Sg113 Mas Low

SOLID
#1.2013
GROUND
a magazine from sandvik mining Outside the tunnel
for automated LHDs
at Rio Tintos
Northparkes mine.
Hefty handling
in Hungary:
Giant power
Conveyor belts:
Futuristic
inventions
Australia:
Automated productivity
Accelerated
action
Rock tools: One for each Sandvik MC470: Robust flexibility
welcome
sandvik news
Exciting additions to truck family..........................4
Dear reader, the profile
sandvik mining places great importance on Maintaining efficiency in Kazakhstan...................6
supporting our customers and helping them meet
the ever-increasing challenges in the industry, trade news
regardless of the market situation. Boost in Western Australia.......................................7
We consistently strive to find ways to improve
the service we provide. Many of these improve- mtrai erm lignite mine
ments will remain unseen by you because theyre A custom solution.................................................... 10
taking place in the background, deep within our
organization but we are confident that you will rock tools
benefit from the results they bring. Drill bit family grows stronger............................... 16
one thing that will never change is our focus northparkes copper and gold mine
on safety, an area in which we continue to invest. The road to total automation.............................. 22
Similarly, we will always invest heavily in R&D.
In this issue of Solid Ground you can read about the sandvik mc470
the MC470 continuous miner, designed to Shearing up with stability...................................... 28
combine high productivity with flexibility, and
the RR321 premium rotary drill bit, which sustaining safety
provides a significant increase in service life
A diamond achievement........................................ 31
compared with its predecessor. Then, of course,
we have the new additions to our underground intelligence
truck family, the TH551 and TH663, bringing
increased productivity and overall hauling
The allure of belt conveyors................................. 33
speeds, and the AutoMine product family, the big picture
designed for open integration with other IT
systems at mine sites. A rare gem .................................................................. 36
Ive hopefully given you just a taste of the
product range
many exciting developments here within Sandvik
Mining, designed to bring you, the customer, Equipment for every need..................................... 38
what youre looking for safety, productivity
and peace of mind. Im not going to take up any
more of your time, so please read on to find more
about what Sandvik Mining can do to help you
meet the challenges you face, both now and in
the future!
SOLID GROUND is a business and technology magazine from SandvikMining,

SE-811 81 Sandviken, Sweden. Phone: +46 (0)26262000. Solid Ground is published twice a year
in English, Chinese, French, Polish, Portuguese, Russian, Spanish and US adaptation.
The magazine is free to customers of Sandvik Mining.
Published by Spoon Publishing in Stockholm, Sweden. ISSN 2000-2874.
Editor-in-chief and responsible under Swedish publishing law: Jeanette Svensson.

Account executive: Johan Andersson. Editor: Chi An Gramfors Englund Sub editors: Michael
Miller, Eric Gourley. Art director: Annika Sundstrm. Language coordination: Sergio Tenconi,
Louise Holpp. Prepress: Markus Dahlstedt. Cover photo: Minco photography. Editorial board:
Tiina Heini, Conny Rask, Christian Ahumada, Roy Jia, Kate Bills, Viktoriya Miroshnichenko.
Please note that unsolicited manuscripts are not accepted. Material in the publication may only
Gary Hughes be reproduced with permission. Requests for permission should be sent to the editorial manager,
Solid Ground. Editorial material and opinions expressed in Solid Ground do not necessarily reflect
President the views of Sandvik Mining or the publisher.
Sandvik Mining Correspondence and enquiries regarding the magazine are welcome. Contact: Solid Ground, Spoon
Publishing AB, Rosenlundsgatan 40, SE-118 53 Stockholm, Sweden. Phone: +46(0)84429620.
Email: solidground@sandvik.com. Distribution enquiries email : solidground@spoon.se
Internet: www.solidgroundmagazine.com.
Solid Ground is issued for informational purposes. The information provided is of a general nature
and should not be treated as advice or be relied upon for making decisions or for use in a specific
matter. Any use of the information provided is at the users sole risk, and Sandvik Mining shall not
be liable for any direct, incidental, consequential or indirect damage arising out of the use of the
information made available in Solid Ground.
2 solid ground 1-13 sandvik mining

CONTENTS 1.13
Mns Berg
10
Compact bucket- 6
Meet Kazakhmys
Copper Corporations
chief mechanic.
wheel excavator in
Hungary is the first
Zhanat Aytokhozhin/Novic Photo Studio

of its kind.
16
The RR321 premium
rotary drill bit serves
longer than its predecessor.
28
The MC470 continuous
miner is built for South
African coal mines.
mns berg
33
Belt conveyors have
operational advantages over
conventional truck haulage.
9
Coal-reliant India
may need new
underground
mines.
22
minco photography
ges
Rio Tintos partnership with

Sandvik propels Northparkes
y Ima
towards 100 percent loading

Gett
automation.
solid ground 1-13 sandvik mining 3

sandvik news
South Africas first MC430

springs into action
Quicker
l South Africas first Sandvik MC430 continuous
miner was in operation in Mpumalanga only a few
than ever
months after it was purchased at the Electra New speedy system
Mining Africa 2012 trade show.
STA Coal Mining has been impressed with the
MC430s power-to-weight ratio and its cutting l With a hydraulic-pressure sampling rate of
rates in the hard coal of Mpumalangas coalfields. 200 times per second, Sandviks recently
The MC430 has several features that will help released advanced electric dump valve system Sandviks new electric
us maintain our excellent safety statistics, says is the quickest tramp iron protection system of dump valve system offers
any cone crusher on the market. fast tramp iron protection.
Bob Nkosi, director partner at STA. I believe the
purchase of this The control and hydraulic system reacts
The Sandvik MC430 instantly to unwanted objects in the crushing and making maintenance access easier.
continuous
machine from
miner Sandvik heralds the chamber, including tramp iron, drill bits, mill balls, Factory-installed electric dump valve kits are
beginning of a solid excavator teeth, pieces of steel or severe available for Sandviks CH870, CH890 and
relationship between packing of fine material in the crushing chamber. CH895 models, while retrofit kits for crushers
our two companies. When coupled with the design of the Sandvik already installed in the field are available for
Hydroset system, the speedy electric dump several additional models.
valve system decreases exposure to pressure Customers who have already installed the
peaks by more than 90 percent, reducing the electric dump valve have seen significant
risk of internal damage to the crusher. improvements in the protection efficiency, says
The external dump valve is located on the Andreas Christoffersson, product specialist for
Strong bond within side of the crusher, increasing operator safety cone crushers.
mineral processing
l Finnish mining equipment supplier Outotec
signed a letter of intent with Sandvik in
September to develop mineral processing
solutions focusing on comminution.
The two companies have collaborated on
several projects in the past, and their mineral
processing solutions complement each other,
creating a complete value chain solution for
processing plants that includes ore crushing,
grinding and concentrating.
Strengthening our relationship with Outotec
will further enhance our proven concept, says
Maximized safety
Gary Hughes, president of Sandvik
Mining.
& efficiency
The quote
Sandvik has + Emergency

escape
l As mines go deeper underground,
the demand for safer, faster and
work most productively with the
LH517 and LH621 loaders.
been operating
window
more efficient hauling continues to Innovative thinking, comprehensive
in cabin
increase. Sandvik presented two research in the complete under-
successfully + Adjustable
steering
new additions to its underground
truck family at MINExpo Interna-
ground hard rock hoisting applica-
tion and customer feedback have
wheel angle
for 150 years, always
tional 2012 to answer those needs. played a major role in the design
and length
The TH551 and TH663 under- process of these new trucks, says
with a strong focus + Optional

onboard
ground trucks have been designed
for state-of-the-art safety, higher
Mark Ryan, product manager for
Sandvik trucks.
jacking productivity and increased overall The trucks feature more than 63
on innovation. hauling speeds to ensure high annual
output. They feature massive hauling
different safety features to protect
operators, maintenance staff and
capacity per envelope size and will be the machines. The ergonomic cabin
Jan Lissker, Sandviks executive vice available with up to Tier 4i-technolo- is 35 percent larger than predeces-
president for group communications, on
business data leader Thomson Reuters
gy engines that boast high torque sors.
recognizing Sandvik on its 2012 list of the characteristics with low fuel The TH551 will be available in
worlds 100 most innovative companies. consumption and low emissions. mid-2013 and the TH663 at the end
The trucks are engineered to of 2013.

getty images
Versatility 1,000
l A steel plant in Vietnam will
benefit from 14 new stackers,
reclaimers and stacker/reclaimers
in Vietnam
by the end of 2015.
The Sandvik materials-handling
machines delivered over the next
three years will operate within a Shifts without a lost time incident (LTI)
celebrated by Sandvik Mining Namibia last
capacity range of 675 to 6,000
November, a milestone that has been
tonnes per hour for materials achieved over the past three years at the
including iron ore, coke and sinter. companys operation in Swakopmund.
The contract includes design,
engineering and supply of all
components, forwarding and
transportation to the steel plant in
Vietnam and installation and
Rio goes all-in on
commissioning of all machines on a automation at Argyle
turnkey basis.
l The worlds largest underground mining
automation system will be installed by the
end of this year at Rio Tintos Argyle Diamond
Mine in Western Australia.
Sandviks advanced AutoMine system will
Fourteen
Sandvik help Argyle improve efficiency, production and
materials safety. The order comprises 11 LH514 electric
handling loaders and two diesel LH410 loaders, which
machines will will be operated from Sandvik control room
be delivered
through 2015. systems above ground. In addition, Sandviks
recently launched Draw Control will enable
accurate tracking, reporting and overall
management of manual production loading
during the mines development phase.
Exploration expansion Argyles production structure is designed

for automation. Sandviks AutoMine system
will help increase block cave annual produc-
DE130x is ATEX certified tion to about 9 million tonnes per year.
l The Sandvik DE130x is a fully certified emergency stop on the feed boom for
exploration drill rig for underground coal increased safety.
applications according to stringent European George Tophinke, global exploration
standards. equipment manager, says expanding coal
The ATEX-certified rig is the latest in markets led Sandvik to bolster its offering to
Sandviks DE100 series of compact core drills include a certified drill in the DE100 series.
for surface and underground exploration. ATEX Historically this series has been very Argyle will
consists of two EU directives one for successful for Sandvik, Tophinke says. We receive its
equipment manufacturers and one for expanded our offering in line with our remaining LHDs
this year.
operators that outline permissions for important ongoing efforts to integrate EHS
explosive environments. into our products.
The DE130x features a redesigned power
unit, upgraded steel parts and a wire Growing
+ ATEX derives its name from
the French title of the 94/9/ AutoMine family
EC directive: Appareils
destins tre utiliss
en ATmosphres l High-quality, reliable fleet automation for
EXplosives. drilling, loading and hauling, single loader
automation, block cave draw control and
process-management systems were among
the highlights of Sandviks offerings at
MINExpo INTERNATIONAL 2012.
One of the major customer benefits across
Sandviks new AutoMine product family is
improved safety, since fewer people work in
potentially hazardous areas. Real-time
process management and control increases
productivity, and smoother control of
equipment reduces maintenance costs.

profile
About oleg li
AGE: 37.
POSITION: Chief Mechanic
of Kazakhmys Copper
Corporation,
Kazakhstan, CIS.
RESIDENCE: Moved from
Zhezkazgan to Astana.
FAMILY: Wife Olga and a
daughter.
Kazakhmys Corporation is a
UK-headquartered copper
mining company whose
primary assets are located in
Kazakhstan. The company
operates 16 open pit and
underground mines along with
two smelting and refining
plants in the Republic of
Kazakhstan.
Copper topper
Oleg Li joined Kazakhmys Corporation in 2001. Since
then he has advanced from being a mining equipment fitter in
a Zhezkazgan factory to becoming the chief mechanic of the
whole corporation. Now he lives and works in Astana, the
capital of Kazakhstan.
WHAT ARE YOUR MAIN DUTIES AS CHIEF MECHANIC?

I ensure efficient usage and high-quality maintenance and
repair of all the technological equipment of Kazakhmys
Corporation.
WHAT DO YOU THINK OF SANDVIK EQUIPMENT? I have
worked with Sandvik equipment since my very first days at
Kazakhmys. It is used in all our mining companies. We have
at least 300 pieces of Sandvik equipment: underground trucks,
loaders, drilling machines basically all of Sandviks product
line. In my opinion Sandvik technology is one of the very
most reliable. And the Sandvik staff is very flexible and
always responds to our problems.
WHAT CHALLENGES DO YOU ENCOUNTER IN YOUR
WORK? The biggest challenge for us and, I believe, for
many companies around the world is to find personnel with
Zhanat Aytokhozhin/Novic Photo Studio
the right qualifications. Another challenge, which is also one

of my KPIs, is to provide a safe work environment.
WHAT ARE YOUR HOBBIES AND INTERESTS? I love
reading and exercising. Im heavily involved in working with
the Youth Kickboxing Association in Zhezkazgan.

trade news
Rio races on TB sweeps

South Africa
Iron ore giant boosts capacity in Pilbara
l South Africas gold mining industry
may have the highest incidence of
tuberculosis in the world, according to
the Department of Healths Tuberculo-
sis Strategic Plan for South Africa
20072011.
TB cases range from 3,000 to 7,000
per 100,000 miners annually. The World
Health Organization classifies an
incidence of 250 per 100,000 per year
as a health emergency.
Tuberculosis has long been linked to
silicosis, a lung disease caused by
inhaling crystalline silica dust, which is a
widespread hazard in the South African
mining sector.
Rio Tinto advanced
plans to expand pro-
duction capacity in
Western Australias Jorge Merino Tafur,
getty images
Pilbara region to 283 Perus minister of

million tonnes annually energy and mines.
by the end of 2013.
l Rio Tinto, the worlds second-largest iron ore Significant stimulus efforts have been
Big time
producer, maintained plans to increase production in
late 2012 as many mining companies scaled back
announced in China, the US and Europe, but its
uncertain exactly when we will see the impact of
investments
operations to combat higher costs and falling prices. these on our markets, Tom Albanese, Rio Tintos l Mining investments in Peru could top
The companys iron ore output jumped 5 percent CEO at the time, said. Given this, and the 50 billion US dollars by the end of the
in the third quarter of 2012 as mines in Western considerable price fluctuations in recent times, we decade, according to the countrys
Australias Pilbara region achieved a quarterly are somewhat more cautious on the outlook over minister of energy and mines.
record of 63 million tonnes. the next few quarters. Showcasing projects for South
While Rio Tinto confirmed in October that the Still, the company advanced plans to expand American and Arab investors in October,
company was cutting more costs, it upheld plans production capacity in the Pilbara region to 283 Jorge Merino Tafur said Perus mining
to increase iron ore production in anticipation of million tonnes annually by the end of 2013 and to and energy sectors surged from 1.87
strong demand. more than 350 million tonnes by mid-2015. billion US dollars in 2001 to 8.5 billion
dollars in 2011.
He also noted potential planned
mining investments of up to 53 billion
The quote dollars by 2020, more than half of which
More needs to be done.

are already under development as gold
and copper projects.
Joseph A. Main, assistant secretary of labor for mine health and safety, says that although
Zambia to
the US mining industry achieved historically low fatality and injury rates in 2011 according
to results announced in late 2012, all such incidents are preventable.
double
copper
Australia wows women l Since the Zambian government
into mining industry privatized the sector more than a
decade ago, mining companies have
invested 6 billion US dollars to
l The Queensland government has scholarships of up to 20,000
rehabilitate and expand processing
launched a scholarship program to Australian dollars over four years to
plants, according to Fredrick Bantu-
incentivize women to study mining help women study such subjects as
minco photography
bonse, general manager of the Chamber

and proceed to jobs in the agricultural science, architecture,
of Mines of Zambia.
male-dominated industry. building services, engineering,
Bantubonse estimated that the
Women currently represent In October, John-Paul Langbroek, geological science and IT.
less than a fifth of Queens- country should double production to 1.5
state minister for education, training Women represent less than a fifth
lands mining workforce. million tonnes within the next five years.
and employment, announced 500 of Queenslands mining workforce.

trade news
China pushes Chuquicamata in
coal-to-gas pilots Chile is the largest

open-pit copper
mine in the world.
l China is investing 14 billion US dollars in
pilot projects to convert coal extracted in
remote regions into natural gas for urban
areas.
The government has green-lighted four
projects in northern provinces that it
hopes will produce 15 billion cubic metres
of gas annually by 2015 almost 7
percent of the countrys demand and
help China meet its need for cleaner fuel
while avoiding dependence on expensive
gas imports.
China hopes to transform its rich coal
reserves into gas via technologies similar
to those used in South Africa for
oil-from-coal projects under apartheid.
In Inner Mongolia last July, state-run
Datang Power launched the first
coal-to-gas conversion plant, which will
have a full capacity of 4 billion cubic
metres by 2014.
France eyes
domestic rare earth
minerals
l Frances minister of industrial renewal,
Upside down
Arnaud Montebourg, hopes to develop new
mining projects in the country after
decades of closures.
Montebourg told a French strategic
metals committee in October that a
planned overhaul of the countrys age-old New start for Chuquicamata mine in Chile
mining code would encourage new projects
while protecting environmental concerns. l As ore grades decline and trucking becomes crushing and conveying (IPCC) system. Trucks
The government also hopes to update a economically unviable, the worlds largest open- currently drive more than 10 kilometres to bring
30-year-old geological survey and target pit copper mine is going underground. lower-grade ore from the bottom of the worlds
strategic rare earth minerals. Chiles massive Chuquicamata, which began second-deepest open pit to the surface.
production in 1915, is forecast to be unprofitable Codelco believes the mines untapped deposits
before the end of the decade. are equal to more than half of all copper
In an effort to avoid closure, state-owned extracted there over the past century. The
Codelco has already invested nearly 4 billion US company is confident an underground mine at
dollars to transform it into the worlds largest Chuquicamata can produce more than 300,000
underground mine. The company will dig more tonnes of copper per year for another 50 years.
than 1,000 kilometres of tunnels below the pit The open-pit mine produced 443,000 tonnes in
and plans to replace dump trucks with an in-pit 2011.
1,000,000,000,000
Estimated value of copper, iron and other mineral deposits in Afghanistan, in US dollars.
getty images
Arnaud Montebourg, US military researchers have estimated the cost of constructing and operating a railway
French minister of network across the country at more than 54 billion US dollars. The price tag and logistical
industrial renewal. challenges of a railway system required to transport minerals out of Afghanistan
could render major mining financially unfeasible.

India must go deep
l As coal-reliant Indias power demands grow and
options for cheap open-pit operations dwindle, some
The Expert
energy industry experts say shifting the focus to Tony Davies is a retired professor of
expensive underground mines may be the only viable occupational health who has focused
way to prevent a major power crisis. on lung diseases for many of his 50
India, which holds massive estimated coal reserves of years working in central and southern
286 billion tonnes, meets close to 75 percent of its Africa. He served as director of South
demand domestically. Much of that is not accessible Africas National Institute of
Forever young
through open-pit operations, which some experts believe Occupational Health from 1985 to
will be exhausted within a decade. 2002 and has published more than
State-run Coal India Limited produces 80 percent of 100 articles, many on subjects related
l Despite its age of 12.2 billion the countrys coal at an average cost of around 13 US to health in the mining industry.
years, one of the tens of thousands dollars per tonne in open pits less than one-fifth as
of stars in the Messier 4 globular much as underground mines. The company says the Q: Why does exposure to quartz
cluster has kept its young features. higher costs and lower output of existing underground dust predispose miners to
And surprisingly, the star is rich in mines make them financially unfeasible at todays prices, tuberculosis of the lungs?
lithium, one of the most sought- but importing is also costly. A: Small particles of quartz (silica)
after metals on earth. Only 10 percent of Coal Indias reach the depths of the lungs and
Normally, the lithium in stars is output currently comes from damage the cells that remove foreign
destroyed over billions of years. But underground mining. material from the air spaces. These
this star has found a way to stay cells are the first line of defense
young, either by retaining its original against tuberculosis. Once the lungs
lithium or by creating a fresh supply. are thoroughly dusted with silica, the
Regenerating lithium should increased risk of contracting
interest mining companies looking tuberculosis persists throughout
into exploration in space. The Moon life. Silicosis commonly progresses or
is the first place where studies are develops after workers retire. It
ongoing. impedes breathing and can eventually
The lithium star in the Scorpius lead to heart failure.
s
age
constellation is 7,200 light years
Underground coal y im Q: What makes the situation in
away, so travel arrangements for a
gett
mines are expensive South African mines so serious?

potential exploration mission should but will be necessary in
be made promptly. India, experts say. A: Uncontrolled exposure to quartz
dust has been associated with high
levels of tuberculosis for a very long
time, but in South Africa a poor
tuberculosis control service and the
uncontrolled spread of HIV/AIDS have
An Australian resources com- pushed the level of new infections to
pany has identified a maiden
unprecedented levels.
resource of more than half a
billion tonnes grading 0.47
percent copper in Indonesias Q: What is the key to reversing the
northern Sumatra. epidemic?
A: The key is dust control and in fact
most occupational disease originates
from aerosols in the workplace. The
interaction of quartz dust, tuberculo-
sis and HIV has proved disastrous for
South Africa. Mines must become
more conscious about controlling
dust. Respiratory protection isnt
always enough, especially for regular
Sumatra hits huge full shift work. Source control cant be

underestimated, whether its the use
prized metals deposit of wet methods, engineering controls

like local ventilation
or specialized systems
l An Australian resources company has resource of more than half a billion tonnes and equipment.
discovered a massive copper and gold deposit in grading 0.47 percent copper. The Beutong
Indonesias northern Sumatra that it says could deposit also holds gold and silver and has a
rival Rio Tintos Bougainville deposit in Papua higher-grade core of 153 million tonnes at 0.63
New Guinea, which was the worlds largest percent copper. Health expert
Tony Davies
open-cut mine when it ceased operations in The company has implemented a scoping
getty images
believes in
1989. study to investigate the viability of a mine at dust source
Tigers Realm Group has identified a maiden the discovery. control.

Mtrai erm Lignite mine
bulky
biz
BKKBRNY, hungary. Eight million years ago,
a forest of swamp cypress trees as tall as 40 metres
towered above what is today an opencast lignite mine
providing fuel for one of Hungarys largest power plants.
Text: Eric Gourley Photo: Mns berg

The worlds largest
compact bucket-
wheel excavator
continuously strips
overburden, helping
Mtrai Erm reach
lignite more quickly.
A rchaeologists
discovered 16 preserved cypress trunks
on the lowest level of the Bkkbrny
pit in north-eastern Hungary several
years ago.
the worlds largest compact bucket-
wheel excavator (BWE) PE100 with a
beltwagon PB100.
Mtrai operates two opencast mines
to produce the 8.5 million annual
While most of the ancient forest tonnes of lignite required for continu-
turned to coal during the Miocene ous operation of its 950-MW power
period, a suspected sandstorm covered plant, the largest such operation in
some of the massive trees, preventing Hungary. The plant produces more than
the wood from becoming fossilized. 15 percent of Hungarys energy
The first European discovery of such demand, a vital domestic operation in a
old trees in their original location country of 10 million people who rely
excited scientists, who can learn about on Russian natural gas and other
the Earths climate during the period. foreign imports for as much as 70
Around the time that the most-intact percent of their primary energy needs.
trunks were extracted from Bkkbrny
and transported to museums for
preservation, in mid-2007, the mines
owner, Mtrai Erm (Matra Power
L ignite, sometimes referred to as
brown coal, has a high moisture
content and is used primarily as fuel for
Plant), contracted with the Austrian steam-electric power generation.
branch of Sandvik Mining Systems on Sixty percent of Mtrais lignite


sandvik solution
First of its kind

l As mining in the Bkkbrny pit moved
into an area where Mtrai had to strip a
growing amount of overburden to access
the underlying lignite seam, the company
demanded a unique excavator to expand
capacity, boost productivity and decrease
reliance on costly shovel-and-truck
operations.
Sandvik designed and built the
first-of-its-kind PE100, the worlds largest
compact bucket wheel excavator with a
theoretical hourly capacity of 6,700 cubic
metres. At an annual capacity of around
12 million cubic metres, the PE100 works
in tandem with the PB100 beltwagon and
boasts more than double the lignite-strip-
ping capacity of other excavators used in
Bkkbrny.
EHS note: The machine

is not in operation in this
photo and the people
are standing a safe
The Sandvik PE100 compact bucket-wheel excavator distance away, avoiding
with PB100 beltwagon (background) is standing still for the potential safety
inspection. In full production the PE100 boasts a
theoretical capacity of 6,700 cubic metres per hour hazard of falling objects.
double that of other systems in Bkkbrny.

Mtrai mining
strategic director
Barnabs Derekas
was pleased that
Sandvik erected
the machine
before the
deadline.
Its an easy system.

The interfaces are The Northern
very user-friendly. Cape is the

largest and
most sparsely
Operator
populated Zoltan
Toth hasof
province been
working with the
South Africa.
bucket-wheel
excavator since
its birth in 2009.
26
comes from the larger pit in Visonta, strategic director Barnabs Derekas our most important measures as an
about 90 kilometres north-east of says. We had our belt systems and a operator. We chose Sandvik because
Budapest. That lignite, with lower spreader. We were searching for a big they offered the best solution based on
heating value, is conveyed a short machine because over time it became a combination of those factors.
distance to the neighbouring power million cubic clear that continued cutting would be Mtrai consulted experts in complex
plant and mixed with a higher heating metres, the significantly cheaper than shovel-and- excavator projects at German utilities
approximate
value lignite that is transported 60 amount of truck in our operation. company RWE. Sandvik representa-
kilometres by train from the younger overburden Mtrai tives for various parts of the machine
N
must remove to
Bkkbrny pit. produce 3.5
eeding an annual capacity of met with Mtrai and RWE every other
Bkkbrny began production in million tonnes of around 12 million cubic metres, week for several months to plan details.
1985 as a shovel-and-truck strip mining lignite annually. Mtrai estimated calculations for the Components for the excavator were
operation. Mtrai debuted its first BWE capital investment and operating and manufactured partly in Hungary and
here in the early 1990s to continuously maintenance costs of a new BWE. The partly in other countries across Europe.
strip overburden and access the company initiated negotiations with As many as 130 erectors worked on
underlying lignite seam more quickly. prominent suppliers in Europe, site daily for almost nine months to
As mining moved into an area where assigning different percentages of build the PE100 excavator and
the overburden covering the lignite importance to three crucial criteria: accompanying PB100 beltwagon,
continued to increase, Mtrai sought a price, technical specifications and which went into production ahead of
unique excavator to increase produc- payment conditions. schedule in mid-2009.
tion capacity and boost productivity. We didnt want to find the cheapest Mtrai conducted a series of
We already had all the other solution, Derekas says. We wanted to capacity and performance tests over
equipment in the pit, Mtrai mining find the best overall solution based on different durations, and the machine


Zoltan Jager, sales manager
for Sandvik Mining Systems,
left, and Simon Csaba, chief
of Bkkbrnys mainte-
nance department, are all
smiles about the bucket- Bkkbrny
wheel excavator.
Budapest
hungary
Europe
Bkkbrny is located in
north-eastern Hungary,
about 150 kilometres
from Budapest.
About Mtrai
Erm and Visonta/
Bkkbrny mines
l Mtrai Erm (Matra Power Plant)
operates a 950-MW coal-fired power
plant in north-eastern Hungary, the
countrys second-largest operation. Over
achieved all targets established in the metres long and features a 12-metre-
the past 35 years, Mtrai has produced

contract two years earlier. wide wheel fitted with 16 buckets. It around 130 billion kilowatt-hours of
Sandvik built up a very unique works in parallel with a crawler-mount- electricity. The company mines around
machine for the deadline, Derekas ed beltwagon that overcomes high 8.5 million tonnes of lignite annually from
says. When it was finished and went bench changes, conveying overburden two opencast operations to fuel the
from the job site into the pit it started an additional 50 metres to one of plant, which produces more than
running immediately and produced the Bkkbrnys three conveyor systems. one-tenth of Hungarys electricity
contracted values. We were very Bkkbrny has to remove as many demand.
pleased. as 26 million cubic metres of overbur- Mtrai mines lignite with lower heating
value from a massive pit in Visonta, about
den to produce 3.5 million tonnes of
S
90 kilometres north-east of Budapest,
hrouded in fog early one winter lignite annually. The first 20 metres of
which is conveyed a short distance to the
morning, the sheer size of the overburden are a mix of dirt and soft, neighbouring power plant and mixed with
1,650-tonne PE100 becomes clear as wet clay. Beneath the clay is a layer of a higher heating value lignite transported
the sun starts to creep over the edge of sand with the occasional thin line of by train from the younger Bkkbrny pit
the Bkkbrny pit and the mist begins coal, but the primary coal seam is even an hour away.
to lift. deeper.
The excavator boasts a theoretical The PE100 enables operators to
capacity of 6,700 cubic metres per hour select specific programs for cutting the
more than twice that of the three different types of overburden, since
smaller excavators in operation at each requires unique cutting forces and
Bkkbrny though actual capacity rotating speeds.
is limited by the width of the conveyor Its an easy system, says Imre
system and capacity of a spreader at the Papp, an excavator operator who has
other end. been working with the system since its
The excavators steel boom is 28 birth. The interfaces are very

400
user-friendly. Everything is clear for live transmissions of technical
the operators. We never have any issues parameters of the excavator and the Tech specs
with the operation. other 12 machines hes responsible for
Unlike Bkkbrnys other million tonnes, ensuring operate smoothly. PE100 compact bucket-
proven lignite wheel excavator
excavators that require the cutting level reserves in the
Weve had no problems with the
to be set manually, Sandviks solution Bkkbrny Sandvik machine, Csaba says. In the Weight: 1,650 tonnes
features a system that can automati- open pit. tender description we said we wanted a Theoretical capacity: 6,700
cally cut the appropriate level based on maintenance-free solution, and this cubic metres per hour
GPS coordinates. Mining engineers in machine has really pleased me from a cutting Height: 20 metres
an office use AutoCAD (computer maintenance standpoint. I have a lot of block Width: 40 metres
aided design) software to plan cutting machines to take care of, and this has Boom length: 28 metres
points and upload the data to a GPS lived up to my expectations. Cutter wheel diameter:
system in the excavators cabin. Bkkbrnys proven lignite 12 metres
When we upload the data into the reserves are about 400 million tonnes Number of buckets: 16
GPS system we manually set to the zero around a century at current Volume of each bucket:
level, and the machine calibrates auto- production rates and Sandviks 1.83 cubic metres
matically, operator Zoltan Toth says. system figures to help Mtrai access Bucket wheel drive output:
An odometer in the operators cabin much of that. 1,100 kW
shows it has travelled more than 550 The primary steer structure is Planned annual working
kilometres in less than four years at designed to operate for 40 years, and hours: 4,800
a maximum speed of six metres per the theoretical lifetime of the bearing in
minute. the bucket wheels main gearbox is
We dont have to worry about 50,000 working hours without
speeding here, Toth jokes, drawing a maintenance around 12 years at the
laugh from Simon Csaba, chief of current 4,800 planned working hours
Bkkbrnys maintenance department. per year.
Our mining systems are built to
A bulletin board in Csabas office a

few hundred metres from the pit
is plastered with pictures of the
last, and this one-of-a-kind BWE is no
exception, says Claus Butter,
Sandviks lead engineer for the project.
excavator being built and in operation. This excavator is just getting started at
Across the room, his laptop receives Bkkbrny.
See the video about Bkkbrny and Mtrai

This excavator is

at www.solidgroundmagazine.com
just getting started

at Bkkbrny.
The Sandvik PE100

compact bucket-wheel
excavator, right, and
PB100 beltwagon work
in tandem almost 5,000
hours per year.

Rock tools
prime
16
power solid ground 1-13 sandvik mining
The new design of the
Sandvik RR321 extends
the drill bits service life.
A new air bearing design means

more operating hours for the
Sandvik RR321 premium rotary
drill bit. With its standard and
ultra-premium bits, the RR family
forms the most comprehensive
range for blast hole drilling.

Text: ke R malm Photos: Mns Berg

T hanks to our know-how and
experience, we managed to find a new
and better configuration of the air
bearings for our RR321 drill bit range,
which has already been honed for 50
years, Nilsen says.
The rotary drilling method has been
around for a century, but the technology
says Petter Nilsen, Sandvik product took a leap 50 years ago with the intro-
support and sales manager, Europe. duction of carbide inserts in the drill bit
The RR321, Sandviks latest model cones. The carbide inserts make the bits
of premium rotary drill bits for blast more durable, and today a whole range
hole drilling, features three air bearings of insert designs are available to cover
with a new design to provide better load all operating conditions. The challenge
distribution. The result is longer bearing is to balance their durability with that of
life, improved bit meters and reduced the air bearings.
drilling costs. This means increased run
time on the rig as well as more holes
between bit changes.
The new design extends the drill bits
S andvik saw that the performance
of its premium air bearing drill
bits needed improvement.
RR321 drill bit
service life by an average of 10 to 15 This is easier said than done on such
Cones
percent beyond what its predecessor the a mature product, so the company
RR320 could achieve. In fact, test decided to devote a substantial amount
results indicate that the increase could of research and development resources Legs
be as high as 50 percent in some cases. to the project. The initial phase included Air bearings
It is quite an accomplishment to get finite element analysis, followed by
this type of improvement on a product laboratory prototype tests. Then the
like the cemented carbide insert bit, viability of the concept was verified in Carbide inserts

tech specs rotary drill bits
Rotary drill bits are mainly used for

The Sandvik DS90KS blast
hole drill rig in Barricks blast hole drilling in open pit mines. The
Pascua Lama open pit original design can be traced back to the
mine is equipped with beginning of the 20th century.
low-pressure air They have three legs, each with a
for rotary drilling.
bearing-mounted cone and pressed
inserts. When a drill rig rotates a drill bit
under pressure via a drill pipe, the cones
will roll in a circular pattern on the rock
surface. The carbide inserts on the cones
then crush the rock, and the cuttings are
flushed up from the hole by compressed
air.
The rotary drill bit is a system of
integrated components, each with its
specific challenges in terms of design and
materials. It is also a disposable article, so
the longer it lasts the lower the drilling
costs will be. At the same time, productiv-
ity will improve because of reduced
downtime for bit changes.
To achieve this improvement, the
combined performance of inserts and
bearings must be optimized.

Carbide inserts make the
bits more durable, so they
can make more holes before
having to be exchanged.

Our products
include rotary
drill bits for all
types of rock
Petter nilsen
The RR family offers

solutions for a wide range
of drilling applications.
field tests over a two-year period. The few years we have seen a very good oped for price-focused customers, but it
final result was an air bearing range development for the RR440. benefits from many of the developments
with more operating hours. The third member of Sandviks of the RR320 and RR321 range.
family of rotary drill bits is the standard Our products include rotary drill
F or those who want even better

performance, Sandvik offers the
RR440 ultra-premium rotary drill bit
model RR220. Compared with the other
two, this bit has fewer features, but that
doesnt mean it has low performance.
Petter Nilsen,
product support
bits for all types of rock, Nilsen says.
This allows us to offer solutions suit-
able for a wide range of drilling applica-
and sales manager.
range, which has already proved its The RR220 product range was devel- tions.
worth for more than a decade. It features
a set of grease-filled journal bearings
with a dual seal to keep abrasive cuttings
out. With the right combination of
inserts, these bits will normally give at On-site results
least twice the operating life compared
The performance ofSandviks RR321 premium air bearing bits has been tested in
with a rotary drill bit with air bearings. several types of mines. Here are two examples.
Even though the ultra-premium
RR440 has been on the market for some Mine type Iron ore Coal
time now, the premium RR321 series is
Bit size 311 mm (12 ) 229 mm (9)
still the predominant choice. However,
a growing focus on drill rig availability Bit type S60 S07
and productivity is causing a noticeable Standard bit distance/
shift in market preference in favour of service life 2,978 m (9,773 ft) / 64 h 5,434 m (17,828 ft) / 47 h
RR440. Longer operating life means
RR321 test bit distance/
fewer bit changes, which gives more
service life 4,163 m (13,658 ft) / 84 h 6,284 m (20,616 ft) / 56 h
drilling time per shift.
The market is gradually moving Distance increase 39% 16%
towards drill bits with sealed journal Bit hours increase 31% 19%
bearings, Nilsen says. During the last

sandvik solution
Performance in the air

l Sandvik wanted to improve the
performance of its RR320 series of
premium air bearing bits. With a wide range
of insert shapes and qualities for different
types of rock already in place, the
company turned its attention to the air
bearings on which the cones are mounted.
The bearings have one row of balls that
handle axial load and two rows of rollers
that take care of the radial loads. During
operation, air is pushed through the
bearings to flush out cuttings and keep
them clear.
After an initial analysis using the finite
element method and subsequent
prototype tests in a laboratory environ-
ment, a new air bearing design was
developed. Field tests over a period of two
years showed that it extended the
operating life by an average of 10 to 15
percent. In some cases the improvement
could be as much as 50 percent.
The secret to success is a different
configuration of the bearing elements,
which gives a better load distribution.
As a result of this successful product
development, the RR321 is now a new
member of Sandviks family of rotary
air bearing bits.

NORTHPARKES COPPER AND GOLD MINE
The mining
PARKES, Australia. Rio Tinto/Northparkes Mines in central
New South Wales, Australia, has successfully implemented Sandvik
Minings AutoMine loading system over the past three years and is
now moving towards 100 percent autonomous loading.
xxxx
xxxxxx
xxxxx
factory
Text: Kate bills & mark Cherrington Photo: Minco Photography


F or Northparkes management,
underground block cave mining is
regarded as a rock factory and the
more factory operations that can be
automated, the more safety and
world, as it moves from open-cut
operations to large underground block
caving operations at a number of sites.
They are looking at Northparkes and
what we have achieved to see what
Australia
northparkes
Brisbane
productivity can be increased and costs they can adapt to larger block caves in
lowered. While Northparkes materials- areas such as Mongolia and the United Sydney
handling system has been fully auto- States, which are operating in much
mated for years, the requirement for more difficult conditions than we do Rio Tintos
manually operated loaders kept the rock here, he says. Northparkes Melbourne
copper and gold
factory vision from being fully imple- Northparkes has a long history of mine is situated in
mented until Sandviks AutoMine innovation on site and has been central New South
Wales, Australia.
loading system.
By automating the loader fleet, we involved with loader automation for
increase the utilization, which we do by nearly 10 years.
being able to operate across shift Joe Cronin, Northparkes LHD
changes and through blast clearance automation manager, says the mine has
times, says Matthew Betts, North- traditionally been regarded as a test
parkes manager for infrastructure and mine for technology for Rio Tinto
mine design for the project. globally. AutoMine loading systems
It means we get more tonnes out of successful implementation at North-
the mine, Betts says. More tonnes parkes sets the stage for rolling out the
means more copper produced. For us system to other Rio Tinto underground
automation is a key enabler for hard rock mines.
Northparkes to produce at a lower unit Theres an old expression within
cost, and mine deeper, lower-grade ore Rio Tinto that if it doesnt work at
bodies cost-effectively in the future. Matthew Betts Northparkes its not going to work,
sees automation Cronin says. Weve got a very high
S uccessful underground block cave as a key enabler level of experience at the mine, very
for extracting
automation is also beneficial for tonnes at a lower high levels of technical expertise, and
Rio Tintos operations around the unit cost. we have a large majority of staff
What is automine
Loading?
l AutoMine loading allows
remote operation and supervi-
sion of an automated under-
ground loader or truck fleet from
a surface control room. The
autonomous fleet is operated in
an area that is isolated from
personnel and other equipment,
greatly enhancing underground
mine safety.
Driving (tramming) and
dumping are fully automated,
while bucket loading is per-
formed using tele-remote
operation. A single system
operator is able to manage the
operation of multiple automated
machines. A wide range of
Sandvik underground loaders and
trucks can be fitted with the
AutoMine onboard package.

Joe Cronin, LHD automation
project manager for Rio
Tinto, and Ashleigh
Braddock, Sandvik
systems engineer for mine
automation, are helping
Northparkes transforma-
tion from manual to
automated operation.
The shift is very

interesting culturally
to watch.
10
whove been here for more than 10 Safety is another major advantage and make it as efficient as possible,
years. Northparkes can therefore more of an automated load and haul system. which is something wed expect to do
readily conduct technology trials, Betts says the environment is safer for in the next 12 months, Cronin says.
because it has the experience needed on the operators working with AutoMine Sandvik has put together AutoMine
site and can facilitate the tests safely. loading. The underground environ- years the loading as a full package to suit the mines
As of early December 2012, 40 ment is hazardous, and theyre Northparkes mine coming needs. Its got the loader
percent of the mines loading opera- exposed to vibration, noise and dust, has been involved automation side, the traffic management
with loader
tions were automated and delivering he says. By automating the fleet we automation. and the production management side, as
productivity benefits. This will soon remove them from that environment well as the interface to our SCADA
expand to 80 percent, with 100 percent and bring them to a controlled office system, he says, referring to the
autonomous operation planned to start environment. companys Supervisory Control and Data
during 2013. Cronin agrees, even though he Acquisition system for monitoring remote
describes Northparkes as a highly stable operations from a central location.
S ome of the immediate benefits

that mine management is seeing
relate to shift changes and blasting
mine with good geology. We dont
have problems with mud rush, high
temperatures or rough roads that cause

re-entry. On some days, theres vibration. But potentially for other

potentially up to two hours where mines within Rio, where those situations
theres no one on the level with may occur in the future as deposits get
manual loader operation, Cronin deeper and we have to extract them in
says. Now, even though theres no more challenging environments, this
one in the mine, the loaders are type of technology will allow the
continuing to produce. extraction of those resources without
Its now possible to plan and be a lot putting any personnel at risk. Sandviks Paul
Anthony Evans
more strategic about how to draw from The next stage at Northparkes is to provides product
the level. Weve probably gone from continue the rollout of automation support for electric
about 20 or 21 hours a day of utiliza- across the other zones in the level. motors and mine
automation at
tion up to 23 hours or even more, he Well work with Sandvik right across Northparkes.
says. this level to get the system optimized

Six Sandvik LHDs have
been fitted with the
AutoMine loading
system at Northparkes.
About
Northparkes
l Northparkes mine is located 27
kilometres from the town of Parkes in
central New South Wales, Australia,
and is a joint venture between Rio Tinto

(80 percent) and the Sumitomo Group
(20 percent).
The underground copper
and gold mine processes
Having had Sandvik on site for some make for a new environment. high-grade copper
concentrate on site
time and them knowing our mines and In the past, those machines have
before it is transport-
our procedures, it was easy to work with been essentially mechanically operated,
ed to Port Kembla,
them for this implementation. so to be working with advanced south of Sydney, and
Talking to Sandvik Minings personnel electrical machinery plus the automation shipped to interna-
responsible for the implementation of systems is a shift thats very interesting tional customers.
AutoMine loading at Northparkes, it is culturally to watch, Braddock says. Northparkes was the first
obvious that they take enormous pride in According to Teemu Lintula, Sandvik mine in Australia to use a
their achievement and the close working Minings automation product line man- variation of the cost-effective
relationship with the Northparkes team. ager, the cooperation with Rio Tinto and block cave mining technique in its
Northparkes has a really good Northparkes has been highly beneficial underground operations. Northparkes
currently has around 300 full-time
reputation as a mine, says Ben Rix, and has given Sandvik valuable feedback
employees.
Sandvik Minings acting Northparkes to further develop its products.
Mines performance contract manager, We are now looking forward to
who describes the relationship as a continued collaboration with Rio Tinto
partnership. with its Argyle Diamonds project, and we
Under our service contract we are also aiming to further develop our
maintain all the mobile equipment in the
production fleet, plus we are now
responsible for the automation infra-
structure and the onboard automation Northparkes started
underground mining
equipment on the machines, he says. using the block caving
We work around the clock, 24 hours a method in 1997.
day, seven days a week, 365 days a year
to keep the machinery running for
production.
There have been challenges on the
way to get the system to work and
operate to a level where the mine can
also be productive, so from a Sandvik
point of view the achievement has been
really satisfying, Rix says.
a shleigh Braddock, Sandvik

Mining systems engineer for
mine automation, has been fascinated
to observe firsthand the transformation
going from manual to automated
operation.
Automation systems in mining,
especially in underground mining,

214
systems, Lintula says. Northparkes has operators point of view, Hartin says. also a system that a lot of people who
set the bar high and is pushing us forward As potential interactions with people in couldnt drive big machines could use.
in achieving those goals. boggers are eliminated, the working The major difference between the auto-
draw points in
environment has become better. matic system and manual operation in
N
Northparkes E48
orthparkes underground block cave, where Theres also more social interaction Morresys view is that its a lot safer. It
technicians Amanda Hartin and Sandvik AutoMine up here, because you can talk to the separates our staff from machine
loading is currently
Ian Morresy have had experience operating. person next to you with none of the operating zones, he says. Ive been
operating loaders underground at the radio noise in the background. underground driving them manually, and
mine, and they are now responsible Morresy says the AutoMine system when youve got boggers in all the drives,
for operation of the automated has its benefits. Its a good system, its it can be a bit hairy at times, so I think
loaders. Hartin finds the automated an easy system to learn, he says. Its this is good.
system a lot more efficient and
pleasant to work with.
With manual loader operation,
wed turn up to work, wed do a shift
change meeting and find out our tasks
for the day, Hartin says. Then wed
head underground, which usually takes
about 10 or 15 minutes to tag on, wed
find our equipment, set up our area
with barricades and the like, then wed
get to work with the boggers [under-
ground loaders].
Now, with the automated system,
she can walk straight into the control
room when she arrives at the mine and
get to work within a few minutes. The
boggers are already set up for us with
the draw points entered for the day.
All the operators have to do is bog
the draw point, then send the loader on Northparkes
its way to the ROM (run-of-mine) area, underground
technician
and it will tip by itself automatically. Amanda Hartin
Then the loader will turn up at the next finds Sandviks
draw point where its needed and we automated
system more
just go again from there. efficient than
Its a lot of technology involved, manual loading.
but its really easy to use from an
Its a good system, sandvik solution
its an easy system Autonomous ore loading
to learn. At Northparkes, AutoMine is currently

operating at the mines E48 block
room. The surface operator is only
required to operate the loader for a
cave, consisting of 10 extraction short time in each cycle: simply filling
drives with a total of 214 draw the bucket at the draw point. The
points. Six Sandvik LHDs five loader then trams autonomously
LH514Es and with a full bucket to the ROM bin,
one LH514 dumps and returns to the next
have been designated draw point.
fitted with the Currently the AutoMine system is
AutoMine working on 40 percent of North-
system, which parkes underground operations, a
See the video about
allows for safe figure that will soon increase to 80

Northparkes at www.
solidgroundmagazine.com operation percent. For the rest of the mines
autonomously extraction drives, autonomous
from the operation is planned to start in
surface control early 2013.

The Sandvik MC470
Shear up
High cutting power is a key feature of Sandviks continuous miner
MC470. This and a heavy frame allow the machine to shear up and
increase productivity in coal and potash mines.
Text: ke R malm
P
+ Health-monitoring visualization
screen on board.
roductive board-and-pillar coal sumps in to full drum diameter, after + Operated by radio remote control.
mining demands a chain of machines which the first car can leave. Shearing
that operate efficiently together. This down will then fill a second car in one
includes shuttle cars and roof bolters, go. Finally, a third car stays behind the
but first in line is a continuous miner MC470 as it brushes the floor before it
that sets the pace. moves forward for another operating
The mines wanted a machine with cycle. The large bunker capacity on the
high productivity and flexibility, says loading table allows the machine to
Gerhard Reiter, product manager at continuously cut during shuttle car
Sandvik Mining. change-out.
Having South African coal mines
particularly in mind, Sandvik developed
the MC470 continuous miner. With a
cutting power of 540 kilowatts and a
W hile productivity is also affected
by other factors, such as overall
availability, this continuous cutting A 3.3 kilovolt power supply +
weight of 127 tonnes, it shears both process and the shear-up function allows for small trailing
down and up to increase productivity. potentially add 30 minutes of coal cable diameter.
Shearing up is an operation where other cutting per shift.
types of machines would typically Like Sandviks successful MB600
become unstable. This happens if the series of bolter miners, the MC470
picks on the cutting drum begin to moves on crawlers. They help the
climb on the face, but the MC470 is continuous miner to avoid unnecessary
designed to prevent that. damage to the floor, which could slow
To use the cutting force properly, the shuttle cars or destroy their wheel
the cutting tools and machine frame hubs. The crawlers are also important to
need to be very strong, Reiter says. create the required flexibility.
Rear stabilizers with an +
operating sequence that
So we ended up with a heavy, robust After around 15 metres of cutting, a minimizes floor damage.
and powerful machine. continuous miner has to move out of
To tap the full capacity of the one entry (a tunnel in board-and-pillar
MC470, the standard operating cycles mining) and go into another one to
for this type of mining need to be allow a bolting machine to install roof
revised. One example is to begin by support, Reiter says Rigid and heavy frame to +
shearing up at a depth of half the drum A quick change will add to produc- handle the cutting forces.
diameter. This will produce around 15 tivity by giving the machine more
tonnes of coal, almost enough to fill a operating time in a shift. The MC470
20-tonne shuttle car. The remaining five has a maximum tramming speed of 25
tonnes will come when the machine metres per minute and an electronically


sandvik solution
Strong and heavy

with a light footprint
l Sandvik Mining was faced with the challenge of
creating a flexible continuous miner with maximum
productivity for board-and-pillar coal mines. It should also
+ Built to protect hoses, cables and keep the floor in good condition for the shuttle cars to
components against damage. stay in shape and move as fast as possible. The solution
was the MC470, a powerful machine on hydraulic track
drives with low ground pressure.
Closest to the face is a cutting drum with a 35-millime-
+ Load-sensing hydraulics with tre pick system. It is mounted on a vertically movable
continuous fluid filtration and boom and propelled by two 270-kilowatt electric motors.
cooling. Below is a floating loading apron with spinners that brings
the cut coal to a conveyor. At the heart of the machine is
a frame that is rigid and heavy enough to handle the
cutting forces, including during shear up. It gets extra
help from a set of rear stabilizers with an operating
+ A scrubber
removes dust from sequence that will minimize floor damage.
the cutting zone. The machine is operated by radio remote control and
built to protect hoses, cables and components against
damage from roof and rib fall. A 3.3 kilovolt power supply
makes handling easy as the voltage allows for a relatively
+ Powered by
small trailing cable diameter. There is a scrubber that
two 270-kilo-
watt electric removes dust from the cutting zone, and the levels are
motors. also kept down by low cutter speed. The onboard
equipment also includes a health-monitoring visualization
screen and load-sensing hydraulics with continuous fluid
filtration and cooling.
+ Cutting drum
with a 35-millimetre
pick system.
+ Floating loading apron with spinners.
+ Hydraulic track drives with

low ground pressure. + Vertically movable boom.

The mines wanted a
machine with high
productivity and flexibility.
gerhard reiter
controlled drive system that keeps a The Sandvik
straight line. And since the roof where it MC470 adds to

productivity by
cuts has not yet been secured, the increasing
miners operate it from a safe distance operating time.
by radio remote control.
So when should you use a continuous
miner, and when is a bolter miner the
best option? The latter is a single-pass
Improved production cycle
machine that cuts one entry width and l The MC470 was first tested in a up in the face and disturb the operation.
bolts the roof at the same time. A regular production environment at That is not the case with this machine,
continuous miner, however, is designed Xstrata Coal South Africas South due to its combination of power, weight
for multiple passes and cuts many Witbank coal mine in January 2010. The and design.
operating conditions included an During its first year of production, the
different entry widths. This makes it a
average mining height of 3.2 metres, a MC470 produced around 800,000
more productive option when several
board width of 6.6 metres and tonnes of run-of-mine coal. This is
entries are cut in parallel, but the bolting 13x15-metre pillar centres. There was 50,000 tonnes more than the current
must then be done by a separate also an occurrence of sandstone layers South African average of 750,000
machine. from 5 to 25 centimetres thick, with a tonnes per year. The encouraging results
In addition to coal mines, the MC470 uniaxial compressive strength of up to have led to further orders from South
is also used for potash mining. 120 megapascals. African coal mines, where a total of
After initial trials to hone the three machines are now in operation.
performance of the MC470, production The machine at Greenside Colliery is
began in the third week of February. This constantly producing at record level,
included a new production cycle, peaking at 121,000 tonnes in the month
facilitated by the machines ability to of October 2012 (average production
shear both up and down. Upward rate: 106,000 tonnes/month). Four
shearing had previously not been an more have been ordered by a potash
Product manager option because the picks could hook mine in Britain.
Gerhard Reiter.
tech specs Sandvik continuous miner MC470
A radio remote-controlled continuous miner on crawlers made for maximum Cutting power: 540 kW (2x270 kW)
productivity in mining applications that demand high cutting force. The MC470 is Cutting width: 3.76 m
designed for typical South African board-and-pillar mining as well as potash mines. Maximum cutting height: 5.0 m
Minimum cutting height: 2.4 m
Drum diameter: 1.3/1.4 m
Loading capacity: 45 tonnes/min
Maximum tram speed: 25 m/min
Total weight: 127 tonnes
Ground pressure: 26 N/cm2
A heavy, robust,
powerful and
flexible machine.

SAFETY STANDARDS
Arctic
safety In the face of some of the
worlds most challenging mining
record
conditions, Sandviks maintenance
team at a De Beers diamond mine
in northern Canada has managed
Text: Lindsay Holmwood to work around the clock without a
lost time injury ever.
N orth of the 60th parallel,

where arctic winds rip unabated across
the Canadian tundra and the sun barely
the mobile underground mining
equipment and related vehicles at the
mine for De Beers, and its
rises in the harsh winter months, a members operate under safety
Sandvik maintenance team is working policies and procedures put in
to ensure that the equipment at the De place by both companies. The
Beers diamond mine operates as it policies largely mirror each
should, and without causing injury. other with the goal of
The team has been working at the recognizing, assessing and
Snap Lake mine in Canadas Northwest mitigating risks before
Territories since 2007. In their nearly things go wrong.
six years there, there has never been a Both companies share
lost time injury (LTI) in which an the desire to get to zero
employee had to miss work, even for a harm, which is fundamen-
day, because of an accident. The tal in terms of how we
reasons for this impressive record are approach our day-to-day
many extensive safety policies and operations, Larsen says.
management systems put in place by Neither company accepts
Sandvik and De Beers but it mostly that an injury is natural in the
comes down to the awareness and course of doing business. The
responsibility of the employees. awareness, enforcement,
Much of the credit goes to the crew coaching and support are there so
and the supervision on site, says Peter that employees are trained to be
Larsen, vice president of Environmen- attentive at all times, and at the end of
tal Heath and Safety for Sandvik the day we have a safe working
Mining Americas. Both companies environment. snap lake
have systems, policies and proce-
dures in place that support the right
thought process when it comes to
safety. From there, the front-line team
B oth Sandvik and De Beers hold the
required certifications and
management systems that form the
and their supervisors encounter foundation of their safety programmes
changing situations where they have to and ensure that the daily work is being
CANADA
decide what to do. We try to put done correctly and safely. But manage-
Snap Lake
systems and a culture in place to ment systems cant cover every conceiv- Diamond Mine in
support the right decisions in every able dynamic and condition. Local Canadas
situation a worker can face. safety programmes then kick in and Northwest
Territories was De
These systems are myriad. The close any gap between the management Beers first mine
45-member Sandvik team maintains all systems and site-specific risks. outside Africa.


Peter Larsen, VP EHS Sandvik Mining
Americas; Neil Miller, Customer Services Sandvik
Mining Americas; Marc Stuparyk, Sandvik Mining
Maintenance Team Leader; Maxwell Morapeli, Snap
Lake Mine General Manager; David Gardner,
President Sandvik Mining Americas; Morag Howell,
Yellowknife Area Sales Manager; and Glen
Koropchuk, COO De Beers Canada, celebrate five
years without a lost time injury last year.
About Snap Lake

Diamond Mine
l Located in Canadas remote Northwest
Territories on the shore of Snap Lake, Snap
Lake Diamond Mine is De Beers first mine
located outside Africa and Canadas first
true underground diamond mine. It boasts
safety-conscious so that there is no job an annual processing capacity of 1.1 million
we do thats unsafe. We dont put our tonnes and a recoverable ore grade of 1.2
All employees participate in a daily people in harms way. carats per tonne, resulting in a production
safety meeting before the start of each This is an understatement. Not only capacity of approximately 1.4 million carats
day and night shift, and a separate has Sandvik gone nearly six years with- of diamonds each year.
once-a-week meeting. Each employee out a lost time injury, but the only The mine began commercial production in
2008 and has an estimated life of more than
also has a five-point safety card that incident of note in that time was when
20 years. The Snap Lake ore body is a
poses questions such as these: Are an employee fell and needed three
2.5-metre-thick dyke that dips an average
entrances and travel ways in good stitches on his elbow. He returned of 12 to 15 degrees from the north-west
order? Is the workplace and equipment straight to work. shore down under the lake. It is unlike most
in good order? And is the work being diamond-bearing kimberlite deposits, which
done safely and properly? The card also
encourages employees to perform an act
of safety each day, a practice of noticing
M ining is known to have certain
risks, and public perception is
that it is a highly uncontrolled environ-
are known as pipes because of their conical
or carrot-like shape.
unsafe conditions such as a power cord ment, Larsen says. The reality is that
that could cause someone to trip. risks can be managed and mitigated. We
Reaching a milestone like this takes dont want to see people hurt. Theres
a long-term focused commitment to
holding each and every employee
no value in a product that has human
suffering associated with it. Risks can be
accountable for their personal safety
and that of their co-workers, from the
Both Sandvik and De Beers have
had to work hard to reach this point, managed and
workers on the maintenance floor to battling a number of challenges that on
senior management, says Cathie
Bolstad, director of external and
their own would pose safety risks, such
as cold, windy weather and soft ground
mitigated.
corporate affairs for De Beers Canada. conditions. Peter Larsen, VP of EHS for Sandvik Mining Americas
The Sandvik employees working at
T he team also uses a system called

Risk Assessment Training to
assess risk, as well as a Big Five Task
Snap Lake, the first true underground
diamond mine in Canada, are flown in
for 12-hour shifts for two weeks, searching for a supplier partner.
Assessment, in which employees followed by two weeks off. There is no De Beers didnt talk about equipment
answer 10 questions about their jobs commercial airport nearby, another or money involved for the longest time,
and job sites before working to identify reason why maintaining a safe Larsen says. When we were approached,
risks and correct unsafe conditions. operation is of paramount importance. the question was more Can we get
Before the start of each job, employees De Beers is committed to mining married, and if we do can we get along?
receive a safe work plan outlining the diamonds safely, securely and profitably, The two companies did a thorough
procedure for a specific job or a repair. without harm to people or the environ- evaluation to see if the cultures and
Historically in the mining industry ment, Bolstad says. To achieve that values would mesh, allowing them to
there are lost time injuries, and goal, its essential to have business get along. Ultimately, the companies
maintenance is usually one of the key partners who share that same principle. aligned closely, and while there have
areas where there are accidents, says Sandvik has had other mining sites been ongoing changes in staff, manage-
Marc Stuparyk, the project manager for with impressive safety records, but Snap ment, resources and the economy, the
Snap Lake maintenance. But with the Lake is special because of the successful culture and safety focus have thrived.
safety programmes put in place by partnership between the two compamies, Were still married, and were
Sandvik and De Beers, we are very which began in 2004 as De Beers was doing just fine, Larsen says.
32 solid ground 1-13 sandvik mininG

INTELLIGENCE
Keeping
it moving
mns berg
F
or more than a century, belt
conveyor systems have helped
Advances in belt conveyor technology
minimize human labour in over the years have led many mines
industrial applications ranging
from automotive to agricultural. to reconsider whether traditional truck
While belt conveyor systems have
been widely used to continuously haulage is always the best option for
transport ore in some mines, truck
haulage has traditionally been the transporting materials.
industry favourite.
But as mines go deeper and trucking Text: Eric Gourley
distances and associated costs continue
to climb, conveyors are proving an
attractive alternative for many opera-
tors, says Craig Wheeler, associate tions at BHPs Newcastle steelworks coal is liberated from the face.
professor in the School of Engineering for more than a decade. While early mining industry applica-
at the University of Newcastle in As bulk materials handling by tions were primarily short in-plant
20
Australia. roller-supported rubber belts has conveyors, single flight conveyors tens
The scales of new mining opera- become more articulate and mobile of kilometres long can today move up
tions are resulting in unprecedented over the years, conveyors have started to 20,000 tonnes per hour at speeds of
demands for greater haulage lengths, to replace an increasing percentage of more than 9 metres per second.
lifts and, of course, capacity, says road truck haulage.
C
Maximum degree
Wheeler, who began a career with BHP of grade that Today, conveyors work closer to the onveyor technology, from
Billiton in 1989 as a cadet mechanical overland face behind blast and load operations components to capabilities, has
conveyors can
engineer and earned extensive belt effectively
than ever before. In many underground developed continuously since the first
conveying experience working in main- traverse. coal mines, conveyors are employed systems were employed in the mining
tenance, operations and design posi- practically from the moment the sector in the early 1900s. Todays


Belt conveyors have clear
operational advantages.
intelligent conveyor designs drasti- capital and operating costs even doctoral studies in belt conveying.
cally reduce friction and rolling further in new mines. With the demand for more and more
energy losses. Optimized trough automated mining operations, belt
shapes and pronounced curvatures are
now common. In-plant and under-
ground conveyors have become more
W heeler says conveyor systems
offer distinct advantages over
truck haulage in efficiency and envi-
conveyors have clear operational
advantages.
Overland conveyors can be routed
adaptable and are able to negotiate ronment. more directly than haulage roads and
tighter corners. Higher-quality Belt conveyors being continuous, can effectively traverse grades of up to
Craig Wheeler,
materials have improved operability rather than a batch transportation associate 20 degrees, while haulage road systems
and increased the life expectancies of system, are used wherever they are professor at are often limited to less than 5 degrees.
Australias
todays overland conveyors to more technically and economically feasible, University of
Conveyors carry more material per
than 30 years in some cases, reducing says Wheeler, who undertook his Newcastle hour over longer distances and at

The wide world of conveyors
Sandvik is credited with
engineering the first steel belt
conveyors in 1902. Today Sandvik
designs, manufactures and installs
complete conveyor systems in mining
operations around the globe.
Sooner or later, every mine, every
crushing plant, every processing plant
will involve conveyors if it doesnt
already, says Thomas Jabs, vice
president product lines, Sandvik Mining
Systems.
Long overland conveyors in Australia
form the backbone of many mining
mns berg
operations and cooperate with the
natural lie of the land, while shorter
in-plant systems across Europe and
South America feature large capacities
and can include belt feeders, conveyor systems, Jabs says. Todays
Solutions for opencast mines also conveyor
high-angle conveyors and totally
components
closed conveyors. include semi-mobile, shiftable and fully are far more
Many mines investigate how quickly mobile track-mounted systems advanced than
they can introduce conveyors to tailored to operator needs. Sandvik is their century-old
now answering more demands for predecessors.
replace some of their expensive
trucks, Jabs says. We have a mine underground conveyor applications,
planning group to help operators which frequently involve extreme
determine at what point it becomes operating conditions.
feasible to make the investment to Weve long served the global mining
replace trucks with conveyors. industry with conveyors for surface
Important factors to consider mining and materials handling
include mine life, geology and deposit applications, but were transforming
shape, scheduled material tonnage into a major player in underground
rates and the price of diesel fuel versus conveyor haulage too, he says.
electricity. Jabs also notes the ever-increasing
Every mass mining operation will popularity of in-pit crushing and
eventually ask those questions, conveying (IPCC).
especially new mines, Jabs says. Its an efficient way to move part of
In addition to popular overland and the processing plant into the mine,
in-plant systems, Sandvik offers bringing it closer to the shovel, to the
Sandvik has designed, innovative mine conveyors, compact- face, so that trucks dont have to travel
manufactured and installed a long distance to a processing plant
type conveyors, apron feeders and
conveyors for many years,
such as this horizontally special conveyors that overcome outside a mine, he says. Conveyors
curved, conventional differences in elevation. are an integral part of each IPCC
Thomas Jabs, vice
troughed overland system Our internal factories produce all system, and theyre the crucial link president product
in South Africa. between primary crushers and
conveyor components, including rollers, lines, Sandvik
pulleys and other integral parts of spreaders. Mining Systems
higher speeds, increasing efficiency Each mines operational needs are haulage with the lower operating costs of
and reducing operating costs. unique, and Wheeler says different conveyors for primary haul out of a pit.
Conveyors also offer distinct envi- factors should be analyzed to determine Choosing the appropriate bulk
ronmental advantages over trucks. A whether ore might best be transported handling system depends on transporta-
conveyor belt in the average mine uses using belt conveyors, trucks or a com- tion distance, throughput and terrain,
one-fifth as much energy as a heavy bination of the two. among other things, Wheeler says.
truck, reducing carbon dioxide emis- Conveyors carry a high cost per Research has shown belt conveyors are
sions. Trucks burn diesel on empty metre, and many operations that lack generally more cost-effective on a life-
return hauls, while conveyors haul fixed haulage distances will always cycle cost basis than both road and rail
material continuously. Conveyors are require the mobility of trucks, he says. transport for throughputs up to 5 million
also quieter, generate less dust and Some mines have learned to combine the tonnes per annum over horizontal con-
consume less land. flexibility of trucks conducting level veying distances up to 40 kilometres.

The big picture
A rare gem
Its unusual crystals and mode of occurrence
distinguish tridymite from all other minerals.
Photo: fred kruijen
l Since the silicate minerals ceramics for linings in equipment Mountains in Slovakia and Pachua
compose about 95 percent of the such as hot stoves, open-hearth in Mexico.
Earths crust and upper mantle, you furnaces and blast furnaces used in In the US, tridymite occurs in the
might think theyre all rubbish. Well, smelting to produce industrial Thomas Range in Utah; the Obsidian
look again and look closely. metals. Cliff in Yellowstone National Park,
Tridymite is a silica mineral (SiO2) Tridymite is actually more common Wyoming; and Mt. Lassen in Lassen
not only valuable to collectors but as a component of opal than as an Volcanic National Park, California,
also used in scientific study. individual mineral. The play of among other places.
This rare and distinctive minerals colours in opal arises from the Tridymite is a high-temperature
crystals are usually microscopic; the diffraction of light from sub- polymorph of quartz and usually
largest are under 1 cm long and very microscopic layers of regularly occurs as minute tabular white or
thin. Here you see tridymite aggre- oriented silica spheres. colourless pseudo-hexagonal
gate from Ettringer Bellerberg in Its unusual crystals and mode of crystals, or scales, in cavities in
Germanys Eifel Mountains with an occurrence distinguish tridymite acidic volcanic rocks.
image width of only 2.5 mm. from all other minerals. The mineral was first described in
Yet they provide key information on Some of the finest examples are 1868 and given its name from the
how crystals form and how they from the Euganean Hills in Italy. Greek tridymos for triplet, as
change in different environments. Other localities include Lyttelton tridymite commonly occurs as
Tridymite is also synthetically Harbour in New Zealand, Cornwall twinned crystal trillings.
produced to make refractory in England, the Northern Slanske anders lindgren
36 solid ground 2-12 sandvik mining and construction

High utility factor
SUPREMELY MULTIFACETED: Silica is extremely
versatile and used in an almost endless range
of applications. A silica-based aerogel was
used in the Stardust spacecraft to collect
extraterrestrial particles. Down on Earth it
may be used in the extraction of DNA and
RNA. In pharmaceutical products, silica aids
powder flow when tablets are formed.
You can also find it in toothpaste as a hard
abrasive to remove tooth plaque. In cosmet-
ics, it is useful for its light-diffusing properties
and natural absorbency. Food and beverage
industries use colloidal silica as a wine- and
juice-fining agent. In its capacity as a
refractory, it is useful in fibre form as a
high-temperature thermal protection fabric.
Microscopic crystal of
the thin, colourless
silicate mineral tridymite.
solid ground 2-11 sandvik mining and construction 37

product range
Excellence in Find the complete range at

mining.sandvik.com
innovation
Sandvik Minings complete portfolio of innovative equipment
pushes the boundaries of modern mining machinery to help
operators improve safety and productivity in todays
increasingly competitive environment.
rock tools and systems drill rigs and rock drills
Deep impact. Sandvik Know the drill. Sandvik

offers the worlds most rock drilling equipment is
comprehensive range of renowned for quality,
tools for exploration, rock reliability and productivity.
drilling, raise boring, coal Every machine we make is
cutting, mineral mining, designed to give the lowest
tunnelling, trenching, road possible cost per foot drilled
grading and cold plan- and a low life-cycle cost. To
ing.As world leaders in meet the needs of all
steel and cemented carbide customers, we offer a wide
technology, our products choice of machines, ranging
have revolutionized the from robust and simple drill
rock drilling industry, while our advanced tool systems for rigs to semi-automated units that give extraordinary production
machines raise productivity sharply. rates and low total cost.
load and haul machines continuous mining and tunnelling
The powerful loaders. Keep on going. Sandvik

Sandvik underground continuous mining and
loaders and haul trucks are tunnelling equipment reflects
extremely productive and the unique advantages of
reliable. They are vigorous total in-house control over
and highly manoeuvrable, the machines and their
offer enormous capacity for cutting tools alike. Opti-
their size and return a very mized cutting technology
low cost per tonne. and machine design result in
high productivity, long
service life and low total
costs.

crushers and screens conveyor components
Maximum size reduction. Roll it up. Sandvik focuses

Sandvik crushing and on developing and manufac-
screening equipment is turing conveyor components
engineered for productivity. to meet customer needs in
We offer advanced solutions mining applications.
for any size-reduction Sandviks complete offering
challenge, stationary or supports modern mining
mobile. We can upgrade practices and includes
existing plants, deliver rollers, frames, pulleys and
complete solutions and effect belt cleaners, safety and
turnkey installations. We also control devices, and dust
supply individual crushers control systems. With an
and screens, as well as key components and a wide range of emphasis on performance and reliability, they are easily
consumables. available through the global Sandvik network both as original
components and as replacements in existing systems.
bulk materials handling equipment breakers and demolition tools
Total handling. Sandvik Hit harder. Sandvik

has the long-term experi- demolition tools make short
ence to design, manufacture work of difficult breaking
and install virtually any and demolition jobs. They
kind of bulk materials are optimized to deliver
handling system. From high-impact cutting or
mining systems on surface crushing force. With high
and underground to power-to-weight ratios, easy
integrated stacking and interfaces and simple
reclaiming systems for connections, they transform
mines, terminals and port a wide range of excavators
facilities, we offer total into highly productive
solutions and turnkey installations. We also offer a wide demolition machines.
range of conveying equipment and quality components for
plants, as well as upgrading and modernization services.
Mine automation safety and environment
Total control. Sandvik Keep it safe. Sandvik

has a deep understanding focuses on the environmen-
of modern mining opera- tal, health and safety
tions and of how automa- aspects of all its products,
tion of loading and hauling but some are designed
processes can contribute to especially for safety. An
safer, more efficient example is the broad range
transport. of products for fire
protection.

Print n:o M11-082:9 ENG-1 Sandvik Mining
Thoralf Klehm, vice managing
director at the Polish coal mine
PG Silesia, is responsible for
the safety of the employees and
keeping productivity increases
on track.
How did PG Silesia

improve both
safety and
productivity?
THIS WAY!
When you are in the mining business, you know that an improved safety record
means a lot to your employees, their families and your company.
This safety mind-set is part of everything we do from research and product
development to on-site service.
Read the story about PG Silesia and join the movement towards
The Future of Mining. Its This Way: sandvik.com/thisway

Sg113 Mas Low

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SOLID

SOLID GROUND is a business and technology magazine from SandvikMining,

Editor-in-chief and responsible under Swedish publishing law: Jeanette Svensson.

2 solid ground 1-13 sandvik mining

Zhanat Aytokhozhin/Novic Photo Studio

Rio Tintos partnership with

towards 100 percent loading

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South Africas first MC430

Sandvik has + Emergency

with a strong focus + Optional

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Exploration expansion Argyles production structure is designed

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WHAT ARE YOUR MAIN DUTIES AS CHIEF MECHANIC?

the right qualifications. Another challenge, which is also one

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Rio races on TB sweeps

Pilbara region to 283 Perus minister of

More needs to be done.

bonse, general manager of the Chamber

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China pushes Chuquicamata in

coal-to-gas pilots Chile is the largest

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mines are expensive South African mines so serious?

Sumatra hits huge full shift work. Source control cant be

prized metals deposit of wet methods, engineering controls

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Text: Eric Gourley Photo: Mns berg

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First of its kind

EHS note: The machine

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Its an easy system.

very user-friendly. Cape is the

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the past 35 years, Mtrai has produced

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A bulletin board in Csabas office a

See the video about Bkkbrny and Mtrai

just getting started

The Sandvik PE100

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A new air bearing design means

Text: ke R malm Photos: Mns Berg

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tech specs rotary drill bits

Rotary drill bits are mainly used for

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The RR family offers

F or those who want even better

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Performance in the air

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The shift is very

S ome of the immediate benefits

re-entry. On some days, theres vibration. But potentially for other

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and is a joint venture between Rio Tinto

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