely efficient maintenance is a cornerstone
of the drive to raise the efficiency of
underground equipment. It has already been
noted that system and process views for the
operations will allow better integration and
optimisation. Other areas of focus to achieve 2
Mt/y include:
Computerised Maintenance Management
System, integrated with the other systems on
site
Enhanced training system to ensure the right
competencies and skills for the
operators/fitters
Use models to identify bottlenecks on a
timely manner (production, simulation, stope
cycle)
Initiate projects to improve efficiency in work
execution, mobile maintenance facilities,
haulage and production drilling and blasting.
The mine gives excellent first impressions
clean mine site area and workshops, with
everything apparently well organised and safety
very well emphasised. Globally, Chelopech is a
somewhat unusual case in that there is little
other highly mechanised underground mining in
the country, so it has to look to its own
resources a great deal. Nevertheless, what has
been achieved there in maintenance advances in
the few years since 2006 when I last visited is
remarkable.
The mine is about as self-sufficient as it is
possible to get. For example, the team led by
Johnny Burger Mine Maintenance
Superintendent and Georgy Atanasov
Supervisor Maintenance Mobile Fleet
completed nine machine rebuilds last year,
saving some $1.8 million. Another good example
is the focus on mobile underground pumps
analysing which are the problem units and why,
and then fixing them (rewinding motors, etc.) on
site as needed. This has dramatically reduced
pumping costs.
Simple things too (attention to detail) have
had a great effect on efficiency and safety. We
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all know there is a better side for pedestrians to
pass by underground machines, the side of
which the operator has the best view. But
underground, in the dark, how do you quickly
work out which that side is when confronted
with an LHD or truck or other unit in a drive? The
answer at this mine is simple, a green light on
the correct side for passing, a red light on the
other, front and rear.
Much of what Burger and Atanasov are doing
is to improve the communication between
operator and fitter, getting them working more
closely together, and taking ownership of their
machines. State-of-the-art work bays and an
extensive underground vehicle workshop have
been installed. These have been equipped to the
highest environmental management and safety
(extensive fire extinguishing for instance)
standards. Extreme car is taken to ensure no
contamination.
Production machines are the focus in the
underground facilities. Operators and
technicians interact every shift in the wash
bay/daily check-PPM facility underground.
Demonstrating the good working atmosphere
underground, this facility carries a name board
on its office that reads underground equipment
beauty salon in both English and Bulgarian!
The main underground workshop is equipped
such that all work on development and
production machines, except rebuilds, can be
accomplished underground. The workshop
includes hose manufacture and a machine shop.
The current ratio is 70% planned and 30%
unplanned maintenance. The target is 80:20.
MAN flatbed trucks are used to deliver spares,
lubricants, etc. to the underground workshops,
and haul items for reconditioning
to surface.
Great savings are made by
doing rebuilds on site, these
include the transport saved by not
sending the machine to an
outsource company abroad. There
are labour and parts cost savings
a number of large components are
reconditioned on site instead of
sending them to a contractor. The
program also saves time rebuild
on site takes four weeks, but
abroad it would be eight weeks.
This of course saves four weeks
production time. Then there are the training
benefits skills and training retention and on-
job training.
Between January 2006 and March 2011, LHD
availability has gone from 70% to over 90% -
truck and LHD availabilities of 98% are not
uncommon! The trucks availability story is the
same, while (linear) utilisation has risen by
about 2% to 63%. The target availability for all
production machines is 85%. Year to date
figures as of May this year were Solo production
drills 86.34%, Axera development drills 86.29%,
for the trucks it was 88.66% and the LHDs
90.47%. The target for utilisation was 20% for
drills and 60% for trucks and LHDs. Year to date
the Solos achieved 27.26% but the Axeras only
10.4%. The trucks were 61.77% and the LHDs
40.75%. The Axeras and LHDs were missing
their utilisation targets because besides
production they are being used in the conveyor
decline development.
Once that project has been completed then
they will return to production. Then the ramp
up will occur, Burger explains, then the
equipment will be utilised to the maximum.
Another reason we did all the rebuilds was to
get equipment availability, so that if you do a
PPM then you have a swing unit as a replacement.
Then we can keep our production sustainable at
all times and also plan and work more wisely.
On surface, the central workshops are used to
commission new underground units but their
main clients are the light vehicles and
underground service vehicles the latter
comprise:
Graders one each Cat 12G and 12H
Two Normet shotcreting machines 5 and 6 m
3
capacity
Two Sika-Putzmeister shotcrete spraying
units
Two ANFO charging baskets
Three Cat 735 ADTs
Two Cat wheel loaders 972G and 972H
Nine fork lifts
Four MAN 13244 flat bed trucks.
The mine uses 102 Toyota light vehicles and
the central workshop is now a Toyota accredited
facility. That workshop comprises a wash bay,
light vehicles service shop (where preventive
maintenance and servicing of light vehicles and
heavy terrain vehicles are executed); rebuild
section, manufacture and machine shop, a
drifter workshop (where all drill rebuilds are
done), stores and office.
New surface workshops just finished in June
are for the repair and servicing of Caterpillar and
other utility equipment. This will take pressure
off the underground workshops so they can
concentrate on the production machines. The
Sandvik L940R rock breaker, which uses an E66 R
impactor, is also serviced in the surface workshops.
Annually the savings generated by these
facilities amount to some $480,000 in the
manufacture and machine shop and $130,000 in
light vehicle servicing. Doing this on site
eliminated the need of outsource vehicle-
servicing and decreased repair expenses. It
saved time and fuel driving vehicles to Sofia for
servicing. The facility is provided with modern
diagnostics and servicing equipment and is
furnished with tyre and spare parts stores.
Being Toyota accredited, this facility can carry
out warranty work on those vehicles.
The manufacture and machine shop is where
repairs of large components, such as booms,
buckets, impactor housings and other parts for
various machines, are executed. LHD buckets
and truck trays are repaired and lined here and
the results are self-evident with buckets
achieving 25,000 hours and truck trays 35,000
hours. As the original buckets wear the
workshop then replaces the worn sections with
additional Hardox plate - areas like the side
walls of the bucket both inner and outer and the
top floor plate and bottom wear strips. As the
primary lip wears the mine then adds pads, thus
adding life to the existing primary lip. Buckets
are also line bored at each major repair. They
are all Sandvik GET buckets fitted with the
Shark 50 mm Blue Pointer.
Top primary lip pads at the front of the
buckets have been replaced with a full floor
plate that works as a dedicated wear piece; also
there are dedicated internal side wall skins. All
these Hardox wear pieces have been developed
by the Chelopech maintenance team. This
system has proven itself in Chelopechs abrasive
conditions.
All turning, welding, grinding, metal working
and premanufacture are done in the machine
shop. Good quality line-boring and
workmanship play significant roles in the proper
execution of the work.
The drifter workshop specialises in hydraulic
cylinders, drifters, impactors, differentials,
gearboxes, rotation mechanisms and other
hydraulic components repairs.
Surface wash bay. Since the new servicing
facility was completed, $130,000 has been
saved in light vehicle servicing. Doing this on
site eliminated the need of outsource vehicle-
servicing and decreased repair expenses. It
saved time and fuel driving vehicles to Sofia for
servicing. The facility is provided with modern
diagnostics and servicing equipment and is
furnished with tyre and spare parts stores.
Being Toyota accredited, this facility can carry
out warranty work on those vehicles
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The pump workshop carries all preventive
maintenance spare parts. There is an electrical
dryer for servicing the repaired pump motors.
There is machining equipment to repair all Flygt
pumps, which are then tested before they are
returned underground.
Also on surface, the Simulator Development
and Technology Centre is another great success.
There is one for drill jumbos and one for LHDs.
While they provide operator training, their main
focus is maintenance training. They were built
up using scrapped components and old
machines. The LHD room includes a fully
operational cab from a Toro 0010, which is
hooked up to a Detroit S50 engine. This allows
simulation of all operations of the machine.
There is also a comprehensive hydraulic test
bench for practical exercises in electro-
hydraulics. The principles of the Posi Stop brake
system are displayed by means of the special
brake pack work bench.
Here technicians and operators learn about
the components of an LHD, how they interact
and how they should be repaired. Various problems
can be programmed to learn troubleshooting.
Fault finding, hydraulics and automation of
underground machines are essential parts of the
theoretical and practical drills.
In a separate room, the jumbo simulator
provides the same training opportunities. It is
fully fitted equipped all main drill rig
components. Technicians gain skills and
knowledge in hydraulic, electrical and drill rig
automation systems. The course involves
electrical and hydraulic drawing analysis, fault
finding and work with manuals and technical
documentation.
These simulation rooms are combined with
classroom instruction. The instruction team has
established a new training program which
consists of several modules covering four levels
of skills and expertise. In order to pass to a
higher level, the worker must gain experience in
the company, attend the courses and pass the
respective exams.
Technician level 1 minimum six months
experience
Technician level 2 minimum 12 months
experience
experience
experience.
The great work that has been put into
maintenance has generated labour efficiency
and raised safety awareness. Discipline has
been increased and motivation and organisation
improved. There is much better control over
maintenance expenses, and the work is of
higher quality. This means longer vehicle life,
better utilisation and process optimisation.
Furthermore, these facilities are providing
training and doing rebuilds for DPMs Deno gold
mine in Armenia.
Communications
In general the challenges for any underground
mines communication system are improved
local and global communications within a
system that is simple to use, improving health
and safety. Chelopech felt its original system
had significant communication limitation
between groups. It also wanted a system to
help improve productivity and equipment
tracking had to be part of that.
Chelopech decided to build its own system
with equipment readily available, mainly from
Cisco and AeroScout. Such a system is fairly
easy to build up and building it saved DPM a
considerable amount of money, according to
Howes. AeroScouts active RFID tags and/or
standard wireless devices send a tiny wireless
signal at a regular interval. That signal is
received by the Wi-Fi wireless network (or
location receivers), and is sent to an AeroScout
Visibility Engine. That uses multiple algorithms
to determine location, and sends asset data
(location, status, etc.) to enterprise software.
The enterprise software uses location and status
data to display maps, enable searches, create
alerts, manage assets, etc.
AeroScout's Wi-Fi Tags are small, battery-
powered devices. The use standard Wi-Fi
networks to track assets and people in real time,
in any environment. This unique Wi-Fi RFID
technology extends the capabilities of wireless
networks to new applications that drive
enterprise efficiency and productivity.
There are to be AeroScout tags on all caplamps
and on all non-Sandvik machines. OptiMine
provides the communications for the Sandvik
machines. Microsense industrial controllers are
also an integral part of the system.
Having built this system, Chelopech Mining
was one of three top finalists for the CISCO
Innovation Awards 2011 in the category: Most
Innovative Business Impacting Network of the
Year.
Plan, schedule, execute
Plan, schedule, execute is a favoured mantra at
Chelopech. It may simply be summed up as an
exhortation for all to use the technology tools
Communications
- wireless
Ethernet, also
showing the
new ore
handling system
capacity
and information at their disposal. Many mines
do a lot of monitoring and do little with the
results. They collect data and dont know what
to do with it.
Equally, another common underground
mining problem that Chelopech aims to
overcome is that of assigning tasks with no
follow up as to whether they are completed as
desired or even completed at all. The aim is to
assign tasks and know that they have been
completed in that shift.
The overarching goal is to improve efficiency
through the productive utilisation of resources.
Those resources are personnel, equipment and
workplaces.
Corporate yearly plans comprise the long
term targets, which are received by CMCS
(Mining Execution Management) to work into
weekly schedules. These are then released for
daily and shift schedules, which are passed to
the underground resources. One of the aims is
that these resources should be empowered so
that they become eager to get their work effort
organised and report the progress.
InSite CMCS software tools guide the
planners to create and fine tune resource
allocation. This shows available resources with
possible capacities to help planners to fulfil the
underground operations CMCS daily production
targets. The overall target is allocated to
resources in the form of task lists.
Chelopech and Sandvik are still working on
the OptiMine Phase II system. The intent is that
OptiMine will pick up the task schedule with
targets from CMCS and distribute them to
portable devices. The tasks are distributed to
HMIs (Human-Machine Interfaces) for WLAN
transmission, no matter if they are carried by
personnel or underground operations CMCS
docked to equipment.
OptiMine Phase II will bring the data captured
at the Sandvik machines back automatically. It
will also provide a means to report events
manually from non-Sandvik equipment. Thus the
responsibility for reporting events moves to the
underground resources with, therefore, less
pressure on the control room receiving VoIP
calls.
OptiMine Phase II will provide straightforward
reporting of the outcome of tasks, using the
equipment measurements. There will be no
room for speculation; the digital value will
always be there. Eventually, the efficient Short
Interval Control will be a simple procedure
where all participants play their role.
The ultimate goal at Chelopech is a central
control room, which is planned to be on surface.
In summary, the integrated infrastructure of the
Central Control Room will provide:
A single point of access into a wide variety of
systems
Serves as a platform for status checks and
intervention if required.
It will enable short interval control in order to
schedule, assign and monitor tasks allocated to
a piece of equipment and crew so that they are
completed in a shift.
It will improve access to information for all:
Enabling remote management of business
processes
Simplified access to information in the event
of a problem.
Know of and solve impending problems
before they affect production
Delays can be identified and corrected at an
early stage, thus reducing the potential for
lost production.
There will be data and information integrity.
The system will provide just one version of the
truth. Thus it will be possible to discuss
solutions to problems rather than arguing about
the accuracy of the data.
Performance management will enable root
cause analysis and cross-functional KPI (Key
Performance Indicators) reporting on business
processes (cost, quality, dependability and reliability).
At this stage, Howes and his team are not
completely sure what the quantifiable benefits
will amount to from all this real time process
control underground but estimate it will be a 10
to 30% improvement above what has already
been achieved. It will also make Chelopech one
of the lowest cost mines of this type and size.
Real- time process control will help find
fundamental problems and allow them to be
fixed effectively. Process control is common in
the concentrator, and it is mainly done by
computer. Underground mines have to have
operators. The aim here is to empower those
operators to accomplish effective real-time
process control. It will also make their jobs more
interesting.
This slide shows the mining operations
management facilities that have been installed
(inside the blue boundaries) and those, all
Chelopech responsibilities, that are still to be
implemented. Maintenance management
CMMS and materials management/inbound
logistics are partly in place, access control/time
and attendance, central blasting, personnel
tracking and fuel and lubricant dispensing
require more work
Planning must be a loop feeding back and forth
from front line planning to the big picture the
life of mine plan
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The central control room is expected to
become operational early next year. The module
that will provide the real-time feedback to the
control room is under development by Gemcom.
The projects
Aside from the communications and
management systems, the main projects to be
completed to double capacity are:
The installation of an underground
crushing/ore handling system
Upgrade of the mine ventilation system to
allow for increased utilisation of mobile
equipment
Upgrades to the process plant including
installation of SAG mill additional flotation
capacity, upgrade of tailings facility, and
water recovery (mostly completed and will be
examined in the second part of the article)
Construction of Paste Fill Plant and related
underground reticulation system (also
completed and to be covered in part II)
New Run-of-Mine pad and crushed ore
stockpile and mill feed system.
Currently ore is trucked from the production
stopes below Kapitalna shaft bottom to the 450
Level orepasses. Ore from these orepasses is
loaded into wagons on the 405 Level and hauled
on a rail tram train to the Kapitalna shaft and
hoisted to surface and into the existing primary
crushing facility on surface. This system is being
completely replaced by a new 2 Mt/y
underground crushing and conveying system
that will take ore from a new ore pass system
underground reporting to the 195 level and
crush, transport and discharge the ore onto a
6,000 t capacity reclaim stockpile on surface.
A Sandvik primary jaw crusher (a 1,070 mm X
1,500 mm unit) is being installed between the
195 level and the 165 level underground. It will
discharge into a 400 t crushed ore bin. The
crusher will be fed from a ROM bin sitting under
a grizzly with openings of 800 mm x 800 mm.
Three sources will feed ore to the grizzly:
A 4.35 m diameter x 135 m long orepass for
151 and 150 Block material above the 260
Level
A 7 m diameter x 30 m deep ore bin for the
Central area (145, 149, 151 and 150 Blocks) for
225 level ore
A truck tip directly on the grizzly for ore in 151
and 150 Blocks, on and below the 195 Level.
The new ore pass system is being constructed
by Deilmann-Haniel Shaft Sinking. Raiseboring
and conventional drill and blast methods are
used to sink the shafts (pilot and slash) and
bunkers in a rock formation that is dominated
by igneous breccia.
Both the 165 m deep orepass inclined at 75o
and the ore bin have been reamed to a diameter
of 2.1 m through raise boring. Subsequently, the
boreholes are extended to the desired
diameters by drilling and blasting. The primary
wall support consists of spinnable cable bolts
(with Minova Lokset resin), wire mesh and
shotcrete. A secondary abrasive resistant
shotcrete layer will be applied from bottom to
top after completion of sinking. The work has
been carried out to the highest safety standards
from a two-deck working stage, equipped with
skids because of the inclination of the orepass.
A plate feeder draws material from the 400 t
crushed ore bin and loads a picking belt (CV1)
for removal of tramp metal using a self cleaning
magnet. Material is then conveyed via six more
haulage conveyors (CV2-CV7) to the surface. The
surface conveyor CV8 will transfer material to
the surface reclaim stockpile where it can be
reclaimed and conveyed to the SAG mill to
provide uninterrupted feed to the process plant.
The total length of the six underground
conveyors is 3.9 km. The total lateral
development required is 4.5 km. The design
capacity of the system, using a 1,250 mm wide
conveyor belt, is 400t/h. As a result of this
underground crusher installation the existing
surface crusher installation will be
decommissioned.
The conveyor decline is an arched tunnel 5 m
wide at the floor and 4 m high to the peak of the
arch. There will be a space of 0.85 m width on
one side of the conveyor, which will be
suspended from the roof. On the other side 2.9
m of drift will allow the passage of vehicles.
At the time IMvisited the operation, the
conveyor incline was being driven from four
faces one each from the top and bottom and
one descending from a mid point, and the other
ascending.
The updated ventilation system will meet life
of mine requirements. The current system exhausts
at 154 m
3
/s, and the new system must achieve
at least 235 m
3
/s. The fan has been chosen and
is currently being engineered to 265 m
3
/s.
Reference
1. Howes, R. Taking the Lid Off, Mining Americas
Summit, Denver, Colorado, June 2011
The Simulator Development and Technology
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I
ndian supplier Tecknotrove says, and all
simulator suppliers would agree, effective
training has a huge impact on productivity
levels in a mine. For any mining company it is
essential that their operators and drivers are
skilled and trained to deliver the highest level of
productivity.
Mining simulators are designed to ensure
effective training of operators of mining vehicles
in complex and real hazardous scenarios under
complete safety. Training operators on advanced
simulators can help reduce accidents and
improve safety, and reduce training costs by
removing the need to put as many hours into
training on real machines let the virtual
machines bear the brunt of the training needs.
In late August Immersive Technologies 1000th
TrainerAdvantage participant received certification.
This certification program was launched by
Immersive Technologies in 2006 to assist its
customers to achieve a strong return on investment
from Immersives simulators, through improved
understanding and application of the technology.
Designed for simulator training supervisors,
the three level certification program includes
classroom and hands-on sessions working with
their simulator under the instruction of an
Immersive instructor. Each level is designed to
progressively increase the trainer's knowledge,
from basic operation of the simulator to
advanced administration and management.
Peter Salfinger, CEO of Immersive
Technologies' said, "We are extremely pleased
by the global acceptance of this certification
program. Consistent feedback from our
customers confirms TrainerAdvantage is an
important tool to help drive the value from their
simulator investment that they expect."
"The training and certification of 1,000
operator trainers is a positive reflection that the
industry recognises the significant difference
well-utilised Immersive simulators can make to
a site's safety and profitability."
"It also provides mines with a valuable
standard to use when recruiting new training
staff for their simulators. It is common now to
see mines advertising for training staff with the
TrainerAdvantage certification."
TrainerAdvantage is one part of a
comprehensive package of support services
available to Immersive Technologies' customers.
Other elements include technical support,
training systems integration and analytical
measurement.
Salfinger concluded, "We recognised long
ago that we needed to do much more than just
deliver great technology to mine sites. We work
hard to listen carefully to our customers and
provide intelligent and customised solutions
that solve their site specific issues."
Immersive has sold 595 simulator equipment
modules (Conversion Kits) to date, up from 380
in 2008. Highlighting the growing interest in this
technology, 125 were sold in the 12 months
ending June 2011. Advanced equipment base
simulators have increased to 251 from 130 in
2008, 45% to existing customers. In the 12
months ending June 2011 55 base simulators
were sold, with the majority of these being the
new PRO3 simulator. The number of countries
using Immersive simulators in 2011 has
increased to 30 from 23 in 2008.
Also from Australia, Sydac creates leading
edge operator training simulation products and
solutions. These simulators immerse the user in
the task at hand by accurately simulating the
behaviour of equipment and the environments
in which they operate.
The company says that with a large team of
software and mechanical engineers, vision
specialists and digital artists Sydac can produce
an earthmoving or mining simulator for a wide
range of applications. The simulator will deliver
measurable benefits in staff performance and
safety levels, whilst minimising training and
operating costs.
ThoroughTec Simulation, one of the well-
established players in mining equipment
simulation has had some very interesting new
sales recently. Oyu Tolgoi mine in Mongolia
recently selected ThoroughTecs latest
generation CYBERMINE
4
mining simulators (IM,
April 2010, p71). Richard Storrie, the Technical
Services Manager at Oyu Tolgoi, advocated the
purchase of the simulators for the mine after
TRAINING AND SIMULATORS
Save accidents and training
costs. Using simulators can
create training and refresher
course applications, serious
situation exercises that allow
operators to build skills in a
practical and cost effective
way, and can also prove
process designs, as
John Chadwick discovers
For concentrators, Outotec
has developed a new
technique of Virtual
Experience Training
witnessing the results attained by
Aurora College and Rio Tintos Diavik
mine in the Northern Territories,
Canada.
Oyu Tolgois development
workforce includes local employees
and highly skilled expatriates
entrusted with training and
supervision. As mine development
morphs into full-scale production
however, more and more experienced
local operators will be needed and
Oyu Tolgoi is committed to having a
minimum of 90% of its workforce
employed from the local community.
To effectively train and up-skill these
local operators for a mega-mine like
Oyu Tolgoi will require specialised
training equipment and an
exceptional training program, said
Storrie.
Wesfarmers Curragh, one of Australias
largest independent coal producers, has chosen
to integrate CYBERMINE
4
surface mining
simulators into its training programs.
Construction works are ongoing for the
expansion of the mine up to 7.7 Mt/y of export
metallurgical coal capacity. Project completion is
expected in the March quarter of 2012.
Greg Sheppard, Wesfarmers Manager of
Engineering and Projects, said: We had taken a
diligent review of the major mining simulator
players in the Market. ThoroughTec impressed
us with their superior accuracy, authenticity and
broad coverage of machines. Wesfarmers has
purchased ThoroughTecs 6 degrees of freedom
(DOF) base simulator unit and interchangeable
cabs for the Komatsu 730E truck, CAT D10T
dozer and Bucyrus-Eyrie 1570-W
dragline.
Richard Giumelli from Wesfarmers
Mining Services, added:
ThoroughTecs ability to customise
to our needs and schedule is just the
kind of customer-centric partner we
are looking for to ensure continued
adaptability to our business
dynamics.
ThoroughTec will also develop
customised CYBERMINE own mine
worlds to replicate the operating
conditions of the mine in the
simulators, increasing the
effectiveness of the training
experience. Student operators of each
of the equipment variants will
therefore be familiar with Curraghs
mining environment before entering
the mine.
The Assmang Khumani iron ore surface mine
will be significantly improving its capability to
enhance operator competency with the
acquisition of two CYBERMINE
4
mining
simulators. Khumani mine has also purchased
interchangeable cabs for Komatsus 860E AC
haul truck and PC5500 hydraulic face shovel.
The new units will not only enable Khumanis
HR, engineering and mining management to
train on loading, hauling and digging, but also
Immersive Technologies Caterpillar 793F
simulator
on more advance equipment like drill rigs in the near future. ThoroughTec
says its attentiveness in supporting customers, along with the flexible
approach to their development schedule and low cost of ownership model
and value for money service plans were accredited as key differentiators
with their competitors.
Mark Walker, ThoroughTec Simulations Executive Director of Mining &
Construction said: Assmang Khumanis selection of ThoroughTec
Simulation is a significant validation of our new fourth generation
CYBERMINE
4
mining simulators leadership in the market, with the
recognition that military level simulators in the mining industry is the
future and it further emphasises our dominance in the Northern Cape area
in South Africa.
ThoroughTec says CYBERMINE
4
is the industrys only dual-role
(interchangeable between surface and underground) simulator. It is
upgraded with many new features including a full 360 panoramic display,
enhanced reporting software, and two HD instructor screens in an enlarged
classroom environment.
ThoroughTec produces surface mining simulators for rigid trucks, ADTs,
drill rigs, excavators, shovels, dozers, loaders, draglines and graders. Drill
rigs, roof bolters, LHDs, haulers, XLP (extra low profile) dozers, locomotives
and scalers are among its underground simulators.
Although the mining industrys use of simulation is relatively young, the
worlds leading mine sites and training schools are increasingly aware that
they need to integrate simulators into their training programs, Walker
said.
You cant imagine a pilot not training on a simulator before taking his
first solo flight, so why isnt it the norm for operators of 90 to 360-plus t
mining trucks to enhance their competency?
Safety, productivity, emergency scenarios, damage to an expensive
vehicle and excessive fuel usage and emissions were among matters that
could be addressed with simulator training, he said.
Americas first advance underground mine training simulator to be
acquired by a University is a ThoroughTec CYBERMINE
4
. The University of
Alaska Southeast (UAS) Mining and Petroleum Training Services (MAPTS)
Director Dennis Steffy said: From start to finish, ThoroughTecs
professionalism has been a real treat, not to mention that they had all the
underground equipment that each mine required.
The University of Alaska Southeasts goal is to develop a world-class
training centre that meets the workforce training needs of the mining
industry by providing high quality, accessible training for both new and
experienced miners. The simulator will be housed at the UA Center for Mine
Training, located in Juneaus UAS Technical Education Center and will have
the ability to train students in modules fully representing an articulated
haul truck (CAT ADT 45B), LHD (Atlas Copco ST14) and bolter (Atlas Copco
Boltec MC).
Instructor training on CYBERMINE simulator
The timing of the new acquisition will
coincide with the ramping up of Kensington and
other mines. This was a missing piece of the
puzzle for training miners from Alaska to be
productive and safe from the first day on the
job, said MAPTS Director Dennis Steffy. It will
vastly improve the opportunities of students for
mining employment. More than 700 students
are currently enrolled in mining classes at UAS.
Kensington mine employs 60 UAS-trained
miners.
Walker said: We are pleased to see the
superiority of our simulators is being well
recognised in North America. This follows recent
expansion of our presence in the region, with
the Yukon Mine Training Association (YMTA) also
acquiring an additional purchase of six machine
simulator cabs to support both surface and
underground machine training. YMTAs Training
Manager Jennifer Russell said: ThoroughTec is
a great company to deal with because of their
high levels of customer service.
Oryx partners with Atlas Copco and says
everything you can do in the real Atlas Copco
drilling machine you can do in the simulator, in
your own language.
Two new Oryx mining simulators for surface
drilling are the Flexiroc D (L6-L8) and Smartroc
D65 and they are already in use in Russia, Chile,
Brazil and South Africa.
Earlier models the Pit Viper and Smartrig
D9C simulators and for underground drilling the
Boomer E2C simulator are in use around the
world.
All of the simulators are designed
as a tool to use together with an
operator training program based on the
Atlas Copco Master Driller program. This
program combines theory and practical
training for operators at three distinct
levels bronze, silver and gold. The program
mirrors the conditions and tasks the operator
faces in different situations in mining
operations.
Sister company Algoryx Simulation is a
leading provider of software and services for
visual and interactive physics-based simulation.
Algoryx has a team of developers and
researches, many with more than 15 years of
experience in interactive simulation.
CAE, a global leader in modelling, simulation
and training for the aviation industry, entered
mining in 2010 following its acquisition of
Datamine, the long-time provider of mining
technical software for geologist and mining
engineers. CAE Mining is therefore focused on
bringing leading technologies and services to
enhance productivity and safety in mining.
CAE trains in the order of 80,000 pilots each
year using a variety of delivery mechanisms
designed for fast efficient learning and high
training effectiveness. CAE develops the full
range of simulators from 2D e-learning modules
right through to its full-immersion simulators.
Whilst the technology is very important, CAE
says it is its ability to take a holistic approach
that resonates with customers. It begins with
gaining an understanding of an organisations
workforce requirements to meet production
plans. In the current expansionary environment,
not only is additional equipment required but
also a corresponding workforce of competent
operators. And typically just in time, so
workforce planning is important and so too is
determining required competencies to
effectively and proficiently perform tasks. Both
are essential inputs for determining the
appropriate delivery mechanisms for training
and assessment. It is also important to have the
appropriate framework and infrastructure to
support training. The entire approach can be
wrapped up in a business case that captures the
role simulators play and the value of outcomes
to be achieved.
CAE uses a methodology of blended learning
coupled with an integrated total solution.
Working with our clients we can build
competency profiles of each role required on the
site(s), determine the level of skill, knowledge
and behaviours required for operational
excellence and test individual applicants on
their current capabilities.
While those new to the industry can
commence with our Computer Based Training
(CBT) system, more advanced operators can be
assessed and enter into the programs further
along the training continuum. Aimed at
transferring knowledge on the basis of mine
terminology and theory and specific mining
machinery, new students are staged through a
learning strategy of both face-to-face and e-
learning solutions prior to moving into the
simulator learning. Entry points into the
programs for students will be dependent on
their pre-training assessment.
After simulator training, CAE's next stage is to
validate the operators capabilities in the real
thing. This component of the learning continuum is
accomplished on-site and commences with a
familiarisation of the environment and mine
equipment. As mine planning and traffic
conditions often change it is imperative that
operators are fully aware of the up to the minute
situation. The operators will now be assessed
on-site and verified as operational ready.
CAE does not however believe that is the final
stage of learning. Taking lessons from the
aviation industry, it is imperative that to
maintain production, safety and life expectancy
of equipment the behaviour of the operator
must be monitored. By collating data from the
fleet management system, individual
performance can be assessed and data re-used
in corrective training in a simulated
environment. Whereas retraining or refresher
training does not typically take account of
behavioural issues, CAEs approach uses real
performance information to build a training
continuum where simulators can play a major
role in the development of people.
eBook training
With the release of the Track Type Tractor
Simulator System, Cat Simulators published an
interactive companion eBook for the tablet to
extend simulator training. The tablet technology
CYBERMINE Komatsu 730E simulator -
workshop
Oryx simulator for
Atlas Copco Pit Viper
blasthole drill
replaces the traditional paper textbook, creating
a fully interactive learning experience for the
user. The eBook allows the student to use the
material in a self-guided format in conjunction
with the simulator, or the instructor can use the
material as part of a classroom environment,
assigning each chapter and testing the student
on knowledge learned before the student trains
on the simulator. The eBook covers a multitude
of information that ties back to machine and
simulator training.
Find out size, capacity and uses for the dozer
in the machine introduction. View the inside
and outside of the machine in 360
walkarounds and a terrain map of the
worksite
Discover what blades and rippers are used on
actual worksites
Learn how to perform dozer machine
applications fully, along with helpful how-to
drawings and images
Find a definition and explanation of each
training exercise and result measured. The
simulator system records and reports the
results of each simulation session through
the training records management program,
SimU Campus. The eBook explains what
these results lead to and why recording and
analysing the results mean becoming a more
efficient operator
View narrated video examples of the correct
way to perform simulated tasks and achieve
the best outcome by seeing what is expected
during the training exercise before actually
attempting to perform the task
Use the SimCalc App to figure fuel use and
double-handling of materials during several
training excercises
Make safety a priority any time the machine
is in use. The eBook features personal,
machineand job site safety information.
Cat Simulators is publishing interactive
eBooks with every new model of simulator.
Timing is everything
VISTA Training has been in the mining business
for over 20 years. In those years it has
witnessed what drives employers to train. Bruce
Rabe, CEO of VISTA Training, notes it long ago
lost track of the number of times [it] received an
urgent call looking for training materials on a
specific subject right after an accident. Most of
the time the accident was a wake up call that
something more serious could happen.
Occasionally the request followed a fatality and
was intended to help avoid future similar
situations. On rare occasions an employer may
have been advised by their attorney to get some
safety training started as a show of good faith
when a law suit was eminent.
The point is; with good consistent training
many of these incidents or sometimes serious
and occasionally fatal accidents could have
been avoided. Yet to do employee training when
everything is going well may be considered a
waste of productive time. It frequently isn't until
an accident happens the true cost related to
failure to train emerges. Think about the time
lost after an accident happens. There may be a
need for medical help for injured employees,
time spent on accident investigations, time for
insurance or government investigations added
to the cost of lost production as well as possible
machine repair or replacement costs. Of course
by then it's too late!
Years of exclusive involvement with mining
and heavy equipment make it easy to relate to
the difficulty of scheduled training in mines that
are constantly pushed for production. Rabe
says it thoroughly understands the need to
make every single available work-hour
productive.
It has devised visually and audibly interesting
lessons and totally flexible delivery methods
designed to task and safety train workers in
small doses. These drip-feed important
information to workers using instructional
design techniques proven to leave a lasting
impression on the learner. Nearly every VISTA
lesson was created by someone who had done
that type of job. Lesson creators are assisted by
professional educators trained in instructional
design techniques to achieve maximum long-
lasting positive results, says Rabe.
Of course the key is to get the training to the
people most in need before the accident happens.
It takes less than 1% of normal production time
to do that. Timing is everything, but most
importantly it is critical to remember; you will
never have a chance to train a dead person.
Immersive Technologies has sold a PRO3
advanced equipment simulator to ResCo
Services, a wholly owned subsidiary of
Australian global recruitment and labour hire
agency Humanis Group. The simulator will be
used as part of Humanis' ongoing strategy to
expand its mining services operations and build
on the strategy to become the largest labour-
hire agency in Australia. The PRO3 acquisition
will extend ResCo's ability to provide high
quality RTO (Registered Training Organisation)
certified recruits to the market.
Salfinger said Utilising the PRO3 simulator,
ResCo will be able to greatly enhance their
recruitment, assessment and personnel offering
to the mining market, reducing costs and
improving the qualification process of its
recruits to their growing customer base.
The simulator provides ResCo the ability to
safely train new and existing mining personnel
in a broad range of operational and safety
scenarios, measuring operators skill and
experience levels prior to being placed on site.
Humanis Chairman Craig Ransley said This
investment is part of the strategic growth for
Humanis in the global resources sector. We
believe that the simulator will provide cost
effective, high quality training and up-skilling of
candidates assisting our clients to address the
critical labour shortages faced by the industry.
ResCo is well recognised for its leadership in
safety management. The introduction of the
simulator to our operator training strategy will
assist in maintaining this position. Being able to
develop the fundamental operational and safety
skills of our operators in a controlled
environment will ultimately reduce safety
related risks on the mine site.
ResCo says the PRO3 will initially be used
with client Rio Tinto (Coal & Allied) at Mt
Thorley Warkworth coal mine, located 15 km
southwest of Singleton, NSW, Australia. The
simulator will supplement the sites own
simulator based training program which is
focused on operator up-skilling and efficiency
training.
The sale to Humanis includes Caterpillar and
Komatsu OEM Alliance modular equipment units
to support both haul trucks and Immersive
Technologies Training Systems Integration (TSI)
package. The TSI package provides Immersive
Technologies customers with a benchmark
standardised training program for implementing
simulation training. TSI packages are developed
to meet the needs of specific simulator
implementations based on best practices
gathered from Immersives extensive global
mining customer base.
Plant simulation
Outotec has developed a new training and
probably unique concept, Virtual Experience
Training, designed mainly for concentration
plant operators. The training course uses
Outotecs extensive knowledge of minerals
processing. The training provides operators with
Enquiries@ImmersiveTechnologies.com | Tel. +1 801 748 0844
www.ImmersiveTechnologies.com
Roadmap to Results
Immersive Technologies supports its world leading Advanced
Equipment Simulators with a best practice approach to implementation,
measurement and analysis, specifcally designed for the mining and
earthmoving industries. This structured implementation framework
provides mines with the support and roadmap necessary for optimizing
their operationalworkforce.
Our expertise has been steadily built from over 10 continuous years of
leadership and dedicated focus in the mining industry, together with
successful business improvement projects at leading mines around
theworld.
Exclusively recommended by
leading OEMs
Immersive Technologies has formal Exclusive
Alliance Agreements with leading Original
Equipment Manufacturers (OEMs) including
Caterpillar, Komatsu, Hitachi, Liebherr and
P&HMining Equipment.
These alliances exclusively provide Immersive Technologies with access
to the proprietary machine technical information necessary to correctly
simulate the operation of the OEMs real equipment, ensuring you receive
the most accurate training simulator.
BEYOND SIMULATION
DELIVERING MEASURABLE REAL WORLD RESULTS
UL131 Conversion Kit
for Caterpillar
R1700G, R2900G Underground Loaders

Roadmap to Ressults
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process dynamics, process equipment and
control systems. Learning and practicing process
situations, such as failures of critical equipment
and process start-up or shut-down sequences,
are certainly safer and more cost effective in a
virtual environment.
Successfully trained personnel make it
possible to improve the utilisation of equipment
and extend the lifetime of the investment. The
results can be seen in terms of cost per tonne
and the total cost of ownership. Competent
employees are essential for profitable
operations and stable process control. Investing
in personnel and their expertise pays for itself
fast, as skilful personnel are able to get the
most out of production, says Kai Rnnberg,
Product Manager at Outotec.
Over the past few years Outotec has supplied
the Almina plant in Portugal with basic
engineering for process modification, two
grinding mills, 51 flotation cells (including four
refurbished flotation cells), a Courier analyser
with complete sampling system and a service
agreement. This was followed by a request: for
Outotec to provide training for the plants
flotation operators.
As most of the operators at the Almina plant
were inexperienced, management wanted to
organise training for them to ensure that the
process would get off to the best possible start.
We wanted our operators to understand what
is happening in the process, to make the
necessary corrections and to take the right actions,
explains Almina Plant Manager Carlos Gil.
Only three of Alminas five team leaders had
previous experience with operating the flotation
process. We wanted to make process
evaluation and decision-making available also
for the line operators, not only for the team
leaders, Gil continues.
Almina requested that the training be
scheduled for July 2010, before the start-up of
the plant. We had conducted internal training
before, but this time we had no time to arrange
the training ourselves. We needed the training
ASAP, and it was essential to increase the
expertise among the operators, explains Gil.
Almina also considered other options,
providers and concepts for the training. What
was most attractive about Outotecs proposal
was the interactive element. In simulations,
people need to think for themselves, says Gil,
summing up the purchase decision.
We have worked with Outotec before, and
we consider them a partner. Based on our
experience with Outotec in the past, we felt
comfortable and assured about signing up for
this training, as we knew that Outotec would
live up to its reputation.
Outotec promised to deliver Almina a new
concept of training in which the operators would
learn how to operate the flotation process,
evaluate how it is reacting, and test different
scenarios without hampering productivity at the
plant, explains Luis Rudolphy, Sales Manager
at Outotec.
Normally operators learn from senior
operators as they work, which can take years.
Now the operators instantly experience how
their decisions affect the entire process, and
they learn to change parameters and make the
best decisions, explains Rudolphy, summing up
the benefits of the training.
The customer requested that the training be
held on its own premises. Outotec limited the
number of participants to a maximum of ten to
guarantee the best learning outcomes.
To maximise the learning experience and
avoid language barriers, the training was offered
in Portuguese. All the training materials were
translated into Portuguese, and an assistant
teacher who spoke Portuguese was involved in
the teaching. Using local language is very
beneficial for both trainer and the trainees, as it
is easier to communicate and it made the
operators more comfortable to focus on the
training. Many of the operators did not speak
English very well, therefore the Portuguese
material was very important to support their
learning, Jair Hortelan, Services Sales
Coordinator from Outotec Brazil, who acted as a
co-teacher for the training, explained.
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Ten of the Almina plants flotation process
operators participated in Outotecs Virtual
Experience Training. Out of these ten, only three
of the operators had previous experience as a
plant operator from years ago. Seven of them
had never set foot in a concentrator plant
before.
With basic level training, the backgrounds of
the participants are not an issue as the training
suits everyone, Rudolphy says, and this was
later proven to be true.
Alminas operators began with one week of
basic training based on generic flow sheets with
no adaption to the customers own process.
The basic training provided the operators with
a real feel for how to run and operate the plant,
including how to react to changes in the process
and how the process reacts to any changes that
are made in the operation, Rnnberg explains.
The technology used in the training
impressed the operators participating. I was
surprised by the similarity of the program to real
life, stated Pedro Pinto, a team leader with
three years of experience as a process operator.
Although the course was compulsory for the
operators, they were happy to participate. I
think we were all committed to the training and
eager to learn more every day. It was a good
experience, agrees Telmo Rosa, another
operator at Almina with three years of previous
experience.
The operators were quite excited over the
opportunity to have practical issues simulated in
the computers and it was the first training that
they had which was more than only theory,
Hortelan continues.
The participants were clear about the learning
objectives of the training: To learn about the
circuits, how they work and how we can achieve
better results. The basic training lasted for one
week, but according to the operators it could
have been longer. Their expectations were
fulfilled, and they gained expertise that benefits
them in their everyday work. We learned about
the performance of the circuits, parameters and
levels. We tried almost everything in the
training, Rosa says. For me the reaction times
and learning to react to the circuits were the
main benefits, Pinto adds.
The operators were tested both at the
beginning and end of the training . Based on the
Outotecs Virtual Experience Training, designed
mainly for concentration plant operators
provides operators with a safe and controlled
environment to study process dynamics,
process equipment and control systems
tests the learning curve was tremendous,
improving from a knowledge level of 43% to
96%.
We now have more confidence in making
decisions. I believe our learning grew by 60%. It
was a very useful course, and I would recommend
it to operators at all levels, Rosa said.
Although we felt that the training was
expensive, it was worth it. After the training we
realised that our operators were able to provide
insights and suggestions regarding the process,
changes and reactions to the process changes.
Now our operators understand the complexity of
the flotation process and are not in the dark.
They can identify what is important in the
process, Gil summarised.
The operators are more confident and
committed, and they are eager to apply what
they have learned. By offering this training, we
have also strengthened the bond between the
operators and the company. I would recommend
this training to other operators as well, Gil said.
The basic training as offered to Alminas plant
operators can be followed by advanced training,
helping operators further understand and
analyse the flotation process. They also learn to
interpret trends and optimise the process by
using additional intelligence tools. The cost and
revenue structures of the process circuit,
maximising recovery and maximising profit in
changing conditions are also taught.
and new plants
Rio Tinto Alcan (RTA) Gove was embarking on a
$3 billion expansion of its alumina refinery in
Australias Northern Territory. The expansion
was expected to nearly double alumina
production, and was predicted to have a 10%
improvement in recovery of alumina from
bauxite and a 25% reduction in residue through
improved digestion technology. RTA Gove had
not previously used this digestion technology
which represented a significant operational risk.
In order to mitigate some of the risk, RTA Gove
decided to develop an operator training
simulator of the process.
RTA Gove turned to Honeywells UniSim
simulation technology for testing and training. A

UniSim simulator was constructed and connected
to RTA Goves distributed control system (DCS)
to mitigate the risk by training the operators and
testing the control system configuration prior to
plant commissioning. The benefits achieved
through the use of UniSim include:
Operators were trained in advance without
adversely affecting plant operations
Simulator allowed for comprehensive code
testing before transferring data to the site
Operating procedures were created and
validated.
The RTA Gove bauxite mine and alumina
refinery are located at Nhulunbuy on the Gove
Peninsula in the east Arnhem Land region of
Australias Northern Territory. The expansion
increased alumina production from 2 to 3.8
Mt/y. The double digestion process chosen to
be an integral part of the expansion uses both
low temperature digestion for removal of
trihydrate alumina followed by high temperature
digestion for the monohydrate alumina. Few
double digestion circuits are in use today so RTA
Gove could not learn from other refineries
experience. Without a simulator, it would be
difficult to effectively train operations personnel
without adversely affecting plant operations.
Another hurdle was that the control system
architecture involved interfacing between
multiple DCS platforms, presenting a strong
probability for a mismatch of data.
RTA Gove chose UniSim to maximise the
effectiveness of its new double digestion
technology by enabling many months of
operator training prior to plant startup. UniSim
Operations is a direct connect, full replica,
dynamic process simulator. It is an integrated
collection of computer and control system
hardware and software, which allows a high
fidelity model of the process to run in real time
and appear from the DCS console as though a
real plant is being controlled.
UniSim software contains a library of modules
that mathematically represent the behaviour of
process equipment, logic and control
components under dynamic conditions. The
modules include heat and material balances,
operating equations, thermodynamics and physical
property calculations. These modules are used
as building blocks to create a realistic
representation of a specific process, area or plant.
At RTA Gove, the digestion process model
includes 135 tank modules, 85 pumps, 1,037
control valves and approximately 158 other
pieces of unit process equipment such as heat
exchangers. There are 386 field operated
devices, mainly manually operated valves and
7,370 control points are simulated. Training
features include 1,242 malfunctions. The
process model takes about 0.2 cpu seconds to
run on a personal computer and the model runs
every two seconds, which is more than sufficient
to realistically simulate the process dynamics.
In order to enable operator training in
advance of plant commissioning, the control
system had to be developed six months earlier
than would have been necessary without the
simulator. While this placed an additional
burden on the control system engineers, the
system was able to be tested and commissioned
on the simulator well in advance of plant
commissioning. This resulted in more than 240
suggestions ranging from nice to haves to
critical needs. This meant that the control system
was fully tested and operational prior to
commissioning allowing the commissioning
engineers to focus on the process and equipment.
One of the biggest benefits weve received
from UniSim is improved operator effectiveness.
Like most operating alumina refineries, our
equipment is operated continuously and many
operators are not well practiced in running
under startup, shutdown or emergency
conditions. Similarly, in new installations,
operators may have even less skills in managing
the process and the knowledge of the
equipment limits, even under normal operating
conditions. UniSim enabled us to train our
operators in advance so they could practice new
skills without adversely affecting the plant,
said Manoj Pandya, Manager , Alumina Projects,
Rio Tinto Alcan.
The RTA Gove project was delivered to enable
many months of operator training prior to plant
startup. This resulted in the operators being
knowledgeable on the process and the control
system, and how to control the process. Thus
the operators became a valuable part of the
commissioning team and were able to retain the
lessons learned from commissioning. IM
RTA Gove turned to Honeywells UniSim
simulation technology to tests and validate a

new process, and train operators
I
n July, Canadas Centre for Excellence in
Mining Innovation (CEMI) announced that the
provincial government is supporting mining
research with an investment of C$2.24 million
from the Ministry of Research and Innovations
Ontario Research Fund-Research Excellence
program (ORF-RE). Laurentian University will be
working with CEMI and colleagues at the
University of Toronto and Queens University in a
broad research effort to improve both safety and
efficiency in deep mining. CEMI has been
instrumental in the design of the research
program and will play a lead role in ensuring
successful outcomes.
The funding leverages industrial contributions
from Vale, Xstrata Nickel and Rio Tinto and will
support the work of more than 75 researchers
and students in a project called Smart
Underground Monitoring and Integrated
Technologies (SUMIT) for Deep Mining, with
Laurentian University as the lead applicant in
the initiative.
SUMITs goal is to apply smart engineering
principles and technologies to make major
advances in the deeper mining operations of the
future. Its 14 core projects are focussed on three
major challenges of sustainable mining at
deeper elevations: Mitigating GeoRisk (for both
workers and investors); Rapid Underground
Development (more efficient excavation), and
Mine Sustainability (better management of
energy, materials, and mine waste).
The kind of research being undertaken by
Laurentian and its partners is critically
important to the future of the mining industry in
Canada and abroad, said Laurentian University
President Dominic Giroux. There is no question
that mines will go deeper in future years as ores
are exhausted at current levels. Laurentian will
be in the forefront of making that work both
safer and more productive.
Dr Peter Kaiser, Principal Investigator for
SUMIT, Chair of Rock Mechanics and Ground
Control at Laurentian and President/CEO of
CEMI, added, By leveraging the collective
expertise and knowledge at Laurentian, Queens
University, and the University of Toronto, we will
be able to contribute to game-changing
knowledge capacity in how the world designs
mines and controls mining operations.
Kaiser explained that in the SUMIT network,
participating mines will serve as living
laboratories so that researchers and innovators
can test next generation technologies and make
observations in the field to facilitate early-stage
innovations in the underground work
environment as well as to produce tested
solutions.
CEMI develops excellence in mining innovation in
the areas of exploration, deep mining,
integrated mine engineering, environment and
sustainability for the metal mining industry. Its
mandate is to deliver innovation to the mineral
industry, from idea to implementation, with one
of the most experienced R&D leadership teams
in the country, and with core competencies in
these fields.
Some of the outcomes expected are:
Ability to detect mine-wide deformation
patterns and to better understand stored
energy flow patterns in active mines
Means to detect higher risk geological
structures that may pose a risk to investors
Engineering rationale to systematically
design rock support in fault-, slip-, burst-
prone mines
Ground control management techniques to
facilitate the implementation of game-
changing mechanised excavation technology
Scientific evidence to implement Ventilation-
on-Demand (VOD) as an energy saving
change
Produce 75 person-years of research, leading
to significant knowledge and science
advances
Value optimisation and efficiencies in mining
operations
Best practice guidelines emphasising worker
health and safety and considering the unique
worker environment, helping to ensure the
safest worker environment possible
Knowledge transfer initiatives such as
website or wiki-based guidelines and short
courses. This knowledge will be made
available to universities and
mining/engineering firms.
Last November, the Rio Tinto Centre for
Underground Mine Construction (RTC-UMC) was
established as a division of CEMI, located in
Sudbury, Ontario. Rio Tinto will be investing
C$10 million over five years to undertake
research lead by the centre to speed-up mine
development with mechanised excavation
technologies including two tunnel boring
systems (TBS) and a shaft boring system (SBS).
The RTC-UMC is undertaking research into
ground and machine performance. For this
purpose, prototype test sites are being
instrumented to improve ground
characterisation techniques and to develop
innovative support systems to facilitate high
DEEP MINING
John Chadwick looks at progress in deep
mining research, advances in ventilation
and cooling, hoist rope monitoring, mine
support and development
Shaft portal at Union section platinum (Anglo
American), South Africa; courtesy of VisMedia
DEEP MINING
speed, mechanised tunnel and shaft excavation
technologies for underground mines in highly
stressed ground and at depth. With the support
of Rio Tinto, CEMI will be collaborating with
recognised researchers in Canada and around
the world.
In 2007 the Deep Mining Research
Consortium (DMRC), another Canadian
innovation program, completed the first round of
projects and began developing new projects
based upon a cost model strategy. One
completed project focused on Diesels at Depth
(2004-2007). Since air density decreases with
altitude, fuel/air ratios get richer and diesel
engines no longer operate optimally the
performance of the engines decreases,
producing more toxic emissions.
The effects of operation at great depth are not
well known and could include reverse effects
due to a leaner fuel/air ratio and possible
shortcomings/failures of the engine and its
associated control modules and systems. The
effect of operation at great depth could vary
depending on the type of engine, i.e. naturally
aspirated, turbo charged and/or electronically
controlled engines.
CANMET-MMSL conducted field experiments
that examined these factors and focused on the
effects of increased barometric pressure and
intake air density on diesel engine emissions in
a deep production mine. The completed project
research shows engine performance is
consistent with extrapolations from high
altitude studies. Increased levels of NOx at
depth should be expected, whereas particulates
are reduced. Instrumentation for measuring
diesel performance at depth is reconfigured.
A second project developed Gelfill as an
alternative fill system (2004-2008): A solidifying
backfill that can be placed quickly contributes to
the stability to deep mining zones. Gelfill holds
the promise of good flow characteristics and the
ability to set without drainage. This is achieved
by controlling additives such as sodium silicate.
This DMRC project included a series of
laboratory and underground trials to optimise
the Gelfill process. A cost-benefit analysis
compared Gelfill to hydraulic and paste fill
systems for various deep mining scenarios.
Encouraged by the early findings, the
consortium members decided to proceed with
additional trials on the path to implementation.
The Hoist Rope Inspection Automation (2004-
2006) program is designed on the premise that
maximising the automation of rope inspections
would add to hoist time in all types of mines,
thereby increasing revenue. High speed, cost-
effective cameras and vision system algorithms
detect rope defects and measure rope diameter
while the hoist rope is moving. Computer-based
signal analysis and pattern recognition systems
interpret loss of metallic area (LMA) and local
faults (LF). Neither of these technologies had
been used previously for hoist rope inspection.
An automated wire rope inspection system
was developed and successfully replaced the
daily, manual hoist rope inspections at Xstrata
Coppers Kidd D Mine in Timmins. Installed in
April 2006 following pilot installations at Vales
Garson mine in Sudbury and BHP Billitons
Leinster mine in Australia, the computer
visioning system performs a 360 inspection of
ropes and detects broken wires with the hoist
skipping ore at full speed.
The Thin Spray-on Liner (TSL) project is
monitoring and addressing all health and safety
issues associated with spraying with
Isocyanates and is testing and evaluating
manual application systems for the TSL.
It has shown that adequate toughness
sufficient to prevent tearing and blast damage
demands the use of Isocyanates in TSL
formation. Adequate coverage given a rough
blasted surface and a minimum application
thickness of typically 4-6 mm imposes special
requirements concerning a) TSL formulation b)
application process control. Adhesion failure
together with bolt connectivity is required in
order to mobilise TSL capacity in the limit of
rock failure.
Ventilation at depth
The VOD project is installing, testing and
measuring the efficiency of novel Ventilation on
Demand technologies to decrease energy costs
and increase productivity. It should increase
productivity and decrease the environmental
Rio Tinto is investing C$10 million to undertake
research led by the Rio Tinto Centre for
Underground Mine Construction to speed-up
mine development. Its Argyle underground
block-cave project is large and complex,
requiring more than 40 km of tunnel
development
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ENERGY DISTRIBUTION
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TRANSPORTATION
impact of energy consumption. The project
focuses on two sites: Vales Coleman and Xstrata
Nickels Nickel Rim South mines. The technical
solution at Coleman (for the 153 orebody -
153OB) is provided by BESTECH and at Nickel
Rim South Mine by Simsmart Technologies.
The mining methods are very different. The
installation of the VOD system was a retrofit to
the existing orebody at Coleman 153, and a part
of the new mine design at Nickel Rim South. The
two test sites thus provide a wide spectrum of
VOD implementation.
At this years CIM Conference in Montreal,
Vales Cheryl L. Allen and BESTECHs Trang Tran
presented a paper on Ventilation-on-demand
control systems impact on energy savings and
air quality. They noted that increasing energy
costs associated with mining have become an
issue that must be addressed by industry to
ensure sustainable production. As underground
mine ventilation systems account for 40% to
50% of a mines total energy requirement,
initiatives to
maximise their
efficiency have been
introduced
worldwide.
For primary
ventilation, surface
fans downcast air via
the Coleman shaft
and McCreedy East
#1 ventilation shaft
and underground
booster fans
exhausting to the
mined out workings
of Coleman, Levack
and adjacent Xstrata
mine. The original
ventilation system
was designed to
supply a constant
volume of air to
levels or areas of the
mine which are
active; but may or
may not have
constant mining
activity.
153OB is narrow
vein and currently
mined by cut-and-fill. Air is supplied to the zone
via a fresh air raise where it is distributed by
booster fan(s) attached to the raise on each
level. As the air travels across the footwall drift
to the exhaust raise access it is picked up by
auxiliary fans located at each stope access.
These auxiliary fans push the air, through
ducting, to the working face and back via the
access drift to the level footwall drift where it
travels to the exhaust raise and enters through
regulated louvers.
The VOD control method, its strategies and
impact on energy consumption and flexibility of
airflow distribution as commissioned at
Coleman Mine was demonstrated as part of an
overall energy management control system
known as NRG1-ECO
. The VOD uses five control

strategies ranging from manual to fully
automated operation using air monitoring
sensors and activity based asset tagging to
adjust the ventilation system by responding to
the activity of mine personnel and air quality.
The system provides real-time monitoring of all
the variables to optimise the control of all
connected equipment.
Allen and Tran explain the system achieves
efficiency by having NRG1-ECO adjust fan speed
and louver position settings in unison to
established set-point flows on the levels. The
use of ramping techniques ensures stable
system responses which mitigate hunting
following minor ventilation disturbances; which
allows the entire system to become more
efficient at directing and channelling the air
supply to the desired regions.
The ability to supply air to where it is
needed and reduce where it is not required
allows any available air to be redirected to
additional mining areas; without increasing the
total airflow to the mine. This flexibility has
potential for increase in mine production.
The application of VOD technology benefits
the environment through the reduction in energy
consumption helping to reduce environmental
impacts from greenhouse gas emissions. For
every kW reduction in energy, Coleman mine is
reducing its carbon footprint by 1,577 kg of CO2.
The estimated energy savings based on the
current VOD configuration at Colemans 153OB is
3,000,000 kWh which is a reduction of 540 t of
CO2/y.
They conclude that the business case for
implementation of a VOD system is based on
energy savings. However, secondary benefits
DEEP MINING
Many types of environmental monitoring
sensors can be integrated into BESTECHs
NRG1-ECO control system to monitor various
parameters including temperature, relative
humidity, carbon monoxide (CO), carbon
dioxide (CO2) and nitrogen monoxide (NO);
providing real-time data to support Ventilation-
On-Demand
such as increased productivity, continuous
monitoring of workplace environmental
conditions, and reduction in mine air heating
fuel can be realized. Further expansion of the
energy management system could include
electronic tag-in/tag-out boards, quick response
of employee location in the event of an
emergency, and awareness of system efficiency
through key performance indicators.
The future is very bright for ventilation-on-
demand, CEMI R&D Program Director Glenn
Lyle told the Sudbury Mining Solutions Journal.
The ability for a mine to be able to effectively
and efficiently move air from one area of a mine
to another will be a tremendous benefit in terms
of energy savings because you dont have to
ventilate to the same levels all the time.
Another equally important benefit is the
ability to increase production by putting the air
where its needed. Most mines tend to be more
ventilation constrained than production
constrained, said Lyle. If you had ventilation
available, you could likely achieve higher
production rates.
CEMI is moving to develop a follow on project
from the VOD. The VOD project was seen as
Phase I and CEMI is currently scoping the next
phase. The goal is to address industry wide
issues associated with the implementation of VOD.
A new tool developed by Sudbury-based
Objectivity links a simulator and a ventilation
solver and calculates the demand for ventilation
based on the number and location of equipment
in the mine at a given time, explained Lyle. This
information is then fed into the ventilation
solver to determine the airflows required on the
various mine levels. The tool will help mining
companies make decisions about moving
forward with VOD systems.
Andrew Dasys, President of Objectivity,
explains that Objectivity developed the
modelling software in order to build a business
case for VOD. The software is called VREX -
Ventilation Rules Engine. The software uses
data from a production model, a long term mine
plan or from an RFID feed to determine what the
specific air demand is in a mine over time. It
then has a number of rules that allocate this
demand to a ventilation model. VREX can also
perform some optimisation to determine the
lowest cost to deliver the air to the designated
working areas.
VREX provides a means of determining
detailed air requirements for any number of
production scenarios, and then it can determine
where capital should be invested and what type
of VOD system should be installed to maximise
payback. Because we are not in the business of
installing VOD systems VREX allows us to create
an objective assessment of the levels of savings
that VOD can bring to operations while taking
into account their specific production profiles.
As part of the VOD project the software also
explores how changes to fleet propulsion
systems will affect ventilation costs - thus it is
possible to determine the benefit of changing all
support vehicles from diesel to electric engines
and see if there is a direct ventilation cost
decrease. Or to determine what affect changing
ventilation legislation may have on ventilation
cost.
The VREX models and initial data collected at
both VOD test sites indicates that there is a
significant amount of energy (electrical and gas)
costs to be saved when using VOD, however the
greater benefit is in creating a safer working
environment and in better allocating the air.
When viewed at a mine wide level this also
provides the opportunity to potentially increase
production by moving air from areas where there
is no activity and scheduling production
activities when there is surplus, air available.
Part of the VOD II focus is to determine what the
production benefits of better air use can be.
If youre going to have VOD, you need to
have a good, reliable sensor network because as
youre moving quantities of air throughout a
mine, you want to know that what you expect to
happen is actually happening, said Lyle.
VOD relies heavily on feedback from sensors
installed underground, so there has been a fair
number of learnings about making sure the
sensors are in the right location, that theyre
DEEP MINING
properly calibrated and properly maintained.
Simsmart's SmartEXEC (Smart Expandable
Energy Control) system is purpose built for
mining. It challenges existing and new ventilation
design and performance through engineering
analysis for total system optimisation. Savings
can potentially exceed 50%.
SmartEXEC is the new upgraded version of
OMVOD (IM, September 2010, pp54-56) that
includes optimisation capability of all mine
electrical consumers in addition to the
ventilation elements. ABB and Simsmart have
worked together extensively on this (IM,
September 2010, pp54-56).
The SmartEXEC system interfaces with a
mines infrastructure to provide real-time control
of existing, expanding, or new ventilation
systems. Using Open Connectivity (OPC), the
control technology is seamlessly integrated into
ventilation design, connecting directly to
Process Logic Controllers (PLCs) via existing
communication structures. This permits
immediate implementation into existing mines
by adding VOD control directly to existing
infrastructure. Since the system interacts
directly with the PLCs, it is not restricted in its
integration or control capabilities. This unique
ability enables mines in any operational state to
reassess their energy needs and find a solution
that fits.
Depending upon the mines size and
production needs, the SmartEXEC system can be
commissioned to use either conventional control
based on physical measurement and demand;
or optionally, mass-flow balance control which
calibrates the optimal air flow for a specific area
based on depth, temperature, air quality, and
demand. While VOD conventional control is
standard in the SmartEXEC system, providing
true optimisation requires constant airflow
balancing and calibration. The optional mass-
flow balance control is a unique feature of the
SmartEXEC system and provides the highest
degree of energy optimisation.
Simsmart works on turnkey projects with its
global partners for electrification, fan motors
and drives, air flow regulators, air quality and
flow instrumentation, automation,
communications (voice and data), tracking and
installation.
Monitoring progress
Also involved with VOD projects, Kirk Petroski,
President & CEO of Symboticware quotes IBMs
Envisioning the future of mining White Paper,
October 2009: New technologies will make a
mine and both its local and remote managers
smarter by becoming instrumented,
interconnected and intelligent - Assets will be
instrumented, interconnected and intelligent,
reporting their location, their status and other
key metrics remotely and automatically
His company is an innovator and integrator of
standardised information-based technology that
enhances the productivity of mobile mining
equipment and mining processes. At the core of
Symboticwares solutions is the SymBot. The
SymBot is used in monitoring applications for
productivity gains, risk mitigation, energy
savings and as a platform for new development
projects where real-time data collection is
crucial for making better and informed decisions.
It offers bi-directional, store-and-forward,
data standardisation and remote configuration
capabilities. Data collected is processed and can
be analysed on-board for real-time reporting
and alerts. Standardised data is also delivered
to data management systems for centralised
control centres and management reporting.
Symboticwares intelligent monitoring system
provides a solution to the industrys ever
increasing need for real-time monitoring.
Monitoring and data applications delivered
through the SymBot include engine monitoring,
automated pre-operation checklist, automated
production statistics, dynamic load weighing,
emissions monitoring, location tracking,
proximity detection, traffic control, tyre pressure
and temperature monitoring, custom data
applications. To date the Symbot has been
integrated with OEM vehicles including
Caterpillar, Atlas Copco and MTI, and as a
standalone third party system can be integrated
with any OEM. Industry adoptors of
Symboticwares technology include Vale, Xstrata
Nickel, Baffinland Iron Mines and Peregrine
Diamonds. Symboticware has recently entered
the US market by partnering with TEC Systems
Group, an electrical, engineering, automation
and software company that that has serviced
Fortune 500 industrial companies since 1984.
SymBot projects include:
An open information management platform
for underground mobile equipment
Sensor network and data collection for VOD
An integrated open Wi-Fi
/ZigBee
sensor
network for process automation underground
SymBot as a critical component for remote
mine exploration, development and
operations in the far north.
DEEP MINING
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Published every two weeks, IM Project News is
crammed with valuable information
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Beyond that, we look at projects in
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At any one time there can be 8,000
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Contact emma@im-mining.com PROJECT NEWS
Project News (21) June 10, 2007
News from those projects making progress towards production more every two weeks
A collection of recent starts and progress reports from around the world - updates on
projects around the globe likely to be in the market for equipment and services.
A collection of recent starts and progress reports from around the world - updates on projects around the globe
likely to be in the market for equipment and services. ..................................................................................................1
PREFEASIBILITY.........................................................................................................................................................2
MEXICO - Tyler Resources - COPPER/GOLD....................................................................................................2
PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD...............................................................................3
PERU - Strike Resources - IRON ORE.................................................................................................................3
SLOVAKIA - Tournigan Gold - GOLD.................................................................................................................4
ZAMBIA - African Eagle Resources - COPPER....................................................................................................4
COLUMBIA - Greystar Resources - GOLD/SILVER...........................................................................................4
USA - Galway Resources - MOLYBDENUM/TUNGSTEN.................................................................................5
CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER.........................................................5
AUSTRALIA - Heron Resources - NICKEL.........................................................................................................6
ARGENTINA - Minera Andes - COPPER..............................................................................................................6
AUSTRALIA - Independence Group - GOLD.......................................................................................................6
RUSSIA Polymetal - GOLD................................................................................................................................6
FEASIBILITY STAGE..................................................................................................................................................7
BURKINA FASO - Goldbelt Resources - GOLD.................................................................................................7
USA - Great Basin Gold - GOLD/SILVER.............................................................................................................7
AUSTRALIA - Moly Mines - MOLYBDENUM....................................................................................................8
CHINA - Golden China Resources - GOLD...........................................................................................................8
AUSTRALIA - Goldstar Resources - GOLD.........................................................................................................8
CANADA - Western Copper Corps - GOLD/SILVER.........................................................................................9
AUSTRALIA - Minotaur Exploration/ Helix Resources - GOLD/SILVER............................................................9
SOUTH AFRICA - Eastern Platinum - PGMs .......................................................................................................9
USA - American Lignite Energy/ Headwaters Energy Services/ Great River Energy/ The North American Coal
Corp LIGNITE.10
CHILE - Freeport-McMoRan Copper & Gold / Codelco - COPPER.......................................................................10
USA - FutureGen Alliance - COAL.......................................................................................................................10
CANADA - Atlantic Gold - GOLD.......................................................................................................................10
MEXICO - Baja Mining - COPPER/COBALT/ZINC/MANGANESE..............................................................11
GREENLAND - True North Gems - RUBY.........................................................................................................12
CANADA - North American Tungsten Corp - TUNGSTEN................................................................................12
MONGOLIA - Western Prospector Group - URANIUM.....................................................................................12
ALGERIA - Terramin Australia - ZINC/LEAD....................................................................................................13
INDONESIA - Finders Resources - GOLD/COPPER........................................................................................13
COTE DIVOIRE - Etruscan Resources - GOLD...............................................................................................13
SAUDI ARABIA - ADV Group/ Bariq Mining - GOLD/COPPER........................................................................13
BRAZIL - Mirabela Nickel - NICKEL...................................................................................................................14
PERU - Monterrico Metals - COPPER/MOLYBDENUM...................................................................................14
AUSTRALIA - Gindalbie Metals/ Anshan Iron & Steel Group - IRON ORE........................................................15
CANADA - Canadian Royalties - NICKEL/COPPER/PGM..............................................................................16
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Contact emma@im-mining.com PROJECT NEWS
PREFEASIBILITY.........................................................................................................................................................2
PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD...............................................................................3
CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER.........................................................5
CANADA - Western Copper Corps - GOLD/SILVER.........................................................................................9
Corp LIGNITE.10
COTE DIVOIRE - Etruscan Resources - GOLD...............................................................................................13
SymBot showing loader status
DEEP MINING
At the recent 2011 Australian Mine Ventilation
Conference, Mark Ogle from Tahmoor coal mine
pointed out that booster fans are relatively rare
in Australian coal mines. However, as mines
become progressively deeper it is likely that
such fans will be increasingly adopted as a
method to sustain or improve the ventilation of
underground workings. The reasons why
booster fans may be an attractive alternative
include:
Increased cost of sinking additional
ventilation shafts with greater seam depths
Environmental objections to shaft sinking
projects
Increasing urbanisation limiting availability of
potential ventilation shaft sites.
Tahmoor Colliery recently implemented a
major ventilation upgrade, which involved
installing significantly larger surface fans on an
existing shaft. However, the two major
ventilation splits underground were not well
balanced, meaning the higher-resistance split
(containing the longwall face) could not receive
the full benefit of the higher pressure and
quantity delivered by the new fans.
Extensive ventilation modelling was carried
out to evaluate various potential solutions and
the recommended option was the installation of
a booster fan or fans.
Proposals were sought from recognised fan
manufacturers and various alternative
arrangements were tendered. Ultimately the
choice was between one large centrifugal fan
and a set (three or four) smaller auxiliary-like
fans in parallel. The successful tender was for a
single centrifugal, an arrangement very similar
to the booster fans that have been operating
effectively at Westcliff Colliery for a number of
years.
The latest SwedVent underground ventilation
fans and ducting systems from GIA Industries
are being installed in six Russian mines
including the Apatit and Olcon mines in
Murmansk; the Mayskoe mine in Eastern
Russia; Alrosa mine in Udachnaya; and the
Magadan Lunnoe and Ducat silver mines.
Four 2AVH224 fan systems have been delivered
to the Apatit mine, each delivering 145 m/s
down the shaft of Russias largest underground
phosphate operation. The fan station has been
installed inside a pre-heated building to blow air
at not less than +2 into the mine.
A similar fan house and pre-heated building
has also been constructed at Olcon, Olenogorsk
in Murmansk housing four SwedVent 2AVH224
fans.
Highland Golds Mayskoe mine is one of the
countrys largest known undeveloped gold
deposits. Two AVH180 fan systems delivering
130 m/s were delivered in September 2010 for
the underground operation. And two AVH160
fan systems have been ordered by the Magadan
Lunoe underground mine in North East Russias
Omsukchan district.
A further two AVH224s, each delivering 104
m/s have been delivered to Magadans Ducat
silver mine. Meanwhile at the Alrosa Udachnaya
mine, a 3AVH125 fan with a duct diameter of
1,400 mm has been installed at the portal
during the driving of the 1.8 km shaft.
The recently introduced new generation of
SwedVent fans features improved silencer
design to provide noise reductions of at least 3
dB(A) for the full range of fan motors rated
between 10 and 500 kW to achieve 75 85
dB(A) at 7 m. The improved sound damping is
due to a specially designed silencer filled with
processed mineral wool to reduce high
frequency sounds.
The ventilation system features advanced
impeller design incorporating a large hub, short
blades and, accurately measured spacing between
the blades to give the fan an enhanced ability to
counteract high pressure systems. The dynamically
balanced impeller rotates in purpose-designed
guide vanes to eliminate turbulence.
Individually adjustable aluminium blades
allow the same fan to be used for a number of
different ventilation conditions by adjusting the
blade angle. For example, a 1,250 mm diameter
fan can be set to deliver 16 44 m/s. The range
of SwedVent fans is available in 630-2,240 mm
diameters with capacities of 1.5200 m/s.
Heat stress
In deep mines, workers can be exposed to very
high ambient air temperatures as a result of
high rock temperatures, auto-compression of
the ventilation air and heat generated by the
mining machinery. While several solutions are
available to combat heat, the cost/benefit of
each must be investigated carefully.
Conventional means of heat control, including
significant increases in the volume of ventilation
to remove the heat or the commissioning of
large refrigeration plants to cool the air can be
very expensive. This could result in rich deep
reserves being left un-mined.
DMRC determined that the economic
benefits from a better understanding of the heat
exposure issues and how they impact on
ventilation system design are likely to be
significant. The objective of this project is to
provide a Heat Stress Index along with a Code of
Practice that may be applied in most Canadian
deep mines. As well as define further studies
heat stress management and heat control. To
date the following tasks have been completed:
Base case measurement of body temperature
(energy expended) by mining task (including
rescue activity) for underground workers
under "hot" conditions
Laboratory simulation study of mining tasks,
measuring associated heat loss while
accounting for a) physiological characteristics
and b) clothing
Early findings contributing to heat stress
management at Vale-Inco.
This project is expected to deliver (over ~ five
years):
Identification of those individuals particularly
at risk of suffering from heat stress
Best practices designed to combat heat
stress including work habits, mining
strategies and dress code
Innovative personalised body coolers.
South African BBE is a group specialising in
mine ventilation, refrigeration and cooling. BBE
provides a comprehensive service from
The latest SwedVent underground ventilation
fans and ducting systems from GIA Industries
are being installed in six Russian mines
conceptual investigations, through technical
feasibility studies, to preparation of detailed
engineering design specifications and project
execution and management. It recently
completed a R3-mllion EPCM contract to design
an underground cooling circuit at Palabora
Mining Cos (PMC) copper mine in Phalaborwa,
Limpopo Province. BBEs design makes
provision for two refrigeration machines to
provide cooling to current workings and mine
development.
The underground cooling circuit comprises
two 1.5 MW Bulk Air Coolers (BAC), 3.0 MW of
cooling coils, chilled and warm water dams, two
3.5 MW refrigeration machines and a 9 MW
condenser spray chamber. The refrigeration duty
not used for the BACs will be used for cooling
coils. The circuit will be located underground on
the Production Level, some 1,200 m below surface.
BBEs lead engineer on this project, Marle
Hooman, says refrigeration systems are not
often located underground at this depth, which
is quite shallow compared to other mines.
However, at PMC high ambient conditions are
experienced throughout the year and the
surface virgin rock temperature as well as the
geothermal gradient of the rock is high,
explains Hooman. Trade-off comparisons were
conducted prior to this work to arrive at the
most favourable refrigeration system. We made
our decision based on achieving the best
efficiencies and lowest operating costs, as well
as a variety of practical advantages.
Construction of the second BAC, condenser
spray chamber, dams and the first refrigeration
machine were expected to be completed by
November 2011.
BBE has worked with PMC on ventilation and
cooling studies since 2004, including various
studies on ventilation layout and mine planning
using the BBE Groups proprietary VUMA-
network (a simulation of steady-state
environmental conditions encountered in
underground mines). More recently, BEE has
been involved in an EPCM project for PMCs
headgear cooling system.
DPM management
The presentations made at MDEC 2010
conference and diesel workshop are now posted
on the website: http://www.mdec.ca/2010/
(thanks to Dr Mahe Gangal). The following is
just some of the important news from that.
Vale employs over 800 diesel-powered units
at its mines in the Sudbury basin. The company
is exploring the use of alternative power
(e.g. electricity, fuel cells) but diesel-powered
vehicles will continue to be a very important
component of underground mining for many
years to come. So Vale is lessening diesels
undesirable features such as noxious
substances in its exhaust.
DEEP (Diesel Emissions Evaluation Program
www.deep.org) has shown that reducing
emissions of DPM from diesel vehicle exhausts
is not a simple task. Older diesel engines,
particularly heavy-duty engines, are the primary
generators of DPM. Newer engines, which are
electronically controlled, are better, but many of
these engines cannot reliably meet proposed
DPM levels. Engine maintenance is an essential
component to having diesels perform while
limiting deleterious emissions, but maintenance
will not by itself be able to reach very low DPM
specifications. Alternative fuels, such as
biodiesel, can assist in lowering DPM emissions,
but will achieve no more than 30-50% reduction.
The best technology for achieving dramatic
reductions in DPM emissions is diesel
particulate filter (DPF) systems, according to
Vales J.S. Stachulak and Doug OConnor. They
reported on extensive tests conducted under the
auspices of DEEP at Vales Stobie mine from
2000-2006. While many of the DPFs tested
there showed good performance for extended
periods of time, the main challenge remaining to
be overcome in implementing DPF system
technology on underground vehicles is to
eliminate the human parameter from their
operation.
With the experience gained from the DEEP
testing at Stobie, Vale is well positioned and
committed to continue its evaluation of DPFs for
the underground environment. More than 50
manufacturers worldwide offer DPFs capable of
filtering DPM, but this number was reduced
significantly by application of several service
and performance criteria. In selecting units for
testing, consideration was given to the expected
DPF reliability, along with its technical and
operational viability under the duty cycle of the
vehicle. The technical support of the DPF
manufacturer and the experience attained
Bulk air cooler for
Palabora mine
DEEP MINING
elsewhere in a particular DPFs use was also
considered.
Tests of two identical MANN+HUMMEL SMF
AR DPFs on two quite different light duty diesel

vehicles at Vales Creighton mine demonstrated
that this system can successfully address soot
emissions control for light duty vehicles with
differing soot emission levels, exhaust
temperatures and duty cycles. This DPF system
is capable of adapting to and thus working in
different operating modes: if needed the active
electrical regeneration takes place; if not the
system regenerates passively (without electrical
heating). In all cases the dosage of the FBC is
moderated to optimise performance against
cost.
Other than the obvious benefits of clean
exhaust and no downtime during operation, the
system is compact, demonstrably robust, and
has long (500800 hours) service intervals.
The SMF-AR DPF system consists of a pleated
sintered metal particulate filter surrounded for
part of its length by an electric heating element,
a controllable FBC dosing system, and a control
unit with self-adaptive control software. They
conclude that the advanced technology of the
system is applicable in the mining industry and
fulfils the expectations of diesel particle
filtration for light duty vehicles. In particular it is
effective in exhaust soot reduction, regenerates
automatically with no effect on operating cycle,
is tolerant of engine variations and of changing
operating cycles, is compact, robust and uses
on-board vehicle electric power.
IMreported in November 2010 (p4) on Rypos
HDPF filters on diesel equipment underground
at the Detroit salt mine.
Kevin Morris presented Biodiesel Test at
Kinross Gold Paracatu Mine. Analysing the
performance of the CAT 3508 diesel engine,
which is used in the 777C haul trucks, as per the
dynamometer test, it was demonstrated that
biodiesel did not significantly alter the power
output for mixtures with percentages of 5 to
50%. For higher percentage mixtures, Caterpillar
noted a reduction in the power. Caterpillar
considers power loses below of 3% to be
acceptable. However, for loses in the range of
greater than 3% Caterpillar considers these to
be problematic.
He noted the important reduction in gas
emissions in diesel exhaust:
Unburnt hydro carbons 14%
Carbon Monoxide 9%
Particulates 8%.
He also noted biodiesels increase in fuel
lubricating properties due to its low viscosity
and ability to degrade in cases of fuel spills.
But against this he explained biodiesel can
cause deposits that build up on the membranes
of the fuel filters resulting in a rapid clogging
the problem worsening when the concentration
of biodiesel increases. Biodiesel also produced
a 2% increase in NOX. Pure biodiesel is 5 to 7%
less efficient than regular fuel.
The fibres in the filter membrane are
hygroscopic, and attract water. The attraction
between the filter and water is greater than the
attraction between water and diesel. As the
water continues being attracted by the filter,
water drops form and increase of size until they
cannot pass through the membrane and fall into
the reservoir, where they are drained.
The ability of the fuel filter to work is based
on the attraction between the filter membrane
and the water being greater than the attraction
of diesel and water. When the Biodiesel is
added, it significantly increases the attraction
with the water. Hence, the water will pass
through the filter and will not be separate,
rendering the filter effectively useless.
Underground transport
In July the Government of Canada, through
Sustainable Development Technology Canada
(SDTC), announced investments in clean
technology projects in Ontario. One of these is
C$1.5 million to Rail-Veyor Technologies Global
for a rail haulage system. This technology offers
interesting benefits in saving ventilation energy
because of its low emissions and low profile
attributes.
The electrically powered Rail-Veyor system
operates remotely through a control centre and
incorporates a light rail track with a series of
interconnected two-wheel cars capable of
continuous movement. The cars travel at speeds
of up to 12m/s or 32km/h as they climb grades
of 20% and negotiate complex turns within a 30
m radius. The open trough formed by all the rail
cars can unload and transport any ore. The cars
are connected to allow for articulated movement
along curves and for dumping.
A unique drive system consisting of two
stationary drive stations and sensors fully
automate the system and provide the forward
thrust. Speed is controlled by an inverter, which
allows for both forward and reverse movement.
The system is able to start loaded cars from any
position on the track.
Vale-Inco is installing a Rail-Veyor material
handling system at the 114 Orebody adjacent to
its Copper Cliff mine. The Rail-Veyor is a cross
between a railroad and a conveyor system that
is propelled by conventional truck tyres at drive
stations located at intervals along the track. The
tyres provide the forward thrust by turning
against the cars side plates.
Vale is driving twin ramps into the orebody,
one dedicated to the Rail-Veyor, the other to
bring in people, supplies and equipment. The
installation will demonstrate the technology
DEEP MINING
Providing Flexible Mining
Solutions Takes Great Skill.
www.twp.co.za
Rail-Veyor unloading
underground and test an integrated loading
system. The material will be hauled to surface,
dumped and trucked to Vales Clarabelle Mill,
but could also be transported directly to the mill
via the Rail-Veyor at some point in the future.
There is a 37.52 gauge Rail-Veyor test track
at Vales Frood-Stobie site in Sudbury. It is
equipped with a loading, dumping and
reinversion loop to demonstrate the
technologys capabilities, but that kind of
structure would only be possible in a fairly fixed
type of installation, said Peter Golde, Chief
Mine Engineer - Research and Development,
Vale-Inco. The test track is a 750 m loop carrying
53 Rail-Veyor cars.
He explains the mine will need to load the
Rail-Veyor when were doing development work
and extending our ramp systems and production
areas, so were looking at something that is
portable, mobile and compact, in other words, a
continuous loading system at the front end of
the process that will grab the broken muck with
some sort of conveyor system and feed the
train.
Vale is currently testing several loading and
crushing technologies at the test track. It hopes
to minimise the amount of oversize material by
controlling the fragmentation. Work on this is
being done by Mirarco. The objective is to
achieve a total target of 5% of material larger
than 458 mm.
Caterpillar is developing a new product for
underground. This goes back to work originally
started by DBT, which was taken over by
Bucyrus and is now part of Caterpillar. It has
DEEP MINING
Caterpillars RockFlow Mover
been tested at El Teniente in Chile over several
years. The company says block cave mines can
improve production by generating a continuous
haulage stream from the drawpoints by using
the RockFlow Feeder and RockFlow Mover.
The product is ready to market and the first
industrial application will be in 2013 in a copper
mine in Chile. The system offers:
Significant cost reduction
High level of automation of the mining
process, taking miners out of the process
High grade safety and is environmentaly
friendly
No diesel fumes/heat for less ventilation effort.
The RockFlow Feeder takes the rock from the
drawpoints and the Mover is the main conveyor
that they feed onto. They are protected by
international patents/patent applications.
Drill advances
Peterstow Aquapower has completed over 35
trials on its closed-loop hydraulic rock drill,
which uses a fraction of the energy of pneumatic
drills (IM, December 2010, pp22-25). Peterstow
opened its state-of-the-art manufacturing
facility in Swaziland last year to produce the
drills, which were described by Ian Cockerill,
Chairman of Petmin and former Gold Fields CEO,
as a game-changing technology.
The company is now fully operational, having
recruited and trained a strong production,
management and project co-ordination team. It says
the ambitious claims have been proven through
trials with mining companies. Cockerill has since
joined Peterstow as a non-executive Director.
Our environmental claims have been borne
out says Executive Director Alan Barrows. In
deep-level mines our drills use around 5% of the
energy of pneumatic drills, sometimes far less.
But the real result has been its productivity. Our
drill speeds far exceed pneumatic drills. In side
by side trials at 3,500 m [depth], pneumatics
took 13 minutes to drill a 1.2 m hole. Peterstows
drill took two minutes.
Industry has long been enthusiastic, but
switching to a completely new method of mining
is a big decision and needs more than bold
claims. Peterstow has spent the last year
proving these claims in mining environments.
Long-term trials in an operating environment
are nearly complete and results are extremely
positive. Once were established in a few mines
we expect we will have to rapidly ramp up
production to meet orders. That wont be long
now says Barrows. IM
STOUT
Offering a single-source supply
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DEEP MINING
Underground testing of a Peterstow drill
T
he Nordic countries make up a region in
Northern Europe and the North Atlantic
which consists of Denmark, Finland,
Iceland, Norway and Sweden and their
associated territories. Sweden has a history of
mining and metal refining stretching back more
than 1,000 years. Its metallic ore and other
mineral resources, and knowledge about how to
use them, have been major factors in building
the prosperity the country enjoys today.
Sweden is currently one of the EUs leading
producers of ores and metals, according to the
Geological Survey of Sweden http://www.sgu.se/
sgu/eng/om_sgu/index.html. It is, for example,
by far the biggest producer of iron ore in the EU,
and among the leading ones when it comes to
base metals copper, zinc and lead and the
precious metals gold and silver.
The countrys mines in 2009 can be seen on
http://www.sgu.se/sgu/eng/samhalle/malm-
mineral/gruvor-sverige_e.html
GTK, the Geological Survey of Finland says
the country offers the exploration industry a
favourable investment and operating
environment with significant potential for new
discoveries as many commodities still are highly
underexplored. Present activity is concentrated
in gold, platinum group metals, base metals,
diamonds and industrial minerals. Finland has
excellent geological databases, good
infrastructure and readily available exploration
services. These factors make operating in
Finland attractive and cost effective. See
http://en.gtk.fi/export/sites/default/Geoinfo/Finnish
_Geology/metallic.jpg
By contrast, in Norway the past 30 years have
seen substantial structural changes in the
industry. Production of metallic ores has fallen
significantly while the production of industrial
minerals has increased considerably. Twenty
years ago the state was a major owner in the
mining industry, especially in metal mining,
through its ownership of Norsk Jernverk/Rana
Gruber and Sydvaranger and its subsidiaries.
The state, after the sale of AS Olivin, no longer
has ownership in the mineral industry on
mainland Norway http://www.ngu.no/en-gb/
tm/About-NGU/.
Veekmas has been manufacturing motor
graders since the 1980s and now offers three
different models for underground mines as
follows:
FG 5 C, 8.1 t, 1.99 m high, 75 kW, all-wheel
drive system
FG 7 C (new model), 9.1 t, 2.46 m high, 90 kW,
all-wheel drive system
FG 15 C, 16 t, 2.65 m high, 150 kW, four-wheel
(bogie) drive system.
Veekmas continuously improves and develops
its products. The FG 5 C has a new canopy/cabin
with even better lateral visibility than the old
one. FG 7 C is a new model which has a
somewhat higher capacity and is higher and
wider than its sister model FG 5 C. The company
says its driving capacity is exceptional for such
a small motor grader as its all-wheel drive
system is exceedingly effective. FG 15 C has
renewed transmission components and new
design.
Sleipner, the Finnish manufacturer of
transport systems for heavy equipment at open-
pit mines has recently expanded its
manufacturing capacity and distribution
channels. The company has a new assembly
plant in Jyvskyl, central Finland, while
continuing with component manufacturing at its
old plant in Tornio, north Finland. With the
expansion the manufacturing capacity is now up
to 100 units annually.
SimMine develops mining simulation
programs and conducts complete mining
simulation projects. Its staff, it says, have in-
depth knowledge and wide experience of
underground and open pit metal mining. This
extensive experience means more mining
understanding, more accurate simulation
models and maximal value to the mine. To be
competitive the company puts [great] effort into
well thought out products and services that help
customers to maximise their profit and benefit
from future investment or production changes.
NORDIC FOCUS
Suppliers in Finland
and Sweden are world
leaders in underground
hard rock mining
machines and mineral
processing, and
a lot more
Alimak Hek provided seven Alimak rack and
pinion- driven elevators for Bolidens Aitik
copper mine, located near Gllivare in northern
Sweden (IM, December 2010, pp12-20). The
elevators are a part of Bolidens total
investment of SEK6 billion in the expansion of
this open-pit mine, which includes a new
modern concentrator that will double the
production capacity to 36 Mt/y
The power of
innovative mining
Innovative mining requires innovative thinking. The power of
Atlas Copcos solutions comes from almost 140 years of experience
in developing groundbreaking technology in close cooperation
with our customers. This is what we call sustainable productivity.
NORDIC FOCUS
SimMine
can be used to optimise resource

planning and to schedule underground
development, assisting in ensuring that
development projects are completed on time,
within budget. The SimMine Development
Package is easy-to-use. It is powerful software
to plan, simulate and evaluate the development
process in underground mining. The company
says that its use to verify plans provides more
accurate results than from commonly used
spreadsheet based schedulers.
Scanias Australian operation showcased the
wide variety of business solutions it provides for
the mining industry during Aimex in September.
It says the Scania approach is designed to
provide maximum availability of assets to
mining operators by correctly specifying a
vehicle for its intended purpose and supporting
this with regular maintenance that ensures
factory-trained technicians keep it in tip-top
condition, while using only genuine Scania
replacement parts. The company offers a
remote area servicing option where experienced
technicians can be flown to a site to provide
routine maintenance, enhancing uptime. It is
also working on a plan to fit mobile workshops
to the back of its trucks so these facilities can
be available on site.
Scania supplies mine vehicles in a variety of
configurations, from 64 and 84, to 66 and
88, including hub-reduction units for use in
very arduous terrain. These mining trucks are
commonly used as water carts, fuel and lubricant
service vehicles as well as explosives delivery
vehicles. Then there are its heavy haulage road
train prime movers that are rated up to 200 t
GVM. Its mine vehicles are used all over the
world, including South America, Southeast Asia
and South Africa, as well as in Australia.
Scania cab configurations range from the
practical and flexible G-series to the more
spacious R-series - voted International Truck of
the Year in 2010. Scania provides high torque
six-cylinder and V8 engines, which all comply
with current emission standards and are
exceptionally fuel-efficient.
Scania also offers stationary engines for
power generation and water pumping. These
feature a modular design to simplify servicing
and increase parts commonality.
Sandvik Mining and Construction has a new
jumbo, the DD421 which, it says, features:
Improved drilling performance with higher
power
Reliability as a result of new design,
improved serviceability and robust structures
Safety as top priority
New high performance drilling system
Robust boom construction complemented
with wide feed offering
Improved maintainability and comfort
through new carrier design
New accurate and efficient hydraulic control
system
Adjustable drilling settings to optimise
performance
The new accurate, efficient, reliable and easy
to use hydraulic drilling control system THC561
provides new features such as adjustable feed
force deviation, meaning independently
adjustable feed force regardless of percussion
power/pressure. Air blowing automatics on the
rock drill return provide cleaner holes for better
blasting quality. Other important features,
though not new to the Sandvik jumbo line, are
adjustable drilling power and rotation speed.
The boom controls are fully proportional. There
is an automatic anti-jamming system. Flushing
and stop and return are all automatic. The
Sandvik DD421 is also available with electrically
controlled TPC561 system and instrumentation
options to improve drilling process.
With a robust TB60 boom and a wide
selection of feeds, it gives optimal coverage of
60 m2, drilling faces up to a maximum of 9,970
mm wide and 6,685 mm high.
The new RD525 rock drills offer higher power,
a new percussion cartridge, simplified structure
(less joints, meaning easier service, higher
reliability), a new stabiliser, separate rock drill
carriage, reinforced flushing housing and
improved lubrication. Main specifications:
Veekmas motor graders can be customised to
customer needs. The company offer many
options, such as ROPS/FOPS canopy/cabin
alternatives, fire suppression system, air
conditioning, heating systems, catalyst purifier,
mudguards, different blade edges, and
hydraulically operated front blade (standard on
FG 5 C and FG 7 C the new model seen here)
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www.alvenius.com
+46 16 16 65 00
Quick Connected Steel Pipe System
Corrosion resistant - Low weight - Impressive ow characteristics
P.O. Box 550, SE-631 07 ESKILSTUNA, SWEDEN. Phone: +46 16 16 65 00, Fax: +46 16 12 26 34
.alvenius.com www m
6 - E 0, S 5 x 5 o . B O . P n o h . P N E D E W , S A N U T S L I K S 7 E 1 0 3 6 2 2 6 1 6 1 4 : + x a 0, F 5 0 6 6 6 1 6 1 4 : + e
+46 16 16 65 00
4 6 3 2
Hole diameter drifting 43 - 64 mm and cut
hole drilling 76 - 127 mm
Power class 25 kW
Percussion rate 93 Hz
Percussion pressure 100 235 bar
They have been tested in different conditions
and applications. In a 900-hour endurance field
test in Australia they achieved longer tool life
with the new stabiliser and higher frequency
17% longer bit life and 40% more meters per
shank.
At the test mine in Tampere, Finland (rock
type: granite, UCS 251, DRI 42 - drilling
parameters: percussion pressure 200 bar, drill
bit D45), the RD525 achieved a 17% higher
penetration rate when compared with the HLX 5.
Even better results can be achieved by increasing
percussion pressure and letting the RD525 show
what it can really do, the company says.
One of the secrets of the RD525 is its higher
percussion rate which means lower energy per
impact. The best attributes of the integrated
rock drill carriage on HLX5 have been included
in the new rock drill carriage design but as a
further improvement the carriage is separate for
easier replacement. The reinforced flushing
housing also provides longer life time and there
are fewer bearings in the shank lubrication
circuit, meaning longer bearing lives. Longer life
is also provided by better cooling of the gear
housing less heat in coupling/shank.
Longer slide pieces mean better guidance and
smaller friction forces. And improved adjustment
of sliding pieces means they are easier to adjust
(adjustable by threads).
Sandvik recently received a contract from
Shandong Gold to deliver 20 mining machines
to the three mines in operation in Shandong
province in China. Sanshandao, Jiaojia and
Xingscheng gold mines are located in a gold
mining area on the north coast on Shandong
peninsula, near Laizhou city. The fleet deliveries
for the equipment are scheduled to take place
before end of 2012, and will be comprised of
Sandvik drill rigs, LHDs and trucks. The contract
is valued at over 7 million. All units are under
contract of sale.
China is of course the worlds top producer
these days and in 2010 Shandong Gold
produced 24.29 t of gold, while the country saw
a new record of 340.88 t in 2010 - a rise of
8.57% over the previous years figure.
The new machines will provide improved
reliability and operating performance for the
mines along with a wide range of productivity
features. Sandvik says the contract represents
the largest single order ever for the mining units
in China and solidifies Sandviks position as
Chinas leading provider of mining technology.
Sandvik was initially selected as we
demonstrated a low risk option, an excellent
understanding of their operations and the ability
to deliver on all the required machines and
services. This is a win-win and we look forward
to our continuing relationship with Shandong
Gold, said Schubert Huang, General Manager
of Hard Rock Mining, Vice President of Sandvik
Mining and Construction Region EAS.
Established in 1996, Shandong Gold Group is
a large-scale state-owned enterprise directly
affiliated with Shandong Provincial Government,
which is also among one of the 520 enterprises
and Chinese top-500 enterprises strongly
supported by the State Government. Depending
on its superior geological and historical
advantages, Shandong Gold Group owns not
only the most comprehensive industrial chain,
the largest and highest concentrated gold base
with advanced professional technology, but
mining group and resources reserve well-known
home and abroad, with gold production,
resources reserve, economic benefit, scientific
level and talent advantages among the top
within the same field in China.
In Australia Sandvik is supplying eight 60 t
TH660 underground haul trucks and an LH621
LHD to Redpath Australia for its contract at the
Mt Lyell copper mine on the west coast of
Tasmania. Mount Lyell is a 100-year-old copper
mine owned by Vendata Resources and is
operated by its Australian subsidiary Copper
Mines of Tasmania.
In late 2010, Redpath Australia won the
tender to provide all activities required to
sustain a mine production of 2.7 Mt/y, said Rob
NORDIC FOCUS
Increased ground clearance on Sandviks new
DD421 drill jumbo means reduced risk of
damage from impact with the ground. It offers a
smaller turning radius than competitive
machines outer radius 8,600 mm/inner radius
3,700 mm. The machine is 13.05 m long and
3.15 m high
Nichols, Chief Executive Officer for
Redpath. Redpath chose Sandviks
60 t trucks for their haulage
application, operator comfort, and
competitive pricing, he said. We
were also interested in the support
Sandvik could provide with operator
training, service technicians and its
commitment to spare parts provision.
In addition, utilising the TH660s
has given us an opportunity to
achieve lower costs than with the
previous fleet, he said.
According to Tim Redmond,
Sandviks Sales and Marketing
Manager, Underground Mining, the
equipment is in for a tough life. Mt
Lyell is a 100 year old operation which poses
some unique challenges for a modern trucking
fleet, with some parts of the layout quite tight,
said Redmond. In a more recent development
you would probably be dumping into a crusher
and then transport out by conveyor, but in this
operation Redpath Mining will be hauling most
of the production to the surface.
Redpaths contract is for three years and
typically trucks in that type of application will be
operating 5,000 to 6,000 hours a year,
depending on how hard they are working,
Redmond said. Conditions are quite wet and
corrosive so tough gear is required. Older mines
are never quiet right for mechanisation as
opposed to a greenfields site, where mine
layout and fleet can be matched. The TH660s
are ideal for this type of application.
TH660 trucks can carry up to 20% more
payload than other makes, while still able to
work in the same drift and tunnel dimensions as
conventional underground dump trucks with
capacities of 50-55 t. The TH660 is a true 60 t
truck able to carry a full 60 t payload of either
ore and waste, using a standard tub
configuration. And loading of the truck can be
achieved without any special training for the
LHD operators, Redmond said.
An innovative chassis structure gives it a
small turning radius, light weight and good
driving characteristics. Weve been pleased
with the markets general acceptance of the
TH660, he said. When the truck first arrives on
site, its not unusual for mine site personnel to
comment on the apparent size of the unit but
when compared with other makes of
underground articulated trucks of the same size
or smaller capacity, the TH660 is actually
shorter and narrower, and of similar height.
Weve also been able to prove that this truck has
the ability to successfully manoeuvre in existing
mining operations, where there are often
concerns due to its perceived size.
Although Redpath Mining will perform
standard maintenance on these new trucks,
Sandvik will provide full product support, with
expert personnel based on site. We will be
responsible for technical and operator training,
and we will base two qualified personnel on site
seven days a week to support the operation,
Redmond said.
Robit Rocktools strengthened its presence
earlier in the year in a share purchase
agreement with Young Poong CND.
The CEO of Robit Rocktools, Jussi
Rautiainen believes this
partnership will form an excellent
cornerstone for Robits future.
Through the co-operation with local
manufacturer we will be able to
expand our product range and to
diversify our production. Factory and
warehouse in Asia will enable us to
serve our customers even better
than before. Local presence in new
time zone allows us to offer Robit's
high quality products at
substantially shorter lead times and
more competitive pricing for our
customers in the region."
Young Poong CND was established back in
1974 and is the oldest and largest rock tools
manufacturer in Korea with a wide range of
drilling tools in the product portfolio. It has
brand new manufacturing facilities in Donghae
and a sales office in Seoul.
Outotec has received a repeat order from
London Mining for delivery of High Gradient
Magnetic Separators (HGMS) to the Marampa
iron ore project in Sierra Leone. London Mining
purchased its first magnetic separators for the
project in 2010. The combined value of the
orders and services is over 10 million. Outotec
partnered with London Mining to develop the
flowsheet for processing tailings (hematite)
from former operations at Marampa. The
installation of the first Outotec magnetic
separators is nearly complete with start-up
expected in 2011. The rest of the equipment will
be delivered in early 2012. This stage of
development will take London Mining's
Marampa concentrate output to 3.6 Mt/y. A
recent prefeasibility study has outlined a further
expansion to 16 Mt/y of premium iron ore
concentrate.
This is the largest delivery of the Outotec
magnetic separators of this scale to a single
site. Besides this delivery, we are currently
working with London Mining's technical team to
NORDIC FOCUS
World Leading within Directional Core Drilling & Borehole Surveying Instruments
Devico AS - P.O. Box 206 - N-7224 Melhus, Norway
Phone:+47 72 87 01 01 e-mail: devico@devico.no web: www.devico.com
The smart way - Just Bend It
Reduce exploration time & cost
Multiple sidetracks
Deviation control
Improve accuracy, hit the targets
Reduce environmental impact
Seven of the Sandvik TH660 underground haul
trucks for Redpath Australias work at Mt Lyell
copper mine on the west coast of Tasmania
were delivered in late September, with the
eighth truck and the LHD delivered early in
November
provide process development services that will
support the Marampa project in its later
stages, said Pertti Korhonen, President and
CEO of Outotec.
In Chile, Outotec has signed a contract with
Codelco, the leading copper producer in the
world, for the design and delivery of
concentrator technology to Codelco's new
Ministro Hales mine in the north of the country.
The contract value is approximately 24 million.
Outotec's scope of delivery covers the world's
largest TankCell
300 flotation cells, concentrate

thickeners and a turn-key filtration plant
including basic and detail engineering, supply of
proprietary and process equipment as well as
installation, start up services and training. The
new facility will have an annual capacity of up to
550,000 t of concentrate, and it is scheduled to
be commissioned in early 2013.
This new contract complements the earlier
contracts Outotec has made with Codelco in
2010 and 2011 for Ministro Hales, valued at
approximately 134 million and including the
delivery of a copper concentrate roasting plant,
gas cleaning system, sulphuric acid plant and
effluent treatment plant. "This additional
contract demonstrates our ability to offer and
implement large process solutions for our
customers. Our strong technology portfolio
covers the entire value chain from ore to refined
metals, said Korhonen.
Normet has acquired Swedish Essverk Berg.
The acquisition of Essverk gives Normet a
physical presence in Sweden and allows us to
better serve our customers in Sweden and
Norway, says Aaro Cantell, Chairman of
Normet. Essverk will be the base for our
operations in Sweden and Norway and we have
a very strong commitment to develop and grow
the combined business, under the new name of
Normet Scandinavia.
From a technology point of view, Tom
Melbye, President of Normet Group, said,
Essverk is completing very well the Normet
product range with its expertise in truck-based
and lifting equipment and also provides extra
manufacturing capacity. The company will also
be the development and competence centre for
truck based equipment including existing
Essverk offering, concrete spraying and new
developments.
Joining Normet, on the other hand, provides
Essverk Berg and its employees with an
interesting future perspective in terms of growth
potential and development, says Tryggve
Sjberg, current owner of Essverk and
designated Head of Sales and Service for
Normet Scandinavia.
Having a strong local presence in Sweden
and Norway will allow Normet to be in closer
contact with its customer base in Sweden and
Norway and provide improved service and spare
parts supply levels, says Pentti Kylijrvi,
Managing Director of Normet Scandinavia.
Normet Scandinavia will continue the sales and
service of Essverks specialised offering and will
also provide sales and Life Time Care services
for Normet equipment and construction
chemicals offering in the area.
Normet is a globally operating and fast
growing Finnish technology company. It provides
advanced solutions for selected customer
processes in underground mining. The group
develops, manufactures and markets machines
as well as construction chemicals for underground
processes such as tunnel support by mobile
robotised concrete spraying, automated explosive
charging and underground logistics. Normet's
offering includes a comprehensive range of life
time care services around the equipment and
around the processes they are used for. Normet
says it is the global market leader in its market
segment. Normet has its own sales and service
companies in five continents, 20 countries and
25 locations. The Groups Net sales in 2010 was
over 100 million. Normet currently employs
over 600 business professionals.
Essverk Berg develops, manufactures and
services equipment for rock and tunnel works,
excavators and industrial applications such as,
for example, truck-based lifting platforms,
equipment for assembling concrete elements for
tunnel lining, etc. Essverk also performs
NORDIC FOCUS
Proven Performance
Larox Flowsys is now Flowrox
FLOWROX VALVES AND PUMPS for abrasive, corrosive and other
demanding shut-off, control, pumping and dosing applications.
EXPERTISE WITH INSIGHT
Over 30 years of experience
More than 100 000 installed products worldwide
PARTICIPATING PARTNER
Long-term partnerships with the customers
Close cooperation between experts in all disciplines
FACILITATING PERFORMANCE
The lowest total costs of ownership
Improved efciency and extended service intervals
Flowrox Oy
Marssitie 1
P.O. Box 338
FI-53101 Lappeenranta
Finland
Tel. +358 201 113 311
Fax +358 201 113 300
info@owrox.com
www.owrox.com
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demanding tunnel contracting and installation
work.
Mill linings in the far north
Metso has signed a contract with Northland
Resources for a five-year mill lining service and
inspection program for the Kaunisvaara project
in northern Sweden. The contract complements
previous project orders by Northland Resources,
announced by Metso earlier this year. The value
of the order is 19 million. The Metso Life-Cycle
Services (LCS) program at Kaunisvaara includes
both the supply and installation of mill liners
and technical and maintenance support for the
SAG mill on the Tapuli process line. Metsos
on-site resources will also conduct liner
inspections to maximise mill availability. The
contract period will commence when installation
of the Tapuli process line is completed at the
end of 2012.
Were pleased to have concluded this
contract as it maximizes the availability of our
grinding line, says Shane Williams, Vice
President, Projects, Northland Resources. As
this is a cost-per-tonne contract, well be able to
forecast expenditure over extended periods of
time. It will be a very useful asset in view of the
total investment involved.
We embrace the opportunity to partner with
Northland in a five-year LCS commitment, says
Joo Ney Colagrossi, President of Services
business line, Metso. The speed at which
operations at Kaunisvaara are progressing is
impressive and we are looking forward to a
rewarding working relationship with Northland
Resources.
The scope of service for the LCS program at
Kaunisvaara consists of Metso Poly-Met mill
liners, liner handlers and essential tools,
technical assistance including maintenance and
shutdown planning, as well as monthly audits
and annual inspection services for the Tapuli
grinding mill.
Northland Resources is a development-stage
mining company with a portfolio of iron ore
projects in Northern Sweden and Finland. The
companys Kaunisvaara project will exploit
magnetite iron ore deposits, feeding a single,
multi-line processing facility in Sweden. The
process yields high-grade, high-quality
magnetite iron concentrate.
In the US, Metso has acquired Copperstate
Industrial Services, a mining services provider
based in Phoenix, Arizona. Established in 1999,
Copperstate has built a highly competent team
of service personnel in the American hard rock
mining region. Its team has been integrated into
the Services business line of Metsos Mining and
NORDIC FOCUS
ORGANIZER
INTERNATIONAL
TRADE FAIR & CONFERENCE
SKELLEFTE, SWEDEN
JUNE 12-14, 2012
NEW BUSINESS OPPORTUNITIES
AT THE HEART OF EUROPES
MINING INDUSTRY
Welcome to Euro Mine Expo, one of Europes most important international
convention venues for the mining industry. It provides the perfect
opportunity to showcase your products and services while taking part in
first-rate seminars. Forge new business contacts and networks, and expand
your business horizons. Experience northern Sweden, Europes centre for the
production of base and noble metals.
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Metso mill lining: one of its latest contracts is
at the Kaunisvaara iron ore project
Construction Technology segment, where it will
continue to service existing clients. The team
will be expanded to further reinforce Metsos
maintenance, repair and retrofit business in the
USA, Canada and Mexico.
This fits directly in the centre of Metsos
profitable growth and development strategy
explains Randy Reisinger, Senior Vice President
of Engineered Services Solutions, which
includes the Spares, Repairs, Engineered-to-
order and Field Service business units. Metsos
objective is to enhance customer satisfaction by
employing a larger faction of knowledgeable,
well-trained service people to meet customers
skills and availability needs.
The Larox Automatic Changeover (LAC) valve
operates on the discharge side of two pumps in
parallel. Both pumps can run simultaneously or
independently. When one pump is switched off,
the ball will automatically drop back stopping
the back flow to the other pump. It is
particularly suited for mill cyclone feed pumps.
As the elastomer covered ball moves, it rotates
with the flow. This ensures that the valve self
cleans and permits it to open and close reliably
even under severe conditions of slurry build up.
The valve body is carbon steel (fabricated)
and can be lined in Linatex, natural black,
neoprene, hypalon, EPDM
rubber, ceramic or urethane.
The ball is replaceable and
made of urethane or rubber
and is available in different
sizes.
The valve offers
considerable flexibility, being
flanged to customer
specification. Shouldered end
connections can be made
available for Victaulic
couplings if required. The
valve body and face-to-face
dimension can be changed to
suit existing applications. Other features
include:
Pressure drop is minimal - pressure ratings -
150, 240 and 365 psig
Flushing port in ball body
Replaceable seats
Lifting lugs
Different mounting brackets can be fitted to
suit application.
Based on the success of its excavator and
wheel loader buckets, KVX has expanded its
range to underground LHD Buckets, combining
the key features and benefits of KVX Buckets
and GET systems. KVX says its system provides
more protection under the base edge
eliminating the necessity for profile bars and a
number of other underside protection items
(better protection and less parts = superior
reliability).
With its very slim profile and smooth floor
design the KVX GET system ensures free
material flow into and out of the bucket (no
hang-ups!) and superior penetration, resulting
in less tyre spin, improved fuel economy, less
wear and tear on driveline, pins and bushes and
better productivity. Little or no front lip
protection is required.
Driconeq, a world leading producer of mining
drilling equipment, has acquired Anceriz
Industries, a prominent South African developer
and manufacturer of reverse circulation mining
drilling products. Founded in 1986 and based in
Johannesburg, South Africa, Anceriz Industries
supplies drilling consumables throughout Africa.
It has a staff complement of 30. The acquisition
represents a significant step in Driconeqs
continuing expansion strategy in the areas of
mining and construction. The company says the
combination of Driconeq and Anceriz creates an
industry-leading, global mining concern with
best-in-class products and a highly effective
distribution platform for drilling consumables
utilised for in-the-hole and rotary operations.
We look forward to giving our customers in
Africa an even higher level of service, to ensure
their competiveness. As a partner, we can offer
them essential support in their daily business,
says Mats Blacker, CEO of Driconeq. The
acquisition of Anceriz - known for its excellent
product knowledge, attention to detail and
customer satisfaction - reaffirms Driconeqs
commitment to meeting client demands by
offering complete solutions with world-class
products for DTH (down-the-hole) and rotary
drilling applications.
Driconeq has a track record of offering safer,
superior products. Its a very important part of
our business plan to enhance our portfolio with
a wider range of competent products. Add to
this exceptional technology; broader channels;
and Driconeqs personalised, professional and
timely service, and we have no doubt that we
are the only service provider in this category
that successfully meets all of our customers
mining and construction needs, concludes
Blacker.
Christer Gyllengam, CEO of Bergteamet,
based in Boliden, says "Bergteamet is one of
Sweden's largest rock engineering firms. We
have long standing experience of work within
the Swedish mining industry. Our clients include
LKAB, Boliden Mineral, Scan Mining, Zinkgruvan
and Sala Silvergruva, among others. We have
worked with the people at Contector for many
years and are well-acquainted with their
products. The Jama scaler is a powerful and
well-designed machine. We have a large number
of Jama machines, which is an advantage, since
it better enables us to coordinate service and
maintenance. We are very pleased with our
scalers. Both the machines and our
collaboration with Contector function well."
Devico, a leading provider of directional core
NORDIC FOCUS
ke Kruukka, Manager, LKAB Kiruna: Our
collaboration with Contector began more than
10 years ago. During the past three to four-year
period, LKAB has chosen Contectors products
on about ten occasions. Among other
machines, we have purchased the JAMA SBU
8000 scaler, which is in service in our mines in
Kiruna and Malmberget. This is an extremely
tough environment where equipment can take a
real beating. In terms of working environment,
our operators really appreciate the JAMA SBU
8000.
KVX says its LHD buckets feature the same
unrivalled GET retention as our wheel loader or
excavator systems; significantly reducing the
risk of breakage, loss or unplanned
maintenance as well the even more significant
downstream costs of fixed plant and production
stoppages
drilling services has increased its capacity for
the global industry with more professionally
trained technicians. The company says it now
has the capacity to take new projects and is
ready to support mining industry with [its]
expertise in cost effective exploration drilling.
Agnico-Eagle in Kittil has used Devico to
steer their boreholes to the targets for the last
two years with great success. In addition to
higher accuracy, the Devico technology has led
to significant cost reduction since the total
meters of drilling can be reduced considerably
when making several branch holes from one
mother hole. http://fem.lappi.fi/c/document_
library/get_file?folderId=48927&name=DLFE-
2786.pdf
Devico has worked with many Scandinavian
diamond drilling companies including ADC
(Arctic Drilling Co), Kati, Protech, Drillcon, Smoy,
Styrud, Arctic Geodrilling (Norway) and E-
Service (Norway) and knows their equipment
and know how very well to secure a fast, easy
and smooth start with a new directional core
drilling project.
Devico says the latest success stories prove
its directional core drilling technology can
reach new record depth. Drilling project in
Guyana was able to deviate and create
directional core branches at a depth of 1,900 m
in NWL size in September.
In South Africa Devico is working on a new
approach to deep reef exploration. The issue
with this type of mineralisation is the great
depth, leading to high cost of surface
exploration, and the limitation in hitting the
mineralisation in a defined pattern with
underground drilling. Devico and Northam
Platinum have found a
solution to this by
drilling mother holes
parallel with the reef
and branching it off at
given intervals. One by
one the branch holes
are bent 25 to 30,
directing them to the
estimated reef
location. As core
samples are taken also
during the steering
process there is no risk
of losing valuable
geological information
at any time. After the
first months of
operation the drilling
technique has proven
highly successful and
has sparked interest in
several other mines in
Southern Africa.
Massive order for Peoles
Atlas Copco has received an order from the
Mexican mining group Peoles. Valued at about
$67 million, it is one of the largest underground
mining equipment contracts ever for Atlas
Copco, and the companys second large order in
Mexico this year. Atlas Copco will deliver a total
of 87 machines, including underground drill rigs
for face drilling and long hole drilling, as well as
products for underground bolting, loading and
hauling. The equipment will be used by
Industrias Peoles and Fresnillo in various
current mines in expansion, development and as
well as advanced exploration.
We are proud to be able to fulfil Industrias
Peoles and Fresnillos growing needs for
The Atlas Copco PV-235
blasthole drill chosen by Osisko
has a weight on bit of up to
29,500 kg and is designed for
rotary or down-the-hole (DTH)
drilling of 152 251 mm
diameter holes
Devico is a global supplier of directional core
drilling and borehole surveying products and
services. It manufactures products such as:
non-magnetic Deviflex, the Devicore orientation
system, and the Magnetic Pee-Wee. Devico
says it delivers on time and on budget,
whether it is a conventional or wireline
directional core drilling project. As demand for
downhole surveying products and services
continues to grow worldwide, Devico continues
to invest in additional resources to maintain the
leadership position in directional core drilling
services and products
NORDIC FOCUS
advanced equipment and service, and look
forward to developing our relationship further
during the coming years, said Bob Fassl,
President of Atlas Copcos business area Mining
and Rock Excavation Technique. Peoles is one
of Mexicos leading mining companies, with
operations focusing on base metals such as
zinc, lead and copper. It is also the majority
owner of Fresnillo, which is the worlds largest
primary silver producer. In January, Atlas Copco
received an order from
Fresnillo for underground
mining equipment worth
about $45 million.
Osisko Mining recently
ordered its seventh PV-235
Pit Viper drill rig from Atlas
Copco Mining and Rock
Excavation Technique Canada
to be used in the Canadian
Malartic Operations, currently
the largest open-pit gold
mine in Canada. Four of the
seven Pit Vipers ordered so
far have been delivered.
Osisko Mining reported commercial
production at the Malartic mine on May 19, 2011,
almost three months ahead of schedule. The
mine, located in Malartic, Quebec, has estimated
resources and reserves of some 9 Moz.
Peter Walsh, Business Line Manager
highlighted Atlas Copcos international
reputation in the mining community and their
local service presence in Cadillac, Quebec, as
key reasons for Osisko Minings selection of
Atlas Copco drilling rigs.
The company has launched the latest in T-
thread drilling systems the T-WiZ range.
Looking a lot like its predecessor, thats where
the similarities end, Atlas Copco says. The
new drill string, with its combination of T-WiZ
Speedrods and T-WiZ
shank adapters, offers
up to 30% longer
service life. That
means fewer rod
changes and more
productivity per shift.
T-WiZ is tough
thanks to the greater
thread stability. In fact,
the company says, its
robust enough to
prevent product
breakage in the
blasthole. Which
means a shift in focus
from all those time-
consuming rod and
shank changes to
maintaining a much
leaner stock.
Regardless of
assignment
underground, in
surface mines theres
no better way to work
through tough
formations and
fractured rock. T-WiZ
features greater thread
stability and quicker rod changes. It reportedly
drills more holes per shift, opening up the
possibility of quicker blasting and a more rapid
advance. With lower labour costs, minimised
stock, less administration not to mention
fewer rods and shanks in circulation T-WiZ
helps drillers stay on top of their projects.
Alvenius recently signed the contract for
supply of a new large diameter DN400 system
with quick connected couplings to the LKAB
mine in northern Sweden.
The Alimak elevators installed at Aitik
facilitate the maintenance and inspection in
different plant areas, such as crushing, ore
stockpile, grinding, flotation and de-watering.
There are high demands on the elevators
durability and reliability. They operate over lift
heights between 14 and 48 m, with payload
capacities of 400 to 1,800 kg. They are equipped
with the modern ALC-II microprocessor-based
control system, emergency phone, and overload
sensing device.
All elevators are equipped with Alimak Heks
online A3 remote monitoring system, which
means the elevators can operate 24 hours a day
fully monitored with any faults being
transmitted instantly for speedy correction and
to minimise downtime.
ABEM Instrument has developed the Terraloc
Pro line of seismographs to deliver high-quality
seismic data to accurately assess geological
conditions for engineering and exploration
studies. Designed for top performance with a
broader frequency range and longer records
than are currently available on the market, the
new system promises to vastly improve the
quality of seismic data. The company says
Terraloc Pro is a stand-alone, compact and
robust, top performance engineering
seismograph. IM
NEW! NORDIC LIGHTS new
LED work light offers long lifetime
and high operational safety with
minimum maintenance. Extreme
Heavy Duty Dampening and
High Light Output.
NEW! NORDIC LIGHTS new
LED work lamp features multi
voltage usage and low power
consumption. The compact
light lasts in though conditions
and is completely waterproof.
NORDIC LIGHTS small LED work light.
Suitable for most applications where a
compact and robust lighting source is
required. Offers multi voltage usage and
low power consumption.
N460 LED
N44 LED
N25 LED
Secorocs comprehensive range of top hammer
bits matches the T-WiZ drilling rods to
perfection with the added benefit of being
easier to release and change. Three sizes are
currently offered the T38-WiZ, T45-WiZ and
T51-WiZ Speedrods and shank adapters
designed for extension or drifting drill strings
Available in configurations of 12, 24 or 48
channels, sun-light visible colour screen,
powerful built-in field pc with windows XP pro,
integrated re-chargeable battery, resistant
casing (IEC IP 66). ABEMs Terraloc Pro is shock
and vibration resistant, operates over wide
temperatures (-20 to +50C ambient),
withstands humidity and dust (IP66) and is
built from industrial grade components
NORDIC FOCUS
Introducing an almost magical drilling system
Were not known for dabbling in make-believe. In fact, few things are more real than the benefits that
come with our newT-thread. Especially when you consider that large rods require a robust thread system.
The newT-WiZ drill string looks a lot like its predecessor, but thats where the similarities end. Were not
about to reveal all our tricks, but youll be amazed to know that T-WiZ offers up to 30% longer service life.
Which means fewer rod changes and more productivity per shift.
So test the combination of T-WiZ Speedrods with T-WiZ shank adapters the benefits are spectacular.
Atlas Copco Secoroc AB
Box 521, SE-737 25 Fagersta, Sweden
Phone: +46 223 461 00
E-mail: secoroc@se.atlascopco.com
www.atlascopco.com
T
hyssenKrupp Robins is delivering an
overland conveyor system for Xstrata
Coppers Antapaccay copper mine in Peru,
seen in this opening picture. ThyssenKrupp
commissioned the Siemens Industry Solutions
Division for the supply of the electrical drive
system. This will be the first installation of a
conveyor system with gearless drives outside
Germany. In comparison to conventional drive
solutions, these drives have not only a higher
efficiency, availability, and reliability, but also
lower maintenance requirements. The conveyor
system is due to be commissioned in 2012.
The overland conveyor in this copper mine
will transport ore over a distance of some 6.5
km from the mine to the processing plant. The
belt will be 1,372 mm wide, travel at 6.2 m/s
and is designed to transport some 5,260 t/h of
material. The Siemens drive system for the
overland conveyor comprises of two slow- speed
synchronous motors each with a total power of
3,800 kW and the associated Sinamics SL150
cycloconverters. Each motor is connected
directly to the drive pulley.
This gearless drive solution has a number of
advantages over the combination of high speed
motor and gearbox usually used on conveyor
systems. The size of the motor is not limited by
the size of gearbox available, thus eliminating
the necessity to install multi-motor drives. The
power required to drive a belt can be provided
by just one drive per belt pulley. This enables
the size of the electrical room to be reduced,
saving space and weight.
The elimination of a whole series of
mechanical and electrical components increases
the reliability and efficiency of the overall
system by between 3% and 4%. The
maintenance requirements of the drive system
are also substantially lower. Gearbox
maintenance work alone can amount to up to
5% of the original investment sum each year.
Lubrication and gearbox cooling systems,
together with their maintenance, are also not
required with this solution.
The gearless drive system for Antapaccays
overland conveyor system is the second of its
type. The first conveyor system to run with
gearless drives was installed in 1986 by
ThyssenKrupp (formerly O&K) and Siemens in
the Prosper-Haniel mine belonging to Deutsche
Steinkohle and its availability is over 98%.
Martin Engineering and Stahura Conveyor
Products (SCP) have worked together for nearly
30 years to help customers achieve cleaner and
safer conveyor operations, with ongoing emphasis
on the simultaneous need for productivity growth.
We are trying to change the way the industry
thinks about conveyors, observes Martin
Engineering Chief Technology Director and CEMA
Director, Todd Swinderman. The equipment has
become much more robust and reliable, but
basic designs havent changed that much.
He explained that in order to take the next
steps toward zero lost-time injuries, engineers
at Martin Engineering are re-examining standard
conveyor features, questioning the existing
approaches and searching for new designs that
integrate safety with improved production.
Instead of emphasising safety first, our motto
should be production done safely, he
continued. People are human, and they can
always make mistakes, but innovative design
can remove much of the inherent risk of working
around conveyors. In the conveyor industry,
design is the next frontier.
Swinderman noted the companys new EVO
Modern Conveyor Architecture, a new approach

to product design that encourages engineers to
question why any given component is
constructed the way it is. In many cases, he
said the company is finding that small design
changes can have a significant impact on safety
and efficiency.
Martin Engineering VP Jim Turner, points out:
The most productive and profitable companies
are the ones with the best safety records.
Our Foundations training programs have
been extremely well-received by the coal
industry, he continued, helping management
and maintenance personnel to identify and
eliminate potential hazards. Recently, Martin
Engineering introduced an online course to its
library of training seminars, allowing
participants to work their way through nine
modules at their own pace.
The two-pronged approach emphasising
design and education helps our customers
engage in safer and more productive conveyor
operations, Turner added. That distinction is
critical: safer AND more productive.
Investments in conveyor safety generate
payback in terms of improved operating results
as well as personal and plant safety. Companies
are finding that their return on investment is
truly a win-win situation.
Richwood notes the importance of clean belts
to conveyor safety: The belt scraper
unbelievably simple in design, yet the one
component of a beltlines infrastructure that can
save operations thousands of man-hours,
CONVEYORS
John Chadwick looks at gearless drives,
grasshopper conveyor advances, cleaning
belts and around them, and much more
CONVEYORS
reduce injury hazard and prevent downtime from
damaged components.
"When the reality of the consequences of a
dirty belt are calculated they have to include the
loss of time, decreased safety and lowered
productivity and even penalties and fines. All of
these can be avoided by successfully applying a
single component: the belt scraper."
So what makes a belt scraper a belt cleaner?
And what makes a belt cleaner an effective one?
"It seems that a good cleaner would have
everything to do with eliminating carryback on
the belt and have the ability to continue to do so
in a reliable fashion," Paul Patton, Richwoods
Senior Manager of Technical Services said.
No operation would disagree that carryback
must always remain at negligible levels so that
ideal production can be achieved with minimal
safety and health hazards. The question is: how
can that be attained?
Patton suggested that the industry would
greatly benefit from a belt cleaning "standard",
the approach for which would involve a
complete assessment of application factors
including belt speed, belt width, the number
and type of splices, the abrasiveness of the
material, and the flow characteristics and
moisture content of the material.
"Each of these factors would have an
assigned number and become an adder in the
calculation," he explained. "When added
together these would provide a score. Using
this numerical classification system the severity
of an application would be determined and the
correct belt cleaning solution could be applied."
The use of this system would not only assist
belt cleaner suppliers to provide customers with
the best solutions, but would also benefit the
end user. Whether the operations needs were
significant or minor, there would be peace of
mind that the proper assessment and best
recommendation had been made.
Richwood, who developed this approach, has
implemented it with great success worldwide
and in all types of mining applications. "Not
only does this method provide a conveyor free
of carryback and eliminate the myriad of
problems that go along with a dirty belt, it also
makes communication about the intended
approach clear and the end result certain,"
Patton said. "When belts are running clean, it all
adds up, to safety, efficiency and greater
productivity."
Joseph A. Dos Santos says the
rationalisation of sandwich belt high angle
conveyor technology is fundamental to the long
term technological and economic success of
high volume steep and vertical conveying.
He goes on to explain that the best elevating
profile depends largely on site and functional
requirements. In general, the best solution is
the most direct path from loading point A to
discharge point B. One example, however,
reveals economic comparisons that would
prompt a combination conventional conveyor
along the ground to an elevating sandwich belt
conveyor, even when ample space exists for a
conventional conveyor solution. This can be a
sandwich belt conveyor with a long approaching
bottom belt. In general, loading point A and
discharge point B will be located for the best
use of space. The total investment comparison
reveals large differences, at the very high lifts,
between the conventional and the sandwich belt
conveyors but not among the sandwich belt
systems. At the highest lift, a 60 DSI Snake
profile has approximately 10% higher
investment than the 90 (vertical) DSI Snake. A
45 profile has approximately 18% higher
investment.
Investment comparison (engineering and
supply) of elevating conveyor options: From
Dos Santos
In a move that Martin Engineering aims will
further raise the quality of its component
finishing and reduce lead times, the company
has installed a comprehensive new paint line at
its global manufacturing headquarters. Long
an adherent to principles of lean
manufacturing, the company anticipates greater
control over preparation, coating and curing,
allowing the firm to deliver material handling
components faster, with greater surface
durability and consistency than before. Upon
completion of the new four-stage coating line,
manufacturing personnel are now washing,
drying, painting and curing with greater
efficiency. With the new equipment in place,
were able to eliminate much of the potential
variability that can plague a coatings
operation, explained Manufacturing
Supervisor Mark Daum. Having control of
surface preparation and cure times has helped
us create a reliable, repeatable process for
achieving the paint quality we want on our
products
Operational considerations might warrant
the higher investment in a 60 system, or even a
45 system. Such considerations are (1) system
clean-up and (2) system access.
Sandwich belt systems at any angle can be
designed spillage free. Minor material
carryback can occur due to none perfect belt
scraping and even the occasional leakage, due
to poor belt alignment and other aggravations.
The magnitude of the accumulation is far less
important than its nature and consequence. At a
vertical system such carryback does not have a
clear path away from the equipment and tends
to accumulate progressively on the rolling
equipment. Periodic cleanup is required,
typically by high pressure wash-down. Wash-
down water at the outer parts of the wing rolls
has contaminated the bearings and caused
frequent premature bearing failures requiring
high rates of roll replacement. No such
phenomenon has occurred at sandwich belt
conveyors of any incline less than vertical. Any
carryback tends to fall away clear of the rolling
equipment and build up is not progressive
towards the bottom.
Access to the equipment is important in any
case. Many specifications require access by
stairway (vertical ladders are not allowed). The
maximum stairway slope, according to
architectural standards, is 50. At higher angles
step ladders (51 to 70) or ladders (71 to 90)
must be used, with
safety lines or safety
cages and landings.
The cost of stair
towers can
sometimes approach
the cost of the
sandwich conveyor
systems.
The Dos Santos
International Snake
Sandwich Belt High
Angle Conveyor is
the only high volume
sandwich belt system
to utilise all and only
conventional conveyor equipment and
componentry. Material hugging pressure is
induced by exploiting the inherent belt tensions
on an engineered alternately curving (snaking)
profile. An investment comparison shows great
savings when conveying to high silos with DSI
Snake sandwich belt conveyors at various
angles from 45 to 90 (vertical). To date,
sandwich belt conveyors have not been widely
recognised as mainstream technology despite
the many successful systems and the
demonstrated economies. There is no basis for
reluctance in the wide use of sandwich belt
conveyor systems. Such systems should be
embraced as mainstream technology and
exploited to lower the costs of silo loading and
other applications.
High angle conveying is equally
advantageous in elevating to other covered
storage systems such as storage barns and
domes. Dome type structures for covered
storage have gained prominence and use. The
DSI Snake profile is ideal for continuously
elevating materials to the top of such domes
The Dugless 900 Mark 11, which is 560 mm
high, has been specially designed to safely
manoeuvre under low-height conveyor systems
to remove spillage without risk to workers or
the surrounding environment. Minprovise
describes it as a revolutionary, powerful and
productive conveyor spillage cleaning machine
CONVEYORS
Belt conveyors which not only move mountains, but move up, down and around them as well?
High tech belt conveyors with horizontal and vertical curves adapt to any terrain or industrial
premises: designed, built and erected by ThyssenKrupp Frdertechnik.

Contour-Conveying!
Innovative Belt Conveyor Systems from ThyssenKrupp
ThyssenKrupp Frdertechnik
Excellence in Technology
Business Unit Mining
ThyssenKrupp Allee 1
D-45143 Essen, Germany
www.tk-mining.com info@tk-mining.com

CONVEYORS
sharing a compatible curving geometry. En-route
to discharge, at the top of the dome, a DSI
Snake system will impart a gentle distribution of
structural loads onto the dome structure. The
combination will be an aesthetically pleasing,
uncluttered system at 45, 60 and 90 (vertical).
Besides the hardware costs such systems offer,
he says, a strong case can be made for the
importance of land area and spatial volume
costs and environmental impact.
Start-of the art testing
Flexco recently welcomed a new addition to its
product development laboratory, which will
accelerate the design and testing of new
products. The 533 kN capacity test rig will boost
product development efficiency, making way for
new concepts and solutions. While there are
other test rigs in the industry, the custom-made
rig was specifically designed by Flexco
engineers to put a variety of products to work
and measure the success and compatibility of
each.
The rig replaces the previous test rig, which
was used heavily for the past 30-plus years at
Flexco.
While the previous rig was focused mainly on
testing mechanical belt fastening systems, the
new rig will test the full line of Flexco products,
including trackers, cleaners, plows, rollers, and
lagging. The rig measures 7.3 m high and 3.6 m
wide and weighs some 27 t. It is modelled
after the DIN-22110-2 Standard and is equipped
with six lagged 800 mm pulleys with a
maximum belt speed of ~8 m/s. Belt widths
from 200 mm to 900 mm can be tested, while
tension can be cycled dynamically up to 533 kN
of force. The rig also features HMI touch-screen
technology, hydraulically-actuated dynamic
tracking, and a catwalk that hugs the perimeter
of the machine for easy viewing and testing. The
new design also allows for greater accessibility
of data acquisition equipment, including high-
speed cameras and vibration and force
transducers.
While the capabilities of the rig are
impressive, the size offers additional benefits,
Westphall states. When you can test cleaning,
fastening, tracking, and other product functions
all at the same time, you not only gauge the
performance of individual products, but also
their compatibility. This aligns with the Flexco
philosophy of a holistic approach to maximising
belt conveyor productivity.
Higher capacities
Takrafs Dr Holger Lieberwirth notes that in soft
rock mining capacities of up to 50,000 t/h were
achieved some 30 years ago with its mobile
conveyor bridges, used for the cost efficient
cross-pit overburden handling. Belt speeds of
well above 10 m/s or a belt width of up to 3.2 m
are not unusual.
However, the capacities of overland belt
conveyors in hard rock mining have not yet
reached those capacities but are designed and
operated normally at capacities up to 10,000
t/h. Some of the reasons for this are:
Maximum belt strength available
Maximum drive power that can be installed
under technical and economic considerations
Maximum capacity of gyratory crushers
Abrasiveness of crushed ore or overburden
and wear of the belt, in particular in the
acceleration area
Lump size and its impact on idler wear, in
particular at increasing speed
Redundancy and respective increased
availability when using two smaller conveyors
instead of one large unit.
The recently developed ST 10.000 will widen
the application range of belt conveyor transport,
Takraf says. Specific breaking strength will be
increased substantially, compared to the
strongest belt to date, the ST 7.800.
Takraf direct drive system for belt conveyors
The diversified product offering at Flexco,
combined with increased belt tensions and the
continuing evolution of belt construction,
prompted us to invest in this new rig, Greg
Westphall, Director of Engineering at Flexco,
said. Its a one-of-a-kind machine designed
and built by Flexco to enhance our testing
platform and accelerate our design process.
He also points out that, although the new rig is
a significant upgrade from the previous one, it
is not designed to replace field-testing. Instead,
the new test rig ensures that products have
undergone rigorous in-house testing before
being placed in the field
The 2.5 m diameter pulleys for the testing
facility at Hannover were designed in the
conventional way. For high strength pulleys in
modern applications complete new pulley
concepts were developed, eliminating the
traditional shaft and the drawbacks related to
that design in particular at high loads.
For the transfer of the power required for high
capacity conveying new drive concepts were
also developed. For drive power of more than
3,500 kW, Takraf believes it is economically
more beneficial to use direct drive systems
instead of conventional motor/gearbox solutions.
The direct drive concept is not really new in
belt conveyor drive technology. But due to wide
application of those drives in other areas the
drives have become technically more reliable
and more economic.
With new solutions using wider diameter
idlers the speed limitations of present hard rock
conveying systems might be overcome to some
extent. Specially designed transfer points
allowing fine material to settle before larger
lumps are loaded onto the belts and the use of
wider belts will allow larger lumps to be
transported by belt conveyors, reducing the
energy consumed for size reduction, in
particular in overburden handling systems. At a
given strength per mm of belt width, such as
10,000 N/mm with the ST 10.000 such increased
belt width will also allow a higher absolute load
on the belt. The
application of a 3,000
mm wide belt instead
of the typical 2,000 mm
wide ones (or less) of
today would increase
the total permissible
load by 50%.
Lieberwirth
concludes that with a
smart combination of
all these developments
in belt conveyor
technology, none of
those in itself really
revolutionary new, a leap in conveyor
applications in hard rock mining can be
expected in the next years. Substantially higher
volumes, distances and elevations which can be
overcome by those technologies will not only
lead to a much wider application in existing
operations but may eventually lead to complete
new mining technologies in open-pit as well as
in underground mining."
Grasshoppers
Conveyor stacking systems in heap leach
operations commonly include one or more long
(overland) conveyors that transport the ore from
the preparation plant to the heap. Any number
of grasshopper conveyors will transport the ore
across the active heap area. A transverse
conveyor feeds the stacker-follower conveyor.
The stacker-follower conveyor is typically a
horizontal mobile conveyor that retracts behind
the stacker. The radial stacker will likely be 25
to 50 m long, with a retractable 10 m conveyor at
its tip. Wheels, discharge angle, and stinger
position are all motorised and are moved
continuously by the operator as the heap is built.
For example, in 2007 SENET was awarded the
contract to supply two heap leach grasshopper-
type stacking systems to URAMIN for its
Trekkopje uranium project in Namibia. Each
Rotor of bearing-less gearless drive motor
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CONVEYORS
CONVEYORS
stacking system consists of:
17 1,350 mm wide x 38 m long grasshopper
conveyors
One 1,350 mm wide x 29 m long transverse
conveyor
One 1,350 mm wide x 42 m long stacker feed
crawler powered indexing conveyor
One 1,350 mm wide x 34 m long self levelling
slewing stacker conveyor with a 5 m
extending stinger conveyor.
Each stacking system is rated at 3,750 t/h of
crushed ore, giving a total yearly throughput of
40 Mt.
Mike Bernard, Vice President and General
Manager of Terra Nova Technologies (TNT) says
TNT is the premier supplier for heap leach
stacking systems, having supplied more than
90% of the fixed pad multiple lift systems
running throughout the world. We are applying
this knowledge to in-pit crushing and conveying.
We offer a new system of self-advancing dumps
that eliminates the need for truck haulage to
establish the waste dump corridors.
Based on our experience operating,
designing and building mobile stacking
systems, TNT has developed and patented a
unique design for Super Sized mobile
conveyors that are self-propelled on crawler
tracks and specifically designed for high
tonnage applications. The features of these
include:
Long reach (250 or 76 m)
Truss levelling
Articulating head and tail sections
Hydraulically adjustable bang plates
On-board generators to power their
relocation.
These features result in shorter downtimes
and higher overall utilisation of assets. Typically
the enhanced mobility of these systems also
results in better use of the available stacking
areas. Whereas conventional shiftable or bridge
conveyor systems would be limited by hills,
crests, and ridgelines, grasshoppers and Super
Portable systems can stack around these
obstacles until they have been covered up by
the material stacked. In fact, several of our
systems are now conducting valley fill
operations.
Over the past decade we have increased the
tonnages Super Portables can handle. Current
72 (1.83 m) systems can stack up to 8,500 t/h.
We have designed systems with 96 (2.44 m)
belts, which will carry up to 20,000 t/h.
Grasshopper or link conveyors are becoming
more popular as fuel and tyre costs rise as they
can eliminate haulage with trucks/wheel
loaders. Telestack notes their application
provides a mobile link between an excavator,
mobile crushing unit and fixed overland
conveyor for efficient transfer of material to
secondary processing stages within ports,
mines and stockpiling facilities. They are of
course popular in stacking heaps for SX/EW
production. Grasshoppers are inclined
conveyors 20 to 50 m long, with a tail skid and a
set of wheels located near the balance point.
Key benefits of its units according to
Telestack include:
Complete site mobility for maximum
flexibility
Dual Power as standard (diesel hydraulic
engine for tracks and electric driven belts)
Eliminate/reduce double handling of material
Reduced operating costs (Fuel, labour,
maintenance etc.)
Reduce dust, noise and emissions
Telestack offers increased and more cost-
efficient production with throughputs up to
1,000 t/h and conveyors that accept up to -300
TNTs most recently completed mobile stacking system in South America. TNTs scope of supply
began at the tripper discharge. This photo shows a total of 27 mobile conveyors extending out from
the tripper, arranged in a stacking line across a 1.8 km pad (total pulley-to-pulley lengths in a
straight line would be 1,981 m the additional length allows some flexibility of layout around the
tripper and for filling in corners). The transfer conveyor is positioned in the roadway so that pickups
can individually pass beneath its head truss. It feeds the series of 23 Super Portables (the first one
of these is at an angle in the photo). The three conveyors at the far end have a diagonal alignment in
this photo because the operators were filling in one corner of the new cell. On the right, a closer look
at the three end pieces of the stacking systems the Radial Stacker, Horizontal Conveyor, and
Horizontal Feed Conveyor. Their arrangement allows the Horizontal and Stacker to retreat 30 (+9 m)
at a time while staying in line with the Horizontal Feeds discharge chute. In this photo the operators
are just about to the point where they need to remove a Super Portable
Retreat stacking with grasshopper conveyors
mm material. They can travel and operate at
gradients up to 1 in 8.
Each unit is independently mobile and can
also be linked in series for maximum flexibility.
This is facilitated by variable hydraulic discharge
heights for smooth material transfer between
conveyors in changing ground conditions. There
are hydraulic levelling rams to adjust belt angle
to prevent spillage in uneven terrain. Other key
features are:
Material transfer rates up to 2,500 t/h (based
on density 1.6 t/m
3
)
Lengths from 20 m to 43 m
Impact bars beneath receiving hopper for 0 -
300mm material
Diesel engine powers 2.5 m crawler tracks
and front steering wheels for easy site
movement
1,200mm wide, four-ply EP630 belt.
Rollers and liners
For conveyor systems challenged by corrosive,
abrasive, sticky materials, P&H Minings
Continental Unit offers Tufkon idler rollers and
conveyor frames.
Surface salt processing operations are one
primary destination for Tufkon idler rollers and
frames, notes Bobby Barnes, Continental
Conveyor Products representative for North
America. Unlike underground salt mines that
are quite dry environments, above-ground salt
mines and salt-processing operations can be
hard on all kinds of equipment, Barnes said.
When you combine humid air with airborne salt
dust, everything seems to rust before your eyes.
This is particularly evident in operations where
large volumes of salt water are evaporated to
obtain raw salt for consumer and industrial
products.
While salt operations have found stainless
steel conveyor idlers and frames to be the best
solution from a useful life and cost standpoint,
Tufkon rollers and coated conveyor support
frames perform the same, but at about half the
cost, Barnes noted. Major salt suppliers have
tried this alternative to stainless steel and they
are increasingly adopting Tufkon components
for their conveyor systems.
Tufkon is a black, high-density polyethylene
material that provides high resistance to
corrosion while repelling sticky or naturally
adhesive materials such as asphalt or potash,
preventing them from gathering upon roller
surfaces and causing conveyor misalignment.
Gummed-up idler rollers and conveyors
become a serious maintenance issue, Barnes
explained. Material build-up on conveyors can
also be a potential safety issue as those build-
ups can de-train the conveyor belt and collide
with drop brackets. That can also ruin costly-to-
replace belts.
Telestack radial
telescopic stacker
stockpiling from
mobile link
conveyors in Chile.
The system provided
by Telestack includes
five tracked mobile
link conveyors, two
tracked mobile
telescopic links and
one TS 1542
(tracked) radial
telescopic stacker for
a heap leaching
application
stockpiling copper
ore at 1,500 t/h
CONVEYORS
Conveyors need to be in good alignment. If
that belt oscillates from side to side, the idlers
can be damaged. Damaged idlers can damage
the belt. Product can be lost. Maintenance cost
can soar.
Maintenance people are the biggest Tufkon
proponents because it helps free them up to
concentrate more on preventive maintenance,
Barnes said. Purchasing managers like Tufkon
because its half the cost of stainless steel
rollers and frames. Operations managers
appreciate Tufkon because it increases conveyor
system reliability and productivity in harsh
environments.
Wear Liners are designed to be an integral
part of any bulk handling conveyor system. They
eliminate spillage and prolong skirt board and
belt life; by preventing fugitive material from
escaping, damage is prevented to the conveyor
loading areas. ASGCO manufactures a variety of
such liners with many options and sizes to
choose from. Abrasion resistant, modular, high-
wear material is used to line belts, chutes, and
bin impact areas.
A copper mine was experiencing extreme
wear on the liners installed in the Tripper Car
Pant Leg chutes of a copper ore tripper
tertiary crusher feed system. Liners were being
changed out every down day (seven-day interval)
due to the excessive wear. Unscheduled down
time due to wear, continued to be an issue in
this application. After a 12 month test using
Armorite Liners, the customer found that the
product out performed anything it had
previously tried. AGSCO reports it had exceeded
all expectations and the customer has now
standardised the Armorite 700 product in this
application on all sizes of liners, and maintains
the cost in savings of maintenance outweighs the
additional cost of the product a minimum of 10 fold.
The customer has now moved to a visual
inspection of the tripper pant-leg
once a month, instead of daily as
previously required with another liner.
At a lower cost per tonne, ASGCO
X-Wear offers a substantial reduction
in operating cost compared to any
other lining material, the company
says. Its energy absorbing design
dramatically reduces noise, and
smooth laminar surface provides
optimum sliding surface with a low
coefficient of friction.
Made with Hardox 400 Steel, X-
Wear (AR) wear liners extend the life
and effectiveness of the sealing
compound while protecting the skirt
board. The straight design is used
where belts are fully loaded and full
chute width needs to be maintained,
while the angled deflector wear plate
liner forces larger material to the
centre of the belt.
In another example ASGCO technology
solved a safety issue for a major iron ore
shipping and handling terminal on the Great
Lakes in North America. The need was to protect
workers from all areas of the conveyor systems
that are accessible or create a safety hazard, yet
allow for easy removal and replacement when
maintenance is required. Before the
assessment, numerous tail sections, drives and
take-ups were not adequately guarded, allowing
access to moving components. Some walkway
areas had to be protected since they were
between a permanent wall and the conveyor
systems. This facility also had multiple
roadways and railroad tracks that passed
underneath conveyors, which posed a problem if
any of the return idlers broke loose from their
drop brackets. Site assessment was completed
along with detailed drawings for component
placement. This will ensure that all personnel
and visitors are entering and working in a safe
environment, while still being able to perform
any PM or replacement issues that arise.
By using various standard sizes of its Safe-
Guard Flat Guard, ASGCO was able to protect
the areas of concern and still allow them access
as needed by easily removing and replacing the
lightweight powder coated panels. Guarding
placement was achieved using both the existing
structure and some minor modifications for floor
mounts. With the standard panels sizes used,
there was no need for special orders. Inventory
panels for replacements or additions are easily
obtained as well.
All overhead areas were secured using the
ASGCO Return Idler Cage, which were easily
mounted to the existing conveyor truss on a
variety of belt widths. In these difficult to reach
areas, where easy access is a major issue, the
ASGCO Return Idler Cage has been an ideal
selection, the company reports. IM
CONVEYORS
At a lower cost per tonne, ASGCO X-Wear, made
with Hardox 400 Steel offers, a substantial
reduction in operating cost compared to any
other lining material, the company says. Its
energy absorbing design dramatically reduces
noise, and smooth laminar surface provides
optimum sliding surface with a low coefficient
of friction
Tufkon rolls are
constructed with a
1020 carbon steel
inner shell covered
with a 125 mm high-
density polyethylene
outer sleeve. Non-
corrosive glass-fibre
reinforced, thermo-
composite roll ends
enclose double-
sealed ball bearings
and encapsulate
each Tufkon idler
roller shaft
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T
he two key nickel assets in First
Quantums development portfolio are
Kevitsa in northern Finland and
Ravensthorpe in Western Australia. However, the
two operations, both nearing commissioning,
could not be more different in terms of
background. Kevitsa is a large nickel-copper-
PGE deposit located 142 km north of Rovaniemi
inside the Arctic Circle in Lapland and is both
one of the world's major undeveloped sulphide
nickel deposits and one of the largest mineral
discoveries in Finland's history. Due to start up
in mid-2012, First Quantum acquired the rights
to Kevitsa when it took over Scandinavian
Minerals Ltd (SML) in 2008.
Ravensthorpe is located some 570 km
southeast of Perth, Australia and is one of the
most famous some would say infamous
mining projects in recent history. BHP Billiton
ploughed some $3.5 billion in the operations
development, which was/is novel due to the
first use of a combination of pressure acid leach
(PAL) and atmospheric leach (AL), called
enhanced pressure acid leach (EPAL). The
limonite was to be treated by PAL, while the
saprolite was to be treated by AL using the PAL
discharge together with additional acid.
The project had originally been approved by
BHPB in March 2004 with a budget of $1,340
million but by November 2006, capital costs had
risen to over $2 billion. The company did not
officially open the operation until 23 May 2008,
although commissioning took place in
December 2007 with first production of mixed
hydroxide intermediate product (MHP) for
further processing achieved in October 2007; it
was originally scheduled to start production in
mid-2007. Engineering issues with respect to
ore beneficiation coincided with huge increases
in project costs in Western Australia as the
mining boom took hold, driving up prices for
materials and labour. There were also mounting
skills shortages and long delays in deliveries of
specialised materials and equipment combined
with falling nickel prices in 2008 in the wake of
the global economic downturn.
Ravensthorpe was finally sold by BHP Billiton
to First Quantum Minerals Australia on 9
December 2009 for only $340 million. Reduced
profitability prospects, a decreasing scope of
the nickel market, and a gap between projected
capital expenditure and production volumes,
were all cited as factors in the low sale price.
First Quantum is expecting Ravensthorpe to
produce an average of 39,000 t/y of nickel for
the first five years after operations restart, while
overall production over the mines expected 32
year life is forecast at 28,000 t/y.
At the time, Philip Pascall, Chairman and CEO
of First Quantum stated: The acquisition of the
Ravensthorpe nickel operation is a major step
towards First Quantum achieving its goal of
becoming a globally diversified mining company.
This project together with the recently
announced commitment to build the Kevitsa
project in Finland has the potential to make the
company one of the worlds leading nickel
producers. We are committed to re-starting
Ravensthorpe which we believe we can
successfully achieve within a realistic
timeframe. We are confident that our experience
from many years of successfully developing and
operating complex projects will be invaluable in
making this a reality. Our exceptional balance
sheet, strong cash flow from the companys
existing operations and the realistic capital cost
base for Ravensthorpe provide us the time and
flexibility to address the commissioning and
operational issues previously encountered in
order to realise the full potential of this
exceptional project.
Kevitsa increasing resources
Kevitsa was discovered by the Geological Survey
of Finland (GTK) in 1987. GTK carried out
diamond drilling consisting of 563 holes with a
total length of 48,474 m. Of these, 278 holes
totalling 32,845 m outlined the deposit. The
Finnish government auctioned the deposit in
1995, and the project was taken over by
Outokumpu. Outokumpu drilled 15 holes for a
total length of 2,220 m, partly for collection of
material for metallurgical testing. Following
(comprehensive) metallurgical testing,
Outokumpu failed to make nickel and copper at
recoveries which warranted development of the
project and it returned the project to the Finnish
Ministry of Trade and Industry in 1998. In July
2000, SML (then called Scandinavian Gold)
engaged SRK Consulting to compile all data and
evaluate the potential for a large scale open pit
mining operation on the Kevitsa property with
hydrometallurgical treatment of a bulk
concentrate using the PlatSol process. The
technical report prepared by SRK was originally
published in April 2001, updated in September
2003 and amended in December 2003. SRK
identified mineral resources to a depth of 500 m
and mineral reserves for an open pit mining
scenario to a depth of 450 m.
SML concentrated on developing the project
using conventional flotation technology to
produce separate nickel and copper
concentrates for sale to smelters. In March
2004, SML commenced a program of
metallurgical development work designed to
produce such concentrates. Extensive bench-
scale testing was followed by mini-pilot and
pilot plant tests which demonstrated that
separate, smelter-grade copper and nickel
Closing our series of articles on First Quantum Minerals,
Paul Moore looks at two world-class mines about to be
commissioned Kevitsa in Finland and Ravensthorpe in
Australia though in the latter case it is a reopening after a
long and difficult road for the former BHP Billiton operation
GREAT MINES Australia and Finland
Stacker reclaimer installation
during BHPB development at
Ravensthorpe 2004-2007
concentrates can be produced at reasonable
levels of recovery. Following this metallurgical
success, in October 2005, SML engaged St
Barbara to undertake a new study (Kevitsa pre-
feasibility study) based on open pit mining with
production of smelter-grade concentrates for
sale to Finnish or overseas smelters. The study
was completed in July 2006 and showed positive
economics for an open pit operation mining 4.5
Mt/y of ore. Further pilot plant tests were
followed at the Geological Survey of Finland in
the laboratory in Outokumpu in 2006-2008. A
break-through in producing a bulk concentrate
with good recoveries was followed by successful
selective processing of copper and nickel
concentrates.
Following the acquisition of SML by FQM,
during 2008-2010, an intensive program of
resource definition and resource extension
drilling has been in progress at Kevitsa. Drilling
has been focused using a new geological model
that has assisted in the definition of a
substantial new body of mineralisation
immediately south of the prior resource. An
updated resource estimation completed in late
2010 has defined an enhanced resource of 240
Mt at 0.30% Ni and 0.41% Cu in measured and
indicated category plus an additional 35 Mt at
0.29% Ni and 0.36% Cu in inferred category.
This has boosted the overall resource by some
96% compared to the resource at time of
acquisition in 2008. The mineral reserves have
also been reassessed and have been developed
using current and predicted economic and
physical conditions that are likely to prevail over
the life of mine.
The terrain at Kevitsa is generally flat, with an
altitude of between 220 m and 240 m above sea
level. The Kevitsa hill, rising to approximately
350 m, is situated in the southeastern part of
the claim block. The land consists of bog land
alternating with slightly raised terrain with pine
forest. Bedrock outcrops on the hills but is
generally covered by a 1-5 m thin layer of
moraine. In boggy land, a 1-5 m thick peat layer
is developed on top of the moraine. While the
climate is sub-Arctic, there is no permafrost in
the area and year-round operation is possible in
Finland.
Installation of Outotec AG mills at Kevitsa
Geology overview
The mineral deposit on the Kevitsa property is
hosted by the mineral intrusion known as the
Kevitsa Intrusion. The Kevitsa Intrusion is
situated within the Fennoscandian (or Baltic)
Shield which comprises Archaean basement
gneisses and late Achaean to early Proterozoic
greenstone belts. Intrusive activity towards the
end of the Archaean generated an abundance of
layered intrusions, including the Kevitsa
Intrusion. The Kevitsa Intrusion measures
approximately 3.5 km north-south by 5 km east-
west and outcrops to the south of the
Koitelainen Layered Intrusion. The Koitelainen
Layered Intrusion measures some 20 km north-
south by 25 km east-west. The area is partially
covered by a thin discontinuous layer of glacial
moraine which can reach up to 5 m in thickness
and comprises a poorly sorted mix of rounded
boulders and cobbles in a matrix of silty sand.
The Kevitsa Intrusion has a roughly circular
outcrop/subcrop and comprises basic olivine
pyroxenites and metaperidotites in the
northeast, gabbros in the west and central areas
and granophyres primarily in the south. At the
centre of the outcrop is a large serpentinite
xenoliths measuring 500 m north-south by 1,500
m east-west. The northern (basal) contact of the
intrusion dips at between 40 and 50 to the
south and is discordant to the bedding in the
metasediments. The intrusion is characterised
by internal layering defined by changes in
petrological composition. This roughly parallels
the basal contact but the dip reduces to 20 in
the upper layers.
The Kevitsansarvi Ni-Cu-Co-PGE
mineralisation (the Kevitsa deposit) is contained
within the olivine-pyroxenite of the Ultramafic
Zone of the Kevitsa Intrusion. The Ultramafic
Zone contains up to 5% sulphide, the majority of
which occurs as granular masses interstitial to
the cumulate silicate mineral grains. Only in one
particular area do the sulphides become nickel,
copper and PGE rich, and it is this area that
constitutes the Kevitsa deposit.
Economic grades are concentrated in a high-
grade core of the deposit, which outcrops at
surface in an irregular, roughly circular; shape
300 to 400 m in diameter and dips at
approximately 50 to the southwest. The metal
grades decrease gradually away from this core
in all directions. Particularly high nickel and PGE
grades have been identified in relatively narrow
vertical shoots near the surface in the centre of
the deposit. The mineralogy is reasonably
consistent throughout the Ultramafic Zone,
comprising largely olivine and orthopyroxene.
The sulphides are finely disseminated, generally
100-500 microns in size. Most of the sulphides
consist of pentlandite (a nickel sulphide),
chalcopyrite (a copper sulphide) and the iron
sulphides pyrrhotite, troilite and pyrite.
As stated, extensive infill drilling during
2008/2009 has resulted in a significant increase
in the amount of geological data and an
updated mineral resource was developed during
2009. This work included a reassessment of the
geological controls resulting in a significant
uplift in geological certainty. Further drilling
continued during 2010 and additional
mineralisation was identified to the south of the
main zone and relatively near surface. These
zones together with additional data gained from
deeper drilling, have been included in the new
mineral resource. A recently completed
engineering study, based on the new mineral
resource estimate, has defined the new mineral
reserves estimate, the mineral processing
methodology and the project development
timeframe and costs.
A detailed Whittle Optimisation has been
performed on the new geological model which
has identified the economically recoverable
portion of the mineral resource. This
optimisation technique utilises the economic
and physical project parameters derived during
the Engineering Study to determine the open pit
limits. Mining and ore dilution factors have been
applied to the mineral resource to determine the
extent of the mineral reserves. The large-scale
mine will be developed in a series of strategic
cutbacks over the life of mine which should
allow a constant feed rate of up to 5.5 Mt/y to
be maintained. Waste mining will be managed
to enhance operational performance and to
satisfy the requirements of the prevailing
environmental permits.
Early Kevitsa mill construction. The Kevitsa
mine has a sub-Arctic climate but mining can
take place all year round
Equipment and process design
Mining is starting with an open pit. The amount
of mineable ore was updated in December 2010.
At 160.1 Mt, the new mineral reserves are
considerably larger than the previously reported
estimate of 107.5 Mt, and the planned stripping
ratio will be in the order of 3:1. At the
commencement of operations, the annual ore
production will be approximately 5-6 Mt which
would deliver a mine life in excess of 30 years.
Given this increase in mineral reserves, together
with the potential for further mineral resource
growth, various opportunities are being pursued
to scale up production to 7.5-10 Mt/y. Expansion
capability has been designed and built into the
treatment plant facilities and an Environmental
Impact Assessment has been completed and
was followed by an application for a revised
environmental permit.
Mined ore will be crushed in a primary
crusher. The primary crusher product will be
screened to send the AG (autogenous grinding)
mill media to stockpile, the mid-product to
secondary crushing and pebble storage for the
pebble mill media; finally the crushed ore will
be ground in a combination of AG mills and a
pebble mill. Two different concentrates will be
produced 89,000 t of nickel-cobalt-PGE
concentrate grading close to 12% Ni. The nickel
content in the concentrate is expected to be
approx 10,000 t. The annual content of PGEs is
expected to be about 34,000 oz. The second
product will be 59,000 t of copper-PGE-gold
concentrate grading about 28% Cu, some PGEs,
and some 5,000 oz of gold. The amount of
produced copper in the two concentrates will be
about 17,000 t. Copper and nickel ore will be
recovered in separate flotation circuits with each
product being thickened
and filtered to produce
concentrates stored
separately for transport.
Off-take arrangements for
the separate treatment of
both concentrates will
target international as
well as local smelters.
Construction of the $400
million facility is
continuing and on
schedule for commercial
production in mid 2012.
The open pit mine pre-
stripping fleet consists of
six Caterpillar 793F
mechanical drive trucks of which the first five
are due to be handed over in
November/December 2011.
For the main fleet, FQM is considering a
trolley-assist fleet and two Caterpillar 795F AC
electric drive haul trucks are due for delivery
end-March 2012. Ancillary equipment includes a
Caterpillar 854K wheeled dozer for clean-up in
the loading areas, a D11T crawler dozer and a
16M grader for mine road maintenance. The
main loading tools consist of a Komatsu PC5500
hydraulic excavator (with face shovel) and a
WA1200 wheel loader, which will go in operation
in January 2012 and are being supplied and
serviced through local Komatsu dealer Suomen
Rakennuskone Oy.
The mine is also using a smaller PC1250-8
hydraulic excavator. The PC5500 at Kevitsa is an
electric model weighing 527 t powered by two
900 kW motors. It has a standard front shovel
bucket of 29 m
3
, reduced to 26 m
3
due to the
addition of a WP4 heavy duty wear package to
meet the Kevitsa ore density of 2.1 t/m
3
along
with heavy wear conditions. Additional
equipment includes a set of cameras to meet
safety requirements and all provide all round
visibility; as well as an automatic cable drum
with storage capacity of about 270 m of cable
and an Arctic temperature package for -40C
conditions, with preheating of engine, hydraulic
and cab. Assembly of the PC5500 is scheduled
for October 2011 and it is due to start work in
January 2012.
The 205 t WA1200-6 has a Komatsu
SSDA16V160E-2 Tier 2 engine. Special features
include a high lift boom with 16 m bucket, and
again it is equipped with a heavy duty wear
package. It also has an Arctic package as well as
installed VHMS health monitoring, ORBCOMM
(a remote machine health monitoring tool), and
payload management system. Assembly of the
WA1200-6 is scheduled for January 2012 and it is
due to start work in February 2012.
The Caterpillar equipment is being supplied
and serviced by the Finland Caterpillar dealer,
Witraktor.
SML placed the original 20 million order for
the Kevitsa grinding mills from Outotec, which
were delivered in 2010. In June 2007, Outotec
had been retained by SML to carry out
engineering work for the Kevitsa project,
including the design of the planned processing
plant. The grinding mills are designed to
process approximately 5-6 Mt/y with upgrade
capability to 10 Mt/y of ore and are fully
autogenous. They were ordered following
comminution test work in Australia at Orway
Mineral Consultants. The flotation orders also
went to Outotec and included the delivery of 14
Outotec TankCell 300 and 54 smaller TankCell
units for nickel and copper concentrate
production.
Detailed design activities are essentially
complete and all major items of equipment are
on-site. Construction of a number of
infrastructure items is complete including the
access road, the incoming power line and the
water pipeline.
The significant increase in the Kevitsa ore
reserve means that at the currently planned
processing rate of 5-6 Mt/y, the mine life would
be extended to over 30 years. Taken together
with the potential for further resources to be
A Liebherr 994 loading a Caterpillar 785C
during BHPB operations at Ravensthorpe
Conveyor to crushed ore stockpile,
Ravensthorpe
recovered, the company is currently scoping
opportunities to scale production up to 7.5-10
Mt/y. In addition, an application has been made
to expand the current mining lease to
accommodate the further infrastructure that
may be required. Kevitsa has an initial annual
production target of 10,000 t of nickel and
20,000 t of copper.
Ravensthorpe background
The Ravensthorpe integrated mine and primary
processing facility is located 35 km east of
Ravensthorpe, in a band of remnant vegetation
in an agricultural region next to the Fitzgerald
River National Park about 570 km south-east of
Perth, Western Australia, and 155 km west of
Esperance. Ravensthorpe holds 27 mining permits
(133 km
2
), two granted exploration permits (31
km
2
) and two exploration permit applications
(174 km
2
) covering a total area of 338 km
2
. As well
as the 100% owned tenements, Ravensthorpe
has agreements in place with other companies
for access to laterite nickel rights on a further 14
tenements totalling 423 km
2
.
Mineralisation occurs in limonite (high iron,
low magnesium and calcium, upper levels) and
saprolite (low iron, high magnesium, deeper
levels) ores in the three deposits Halley's,
Hale-Bopp and Shoemaker-Levy. Between the
three ore bodies the nickel ore resource is
currently given as 384 Mt.
Mining in Ravensthorpe predates the current
nickel mine, with gold discoveries dating back to
1898. The town experienced a down turn after
the First World War but mining for copper
continued up until the 1970s. A railway line
connected Ravensthorpe with the port of Hopetoun
from 1901 to 1925, when the line was closed.
BHP Billiton commenced a feasibility study
for Ravensthorpe in 2002 for opening a nickel
and cobalt mine and processing plant. The
project was approved in 2004 and construction
commenced shortly afterward. The plant known
as the Ravensthorpe Nickel Project was
commissioned in late 2007 with first production
occurring in October and the first 5,000 t being
produced by December 2007. The plant was
officially opened in 2008. In January 2009, BHP
Billiton announced that it was suspending
production at the Ravensthorpe nickel mine
indefinitely, due the reduction in world nickel
prices caused by the global economic crisis and
the LME nickel price dropped to as low as
$8,810/t in late 2008.
Deposit geology
Ravensthorpe lies close to the southern margin
of the Archaean Yilgarn Craton, within the
Ravensthorpe Greenstone Belt. The project is
centred on the Halley's deposit, a single 3 by 1
km tabular lateritic nickel oreboody along with
the adjacent Hale-Bopp
and Shoemaker-Levy
deposits. The lateritic
nickel deposits are
developed over an
ultramafic suite with
rare interflow
sedimentary units of
the Bandalup
Ultramafics, a NNW
striking, serpentinised
komatiite suite with
rare interflow
sedimentary units. The
Bandalup Ultramafics,
which are up to 1,500
m thick, overlie the up
to 750 m thick Chester Formation, and are
overlain by the 2,000 m thick Maydon Basalt
and then the 1,000 m thick Hatfield formation.
Thick, irregular intrusions of serpentinised
peridotite to dunite, 500 to 3,000 m wide, occur
in an arcuate zone some 21 km long, which lies
on the northeastern limb of the major syncline
and includes bodies in adjacent granitoid rocks
of the Manyutup Tonalite.
The ultramafic parent of the lateritic deposits
has been described as a serpentinised 'dunite'
(34 to 48% MgO and anhydrous) containing
close packed pseudomorphs after coarse-
grained anhedral olivine and accessory
magnetite, which is variably altered to
serpentine-talc-magnesite rocks.
A thick, up to 80 m, lateritic regolith is
interpreted to have developed on the Bandalup
Ultramafics during the Tertiary Period, and is
partially preserved at each of the deposits. The
regolith profile comprises at the top a lateritic
residuum a strongly indurated, ferruginous
and siliceouscrust with a leached siliceous
pedolith that is largely depleted in nickel,
copper and magnesium but enriched in silica,
iron and aluminium. Then there is a ferralite
zone consisting of weakly to strongly indurated,
porous, cellular rock, dominantly composed of
iron oxyhydroxides (mainly goethite), silica and
minor clay. It is highly porous due to the
relatively isovolumetric leaching of almost all of
the magnesium and is generally enriched in
nickel, locally enriched in cobalt and forms the
majority of the Halleys deposit. Then there is a
saprolite-clay-serpentine-goethite-carbonate
weathered ultramafic with local silica veining.
The top of the saprolite is usually marked by a
rapid decrease in magnesium and a coincident
increase in iron as the boundary is conformable
with the base of limonite and goethite
formation. Nickel grades increase rapidly above
a 0.3% threshold above the base of the
Saprolite sizer feed grizzly at Ravensthorpe
saprolite. The zone of nickel enrichment and ore
occurs as a single gently undulating slab.
Around two thirds of the zone lies within the
ferralite horizon while the remainder is within
the upper saprolite. Higher nickel grades tend to
occur at one or two horizons within the
enrichment zone, with the most continuous
being towards the top of the ferralite zone,
associated with the main zone of cobalt
enrichment, although peak cobalt grades are
generally found 2 to 4 m higher in the profile
than the nickel peak.
Magnesium is the most important gangue
component in the ore as it is the principal
consumer of sulphuric acid in the PAL circuit. As
such there is a direct relationship between
magnesium grade and operating cost.
The beneficiation problem
Before the ore passes through the leaching
circuit it must be upgraded the original design
saw the ore pass through a beneficiation plant,
scrubbing and screw classifiers, that are meant
to separate waste material such as silica, sand
and gravel from the valuable nickel ores. As a
result the ore feed to the primary processing
plant is of significantly higher grade than the
grade of the ore mined. The limonite ore
represents two thirds of the feed source, and
can be upgraded to almost twice the mined
grade due to high silica content of the ore. The
saprolite ore also upgrades, but to a lesser
extent than the limonite. Soon after the
acquisition, First Quantum indicated the
beneficiation plant as one of the main problem
areas as it believes that screw classifiers in
particular are not the appropriate technology to
achieve a proper and consistent size split.
Instead, the idea is to use screens in addition to
screw classifiers to de-water and classify the
ore. The valuable nickel bearing material is
contained in the fines fraction, and achieving a
proper size split and ability to reject the nickel
barren material is
crucial. The crushing
issue was that the
ore is sticky and
was often getting
stuck in the flow
the new
beneficiation
approach and two
separate crushing
stations housing
sizers allow the ore
to pass through
more easily.
Sandvik installed
the four sizers (two for saprolite, two for
limonite) at Ravensthorpe with an additional
two spare machines. The six sizers are all of
model number CR610/08-25. The four that are
working are currently crushing at a rate of 1,800
t/h which exceeds their specification design rate
of 1,500 t/h.
The onward processing is a combination of
pressure acid leach (PAL) and atmospheric leach
(AL), called enhanced pressure acid leach
(EPAL). The limonite is treated by PAL, while the
saprolite is treated by AL using the PAL
discharge and additional acid. But it is complex
as the EPAL process entails separate mining,
stockpiling and beneficiation of the ores. Alan
Taylor of ALTA Metallurgical Services points out
that atmospheric sulphuric acid leaching (AL)
has a low capex than PAL with less aggressive
leach conditions, lower maintenance costs and
atmospheric pressure operation which is simpler
than PAL. It also has a higher on-stream
availability and individual leach tanks can be by-
passed. Challenges include a high acid
consumption; longer retention times than PAL;
the need to process leach solutions with high
impurities, especially iron, and lower recoveries
than PAL.
Construction of the original project was
managed jointly by Hatch Associates and GRD
Minproc. Outokumpu Technology (now Outotec)
was awarded a 35 million contract originally
that included the largest-ever thickener order in
Australia and consisted of six 42 m diameter
counter current decantation (CCD) high
compression units, four 30 m neutralisation high
rate thickeners, three 20 m beneficiation paste
units and two 20 m pressure acid leach paste
(PAL) thickeners. A further contract includes
two shell supported drum scrubbers with
diameters of 4 m and 5 m diameter respectively.
The two scrubbers treat saprolite and limonite
feed streams, before entering beneficiation and
PAL thickening duties. Two of the 20 m
beneficiation thickeners treat the limonite
stream prior to PAL, whilst the other
beneficiation thickener will treat the saprolite
stream prior to the atmospheric leach circuit.
The 20 m PAL thickeners treat hot and extremely
corrosive materials. They are protected by the
use of an array of exotic stainless steels and
other surface treatments. Both thickeners are
supplied with FRP roofs to prevent gas
emissions and heat loss.
Modifications and mining
The process plants annual capacity as
calculated by BHP was 50,000 t of nickel and
1,400 t of cobalt while First Quantum estimates
28,000 t/y nickel output capacity over the life of
the mine and 39,000 t/y for the first five years.
The decline in production after year five is a
function of lower grade material being
processed. Using price assumptions of $6.75/lb
of nickel and $12/lb of cobalt, Ravensthorpes
unit cash cost of production is expected to be
approximately $5-6/lb of nickel.
In 2009, Lycopodium was awarded an EPCM
services contract by FQM as part of the
recommencement of operations. A major focus
of the work is the comminution circuit which as
stated has been modified to allow for more
efficient processing of the sticky laterite nickel
ore. Lycopodium has worked with First Quantum
at Kolwezi in the DRC so the two companies
already have an established relationship.
Lycopodium stated: This is considered a
strategic opportunity to further our expertise in
this area and expand our services to a key
client. Lycopodium completed the detailed
design of modifications which include the two
new ore crushing stations (one for saprolite and
the other for limonite); a new dewatering
facility; new buffer ponds with one month
production storage capacity; an upgraded
Tailings Storage Facility; a new lined sands dam;
a new nickel product bagging facility and
container loading facility and an additional
diesel power plant (5.5 MW to 13.5 MW).
Upgrade and modification work scheduling is
expected to allow initial production to
commence in late-2011. This will be followed by
approximately six months of commissioning and
ramp-up. In order to provide further
enhancements to the plant, the revised capital
requirement for the modification has increased
to approximately $190 million. This work has
been substantially completed.
The mine will use a conventional drill and
blast, load and haul mining system. The open pit
fleet acquired from BHP Billiton includes two
Liebherr 994 backhoe configuration hydraulic
excavators, 10 Caterpillar 785C trucks, a
Caterpillar 992 wheel loader; D9 and D10
crawler dozers, 773 water truck, 16H grader, and
a smaller 330 backhoe excavator. The mine has
five Atlas Copco ROC L8 blasthole rigs as well as
ROC L8 RC drill rigs. IM
Part of the downstream EPAL plant at
Ravensthorpe. This is actually not where the
main modifications have taken place
E
xplain where Thiess fits into the Leighton
Group in terms of contract mining expertise,
relationships with other companies in the
group, and regions that you serve?
Thiess, Leighton Contractors and John Holland
are the three main operating companies within
Leighton Group that offer contract mining
services. However, we all compete with each
other for contracts as we all operate as distinct
entities. In addition, Leighton Contractors owns
HWE Mining, another important player, and is a
major shareholder in MacMahon, another
contractor. Thiess and Leighton Asia also
compete in the Indonesian market. In terms of
Thiess expertise, out of our 16 current contracts,
15 are in coal/coal overburden and one copper-
gold. This is an OZ Minerals project; the Malu
open pit at the Prominent Hill project, where we
currently have the contract for mining until
September 2012. We are also diversifying our
portfolio by returning to mining operations in
Western Australia where there are significant
iron ore reserves. Were looking to establish
long term relationships with clients to help them
get the most out of their iron ore mining
operations. The majority of our business
remains in Australia, where for established and
well regarded contractors with a track record,
there are still a lot of opportunities as the
mining industry is still expanding rapidly.
What about the Indian and
Indonesian markets?
While the Indian market
still has a lot of
potential, the coal
industry is still
controlled by the state;
and the process of
tendering for mining
contracts has a
tendency to be
slow and
bureaucratic
with the move to the
latest equipment and
high productivity
mining. In addition,
the companies that
are awarded coal
blocks have to have
links to or own other
consumer companies
such as power
stations or
metallurgical
facilities. However,
Thiess does have two
contracts there a
mine development
and life of mine
operating contract for
the prestigious Pakri
Barwadih coal project
in Jharkhand from
NTPC and also a deal to build the infrastructure,
then operate the Chitarpur coal project in
Jharkhand state for 20 years. In Indonesia there
are strong domestic players such as PAMA and
BUMA that have most of the larger contracts,
PAMA alone having 35% of the market across a
wide cross section of the major clients. At the
same time they havent yet ventured outside
Indonesia.
What are your thoughts on the new Indonesian
Mining Law?
The concept of local, national and other service
providers with restrictions on the operations of
non-Indonesian players we dont feel entirely
comfortable with and we are looking at how we
deal with that going forward. The Indonesian
government needs to provide more clarity on
this than they have done to date. Having said
that, there is a three year period for companies
to conform to the new laws it may mean we
have to start looking at other partnership
options such as joint ventures to continue
operating there effectively.
Can you comment on the mining method
employed by Thiess at its surface contract
mining sites? Are you looking at broadening
your horizons into areas like IPCC?
We are well known as always having used a haul
truck with backhoe hydraulic excavator formula,
and our investment in the latest equipment
continues. We have the first two commissioned
models of the new Liebherr 9800 ultraclass
excavator, and have put in 18 Caterpillar 797F
trucks at Burton and Curragh. There is always a
race to develop larger equipment in the truck
and shovel area but at the same time, there is
an increasing focus on new innovations, of which
in-pit crushing and conveying is one. We think
that IPCC will see more application in the future,
as will autonomous mining. So we are looking at
other mining technologies. That said, at Thiess
we think there will always be a place for truck
and shovel mining, and maybe there are IPCC
options that still employ some conventional mining.
Also there is the issue of the high initial cost. This
is the same with draglines which Thiess operates
but which are owned by the customer. It is possible
HIGH PROFILE
In an exclusive interview with Bruce Munro, Managing Director of Thiess, the worlds leading
surface contract miner, Editor Paul Moore explores some of the issues unique to contract
mining, as well as the Thiess approach to equipment and technology
Thiess has bought a
fleet of Caterpillar 797
trucks which are
working at the Burton
and Curragh
operations
we could do the same with IPCC, where the mining
group buys the system but we operate it for them.
Do you see a lot of variation between different
mining groups in their attitude to contract mining?
Certainly among the coal groups it varies
considerably. Rio Tinto for example chooses to
do very little contract mining in Australia, but on
the whole contracting still dominates. In
Indonesia, virtually all coal mining by Kaltim
Prima and others is via contractors. In some
cases, a mine will use contracting for
development and main production in the early
stages of a project to minimise risk to the initial
balance sheet and protect against long lead
times for new equipment, and may form an
integral part of their mine plan. The short
answer is that different companies do it in
different ways.
You mentioned lead times. Are they still an issue
for Thiess as a major equipment buyer?
They are less of an issue now that they were a
few years ago. But it is still typical to wait two
years from making a firm order to having a
machine commissioned, something that can
create major headaches for contract miners who
projects. To combat this there are cases where
the mining client will put in the initial order for
equipment first and then pass the machines to
the contractor. But this can create its own issues
as the contractor may have preferred to use
equipment from a different OEM
Do you see further consolidation in the contract
mining sector?
Yes there is still room for consolidation. Forming
a new contract mining company would require a
huge investment, hence the larger groups are
dominating the market for big capital projects.
Also having a bigger balance sheet and a wider
range of projects allows the larger groups to
cope better in difficult economic times. In
Australia, the top tier is basically Leighton
Contractors, Thiess, MacMahon and Downer EDI
with a mid-sized group of another eight or so
companies, but they tend to focus more on
early mine development/earthworks rather
than true contract mining and as their
contracts tend to be shorter, they are more
at risk of economic uncertainty. IM
HIGH PROFILE
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s and short courses.
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One of the new Thiess Liebherr 9800 ultraclass
hydraulic excavators working at Burton
Deloitte has won the prestigious 2011
Australian Business Award Winner for
Product Innovation for Bamboo, a
smartphone platform which is
revolutionising how organisations
manage their business continuity and
emergency response. Deloitte
developed Bamboo to assist clients and
their employees access critical
information and tools during a crisis.
Bamboo is a smartphone platform
which stores clients continuity
management procedures and action
plans in a user friendly and practical
way on employees mobile devices such
as a Blackberry, iPhone and Android.
Iron ore producer Fortescue Metals
Group has rolled out Deloitte Bamboo
across the companys two mine sites
(Cloudbreak and Christmas Creek),
operations and expansion areas. The
application will be accessed and used
by a growing team of employees as the
company expands.
The main drive motor of the first huge
ThyssenKrupp in-pit crusher at CITIC
Pacific Minings Sino Iron project was
operated for 30 minutes in July 2011,
marking an important milestone for the
Chinese-owned magnetite project near
Cape Preston in Western Australia. The
crusher is the first unit of a series of
equipment to be commissioned as the
plant moves from construction to
commissioning in 2011/2012.
Mining services company ADG Global
Supply has established a new London
based office and distribution facilities in
London and Antwerp as a part of an
expansion into Europe. ADG says its
increased presence in Europe will
allow the company to better service
exploration and mining clients
operating across Africa. ADG is a
Western Australian companty which
currently has clients operating in 13
countries throughout East, West and
Central Africa. In FY 2011, ADG doubled
its revenue from its industrial products,
global procurement, supply chain and
project logistics services into Africa to
A$21 million.
Aureus International put the spotlight
on its low profile, reinforced Eternity
underground mining tyres during last
month. The tyres are designed to
reduce equipment height without
reducing the load carried. They have
been designed by American engineers
and offer great operational benefits,
the General Manager of Aureus
International Gautam Roy said. In
underground mines, one of the
challenges that equipment-design
engineers face is the increasing need to
reduce the height of the equipment
without compromising the expected
capabilities and safety standards.
Krummenauer featured its Globoid
shearer drum and EB-water spray
system, said to set new standards in
efficiency, durability, safety and dust
reduction in underground longwall
mines, during AIMEX. The German
company is establishing itself in
Australia following the supply of its
equipment to mines in Europe, Russia,
Poland, Romania, Ukraine, South Africa,
China and, recently, the Westcliff mine
in NSW. The Globoid shearer drum and
EB-water spray system were developed
to alleviate many of the problems
associated with longwall shearer operations
and conventional cylindrical drums.
Eickhoff gave the Australian mining
industry its first look at new
developments it has incorporated into
its SL shearer loader series for the
longwall at AIMEX. The SL 300 featured
is the latest addition to what the
company describes as "the smartest
mining machine in the world". The SL
series effectively automates a longwall
operation, allowing operators to focus
on monitoring functions. "The SL series
at the forefront of a machine generation
which will enable fully autonomous
mining systems in the future."
J. H. Fletcher & Co has been building
diesel powered scaling machines using
inverted articulating booms with a
Caterpillar 320 crawler undercarriage
base for the last 11 years. The current
model covers mining heights up to 5.2
m but the concept can easily be applied
to heights above 9 m using a larger
Caterpillar undercarriage. The crawler
undercarriage provides both a stable
and nimble platform for the scaling
operation. The 360o swing of the upper
chassis and boom provides for precise
attack angles, exceptional
manoeuvrability and maximum
coverage area. In addition, the unique
boom design coupled with proportional
joystick controls allows the operator to
easily follow the contours of the face,
back and ribs to remove loose material
in the most difficult profiles.
The Caterpillar D11, since 1986, has set
standards for machine productivity,
durability, reliability, safety and
operator convenience in high
production dozing applications. The
new D11T and D11T CD elevate that
standard with design refinements that
include Enhanced Auto Shift, Dynamic
Inclination Monitor, automatic climate
control and available automated ripper
control. The D11T and D11T CDs 634 kW
Cat C32 engine can work fuel efficiently
anywhere in the world, and with blades
ranging in capacity up to 43.6 m3 and
operating weights up to 112,698 kg, the
D11T and D11T CD can work productively
in the toughest of materials.
Runge has launched XERAS Reader.
Following the success of XERAS, the
financial modelling tool of choice for
mining, XERAS Reader enables users
that do not have a XERAS licence to
access the data calculated in XERAS
financial models. XERAS Reader allows
a user to access the assumptions, logic
and processes used within a XERAS
model. XERAS Reader comes with the
unique drilldown feature, and powerful
auditing, graphic and reporting tools
that are available within XERAS. Client
feedback drove the development of
XERAS Reader said Darren Rostron,
Product Manager - Financial Solutions.
Our customers told us that they needed
their stakeholders and clients to be able
to review XERAS models and data.
Murray & Roberts Cementation Zambia
has been awarded the shaft sinking and
equipping of the Synclinorium shaft for
Mopani Copper Mines in Kitwe. The new
shaft is expected to add about 25 years
to the life of the Nkana copper and
cobalt mine near Kitwe. The main shaft,
which will be sunk to 1,200 m with a 7
m diameter, will be equipped as a rock
hoisting shaft on this brownfields mine
to service a new area under development.
A 6 m diameter raisebored ventilation
shaft will form part of the full project.
By 2018 the new shaft will boost
Nkanas ore production from 3.4 Mt/y to
5.1 Mt/y. Mopani is an integrated
copper and cobalt producer located in
the Zambian Copperbelt. Mopanis
operations comprise four underground
mines, a concentrator and a cobalt plant
around the town of Kitwe and an
underground mine, concentrator,
smelter and refinery at Mufulira. IM
To keep up with this news in detail,
go to www.im-mining.com
FROM: WWW.IM-MINING.COM
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items to its website, mainly technology
related. Here are some recent highlights
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PROJECT NEWS
PREFEASIBILITY.........................................................................................................................................................2
PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD ...............................................................................3
CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER .........................................................5
CANADA - Western Copper Corps - GOLD/SILVER .........................................................................................9
Corp LIGNITE.10
COTE DIVOIRE - Etruscan Resources - GOLD ...............................................................................................13
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PROJECT NEWS
PREFEASIBILITY.........................................................................................................................................................2
PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD ...............................................................................3
CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER .........................................................5
CANADA - Western Copper Corps - GOLD/SILVER .........................................................................................9
Corp LIGNITE.10
COTE DIVOIRE - Etruscan Resources - GOLD ...............................................................................................13
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Tel +44 (0) 870 112 9191
P.O. Box No 3258
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Mining business in
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Makati Central Post Office
1272 Makati City
info@philippineminingclub.com
www.philippineminingclub.com
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Consulting services from exploration
through to mine closure
srk consulting
www.srk.com
AEL Mining Services 31
www.aelminingservices.com
Alvenius 50
www.alvenius.com
Aramine 41
www.aramine.com
Atlas Copco 27, 49, 59
www.atlascopco.com
BASF 5
www.meyco.basf.com/mining
Becker Mining Systems 37
www.becker-mining.com
Bestech 35
www.bestech.com
BioteQ Environmental Technologies Inc. 79
www.bioteq.ca
CAE Mining 24
www.cae.com/mining
CAT Mine Star System IBC
www.catminestarsystems.com
Cheminova Danafloat 52
www.danafloat.com
Clayton Equipment Ltd 79
www.claytonequipment.com
Cubex 45
www.cubex.net
3D Laser Mapping 79
www.3dlasermapping,com
Devico A.S 53
www.devico.com
DRA Mineral Projects 79
www.drasa.co.za
Dywidag-Systems International 30
www.dsi-mining.com
Euro Mine Expo 2012 55
www.eurominexpo.com
Flowrox Oy 54
www.flowrox.com
FLSmidth 65
www.flsmidth.com
GIA Industri AB 39
www.gia.se
Haver The Screening Group 9
www.haverscreeninggroup.com
Immersive Technologies 29
www.immersivetechnologies.com
Infomine 77
www.infomine.com
Ishigaki 33
www.ishigaki.co.jp
Manitou 11
www.manitou.com
Martin Engineering 67
www.martin-eng.com
Metso Minerals IFC
www.metso.com
Micon International 79
www.micon-international.com
MineArc Systems 32
www.minearc.com
Mine Hoist International Ltd
A division of Mining Equipment Ltd 47
www.minehoist.com
Minova International Ltd 17
www.minovainternational.com
Nordic Lights 58
www.nordiclights.com
Objectivity 43
www.objectivity.ca/vrex
Outotec 51
www.outotec.com
Oy Kati AB Kalajoki 57
www.oykatiab.com
Putzmeister 12
www.putzmeister.es/shotcrete
PAUS 38
www.paus.de
Rana 36
www.ranacaregroup.com/mine
Redpath Mining 25
www.redpathmining.com
Rema Tip Top 13
www.rema-tiptop.com
Rexroth Bosch Group 15
www.boschrexroth.com
RME Mill Relining Systems 71
www.rmeglobal.com
Rulli Rulmeca S.P.A 61
www.rulmeca.com
Ruukki 21
www.ruukki.com/mining
Sandvik Mining and Construction 7, OBC
www.sandvik.com
SEI Industries 24
www.sei-ind.com
SRK Consulting 79
www.srk.com
Thoroughtec Simulation 23
www.thoroughtec.com
Thyssenkrupp Frdertechnik 63
www.tk-mining.com
TWP Projects 44
www.twp.co.za
Vermeer 19
www.vermeer.com
Weihai Haiwang Hydrocyclone Co., Ltd. 46
www.wh-hw.com
Weir Minerals FC, 2
www.weirminerals.com/WBH
October 2011
26-29: ExpoMineria 2011 Acapulco, Mexico,
VIII National Meeting on Mining Law and IX
Latinoamerican and Caribbean Meeting on
Mining Legislation, Buenos Aires, Argentina.
www.derechominerolatin.com.ar
November 2011
1-3: 8th Fennoscandian Exploration and Mining
conference (FEM 2011), Levi, Finland.
http://fem.lappi.fi
6-8: China Mining Congress & Expo, Tianjin
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www.china-mining.org/en
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Langley, Perth, Australia.
www.strategic2011.com
14-17: Flotation 2011, Cape Town, South Africa.
www.min-eng.com/conferences
December 2011
November 28-December 2: NWMA 2011
Annual Meeting and Exposition, John Ascuagas
Nugget Casino Resort, Sparks, NV, USA.
www.nwma.org
February 2012
6-9: Investing in African Mining Indaba, Cape
Town, South Africa.
www.miningindaba.com
19-22: SME Annual Meeting & Exhibit,
Washington State Convention And Trade Center
Seattle, Washington, USA.
www.smenet.org
March 2012
4-7: PDAC 2012, Toronto, Canada.
www.pdac.ca
7-9: Mining Vietnam 2012 exhibition, Hanoi.
www.allworldexhibitions.com
April 2012
16-19: 15th International Seminar on Paste and
Thickening Tailings, Sun City, South Africa.
www.saimm.co.za/saimm-events/upcoming-
events
16-21: Intermat, Paris, France. www.intermat.fr
24-26: Third International Conference on Shaft
Design and Construction 2012, London, England,
United Kingdom. www.iom3.org/events/sdt
June 2012
6-8: IV International Exhibiton on Mining
Equipment and Mining Services: San Juan, Key
Factor of Argentine Mining Development, San
Juan Province, Argentina.
www.sanjuan-minera.com.ar
19-21: Hillhead 2012, Tarmacs Hillhead Quarry,
Buxton, UK. www.hillhead.com
September 2012
10-14: Electra Mining Africa 2010, Johannesburg,
South Africa. www.electramining.co.za
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www.minexpo.com
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November 14-17:
Flotation 2011, Cape
Town, South Africa.
www.min-eng.com/flotation11
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OCTOBER 2011

Informed and in-depth editorial on the world mining industry

centrifugal slurry pump, allowing non-stop operation.

expeller for better sealing and

ARMAN in the new W WA

on the new WBH

R1700G, R2900G Underground Loaders

simulation technology for testing and training. A

simulation technology to tests and validate a

. The VOD uses five control

AR DPFs on two quite different light duty diesel

can be used to optimise resource

300 flotation cells, concentrate

Modern Conveyor Architecture, a new approach

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