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The mining industry is currently experiencing several key trends; a fall in commodity prices and an increase in mining production costs (of almost 30%, according to consultancy firm PWC). In addition, the World Economic Forum forecasts a massive step change in the technology being utilised, not least the internet of things (IOT), robotics and artificial intelligence (AI). As so many articles in this August 2024 edition of International Mining Engineer demonstrate, the sector is currently embracing this transformation while remaining committed to its original priorities of safety and productivity. The article titled Smart ventilation (page 36) explores an innovative solution called Ventilation on demand (VOD) that works by utilising mine-based sensors transmitting real-time data on key parameters such as vehicle use and personnel.
In other good news it seems that greenwashing may be less commonplace in mining than it once was. Many operators and their suppliers recognise that sustainability is an economic imperative. For example, the cover article Electrifying underground operations (page 6) explores how electrification, and in particular, a battery powered electric truck trolley system, is helping mine operator Boliden meet its emission-lowering targets.
New mining opportunities are another key area of interest and Dig deep (on page 18) looks at how technology designed for deeply buried resources has been reconfigured leading to less downtime.
Nicola Brittain Acting Editor
18 Dig deep
An electrified haulage system moves a Swedish mine one step closer to an electrified future
Battery-powered pioneer
How one equipment company has put rechargeable batteries at the heart of its business
Storage volume boost
Sideboards that can haul more material with each load
Change is possible
How an operator's choice of engine can significantly lower production costs
A look at new technology that provides access to deeply-buried resources
Tailings triumph
Enhancing pump reliability in tailings operations
Top tier tools
How the best tools help miners avoid downtime
DRILL & BLAST
Insight into extending the capacity and lifespan of crushing applications
A logistical feat A look at the logistics behind a new drilling record
Clearing contaminants A turbo compressor that promises to reduce costs at treatment works
The new AI frontier An AI-driven voice technology that will prevent accidents in industry
One industry expert explores new ventilation techniques
Sense your way to safety Introducing a radar sensor that helps mine workers avoid collision
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
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GROUP HEAD OF MARKETING
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Setform Limited, 6, Brownlow Mews, London, WC1N 2LD, United Kingdom
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cargo
into a recent conveyancing upgrade
A jaw crusher range brings a diesel electric powerline to the aggregates market
A buyer’s guide to belt buying
One expert shares their dos and don'ts of industrial conveyor belt buying
How cleverly designed surface mining equipment boosts operational stability
How one diamond producer is using sorting technology to recover unbroken diamonds
Customised solutions to help with the energy transition
How one hauler manufacturer is expanding into West Africa
Setform’s international magazine for mining engineers is published four times annually and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Process, Design, Transport, Oil & Gas, and Power.
How one electrified hauling system nudges a Swedish mine towards an all-electric future
Beneath the surface of the Malå municipality in northern Sweden, an underground mine has been in operation for over 80 years. With a production capacity of around 750,000 tonnes per year,
the Kristineberg mine is the largest contributor to the Swedish mining company’s Boliden Area Operations process plant, and produces minerals such as copper zinc, gold, silver, and lead.
Operations such as those at the Kristineberg mine, however, continue to face rising pressures to balance increased outputs of critical minerals and metals with lower carbon emissions and energy usage. Demand
for minerals critical to society’s cleanenergy transformation is predicted to increase between 1.5 to seven times by 2030, according to the International Energy Agency (IEA).
According to experts in the field,
haul fleet electrification is one of the most effective and realistic ways to reduce CO2 emissions in mining and help the industry reach its sustainability targets. To realise the all-electric mine of the future with
The truck features a trolley pantograph connected to an overhead catenary line This project is supported by funding from the Swedish innovation agency Vinnova
Demand for minerals critical to society’s clean-energy transformation is predicted to increase between 1.5 to seven times by 2030
sustainable, productive operations and improved working conditions, Kristineberg mine’s operator Boliden and equipment manufacturers Epiroc and ABB have passed a new technology milestone by successfully deploying the first fully batteryelectric truck trolley system on the mine’s underground test track, with a 13% incline.
Coinciding with reducing carbon emissions, the electrification of mining also promises improved health and safety for the industry’s workforce. By deploying this system, the collaboration partners aim to prove that the underground working environment can be significantly improved, with reduced emissions, noise and vibration while lowering the total cost per tonne.
“Over the past three years, we have worked in close collaboration with the ABB and Epiroc teams to bring the electric mine of the future one step closer,” says Peter Bergman, general manager of the Boliden Area at Boliden. “The most important thing for us is of course that the technology works in our own operations, but we also see added value in working with our partners to drive technology development so that the system can be used in other mines.”
COLLABORATIVE EFFORTS
Each partner has provided a unique set of expertise to this development process, demonstrating the value of industry collaboration. One of the technologies seen in the underground hauling fleet electrification system is Epiroc’s battery electric Minetruck MT42 SG.
Epiroc’s largest battery-operated mine truck boasts high capacity and productivity, thanks to its efficient drivetrain configuration ensuring low energy consumption and extended driving range. As it is a zero emissions truck, operators are not exposed to diesel particulates, and toxic gases such as nitrogen oxides, hydrocarbons and carbon monoxide (NOx, HC and CO).
Meanwhile, the trolley solution is equipped with ABB’s DC converter, HES880 inverters and AMXE motors to enhance the power. The truck features a trolley pantograph connected to an overhead catenary line, a concept which is highly suitable for long haul ramps. The electric trolley line gives additional assistance to the battery-electric mine truck on the most demanding stretches up-ramp while fully loaded, enabling further reach and battery regeneration during drift, which increases productivity.
ABB created the infrastructure from grid to wheel, including the electric truck trolley system design and the rectifier substation for the test track. According to its developers, the eMine Trolley System can help mining trucks decrease diesel consumption by up to 90%. A trolley assist operation also gives the trucks under load an additional boost as they climb the gradient on the hauling route.
Within the trolley system, rectifier substations are needed to supply and control power to the overhead line system and trolley trucks. AC power is distributed through a medium voltage for the rectifier transformers and auxiliary systems in the mine’s substation and overhead line system. These rectifiers, attached to an e-house, convert the AC voltage to suitable levels for rectifiers. These then further convert the electricity from AC to DC, making it suitable for the mining trucks.
Boliden, Epiroc and ABB are moving towards an all-electric mine
According to ABB, the entire trolley system can also be embedded into the ABB automation platform meaning mining operators can remotely control and monitor the system and optimise energy usage for the highest efficiency and lowest costs.
AN ALL-ELECTRIC FUTURE
ABB wanted a solution that could adapt to voltage fluctuations along the system, and so collaborated with partners to build a digital twin to simulate all scenarios. This resulted in the trolley system, with intelligent switchgear, measurements and transparency as well as the ability to adjust power where needed at any given moment.
“Together we can accelerate the transformation and reach a steep curve in mining technology innovation like we have done in Kristineberg,” says Wayne Symes, president of Epiroc’s underground division. “In a short space of time, we have implemented and delivered technology that has reduced CO2 emissions, substantially extended travel distance for battery-electric driven vehicles on heavy ramp haulage, reduced operating costs, and improved the health and safety of mining environments.”
“We are passionate and committed to creating real progress for the mining
industry,” adds Max Luedtke, global business line manager of Mining at ABB. “Seeing the industry’s first battery electric truck trolley system live is not only the result of a collaborative achievement with Boliden and Epiroc, but it is an industry milestone. We launched the ABB eMine concept of methods and solutions to bring electrification to the whole mining operation, from the grid to the wheel, and the installation at Kristineberg demonstrates the power of these capabilities.”
Boliden plans to implement a full scale, autonomous electrictrolley system in its Rävliden mine, a satellite orebody and extension of the Kristineberg mine, and has placed an order for four Minetruck MT42 SG Trolley trucks from Epiroc. The total distance will be 5km at a depth of 750m. The company hopes that once achieved, Rävliden will have both reduced carbon emissions compared with a mine using conventional technology, and set a new standard for the all-electric mine of the future.
For more information visit: new.abb.com/mining or www.epiroc.com or www.boliden.com
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BATTERY-POWERED PIONEER
How rechargeable batteries are central to one mining company’s business
The mining industry, historically associated with high energy consumption and pollutant emissions, is undergoing a transformation. Environmental and regulatory pressures are pushing industry players to adopt cleaner and greener solutions. It was with this in mind that French mining equipment specialist Aramine began to develop its range of batterypowered machines, an initiative that was aligned with its sustainable development strategy. The French company, set up almost 50 years ago, is a key player in the underground mining sector worldwide – it has developed expertise in technological innovation, environmental sustainability, and operational performance. Recent advances have included the design of electric cable machines, then batterypowered machines, since the company has recognised that electrification of the mining machine fleet represents a major step forward. This shift towards electric solutions also marks a significant turning point for the mining industry more generally, combining energy efficiency, carbon emissions reduction, and improved working conditions.
The rear of the machine can be detached to install another energy module in less than 15 minutes
Aramine began to develop its range of battery-powered machines, an initiative that was aligned with its sustainable development strategy
FIRST BATTERYPOWERED MACHINE
In 2016, Aramine’s teams launched the L140B LHD loader, the French manufacturer’s first battery-powered machine. With a tramming capacity of 1.3t, this machine has a major advantage: the energy module at the rear of the machine, including the batteries and their chargers, is completely detachable in less than 15 minutes with a unique hot swap: the Quick Replacement System. The batteries can therefore be recharged close to any power source, without the need for an expensive fixed installation. With an operating time and recharging time of four hours each, a machine with two energy modules can operate without interruption.
THE L440B LHD LOADER
Using their expertise in designing larger diesel mining machines, as well as all the technology included in the L140B, Aramine’s engineers designed the L440B LHD loader, the second battery-powered machine in its range for small and medium-sized sections of underground mines. The product offers a tramming capacity of 4.5t,
more than three times that of the L140B. The first units are due to leave the technical centre in France over the coming months.
Aramine’s battery-powered machines are designed to operate in the most demanding underground environments. Their electric motors offer a number of advantagesfirst, they significantly reduce CO2 emissions, thereby improving air quality in mines. According to the European Union’s ADEME CO2 emissions factor, each L440B saves 438t of CO2e, over 8000 hours of use compared with its diesel equivelant, leading to a reduction of 17kg of CO2e per hour of use.
Aramine’s eShop
In line with its ‘pioneering spirit’ and demonstrating its resolute focus on the digital transition, Aramine launched its eshop a few months ago. The shop, available via shop.aramine. com, offers 850,000 computerised spare parts references for all types of mining machinery. Sales at the shop are rising steadily, and saw a particularly good performance in the first-quarter 2024, thanks to the renewed confidence of customers. Feedback has been that they appreciate the
Additionally, these machines reduce noise pollution and heat, helping to create a more pleasant and safe working environment for operators. With cutting-edge battery technologies, these machines can operate for extended periods without interruption, reducing the need for frequent recharges leading to increased productivity and reduced operating costs. In addition, batterypowered machines generally require less maintenance than their diesel counterparts since they have fewer
The L440B battery-powered LHD, coming in a few months, with a 4.5 tramming capacity
moving parts, which reduces the risk of mechanical failures and maintenance costs. Finally, downtime is minimised and the machines can remain operational for longer, maximising their efficiency and profitability.
As well as designing batterypowered machines, Aramine is improving the life cycle of its batteries with much consideration of how they can be reused. Since mines are often located in isolated areas, renewable energy is ideal for facilitating the transport of electricity to them. Aramine therefore offers its customers a solar station for recharging L140B batteries. This solution is particularly useful in areas with high levels of sunshine
‘company’s responsiveness and efficiency’, according to Aramine.
Aramine’s warehouse, from which all orders placed on the eshop are shipped worldwide
STORAGE VOLUME BOOST
Sideboards can haul more material with each load while minimising material loss
The primary advantage of a sideboard is its ability to provide ample storage space. And while this is more commonly seen in the furniture industry, haul trucks used across the mining, aggregates and construction sectors also offer this solution.
Indeed, US-based construction equipment supplier PhilippiHagenbuch, a specialist in off-highway truck customisation, has developed sideboards capable of hauling more material with each load while minimising material loss.
According to the company, its sideboards are easy to install and precisely fitted to vertically extend the sides of off-highway haul truck bodies. The company works with each operation to custom engineer sideboards to achieve the optimal height based on the truck’s rated weight, the material being hauled and the loading equipment.
Sideboards increase the haul truck’s capacity while reducing or even preventing spillage, keeping haul roads clean, thereby reducing downtime (to clear the road) and protecting haul truck tyres.
“We have decades of experience in providing customised and durable solutions for hauling operations,” says Josh Swank at Philippi-Hagenbuch. “Our sideboards aim to help producers enable their trucks to haul their full rated capacity. Sideboards offer a simple low-cost way of adding volume to a truck body.”
THE SOLUTION
The company’s sideboards are available in one inch increments from six inches to 40 inches. In some cases, they may be available in larger sizes, depending on the haul truck, the environment and the material being hauled. The company also considers the operation’s loading equipment to
Operations can use sideboards alone or pair them with Philippi-Hagenbuch Autogate Tailgates
ensure the final height will not exceed the loader’s capabilities.
CALCULATION BASED ON DENSITY
Philippi-Hagenbuch works out the proper size for sideboards using a calculation based on material density, 2:1 heap capacity and haul truck body volume. For example, if a haul truck’s capacity is 71 tonnes and the volumetric capacity is 52.3 yd3 at a 2:1 heap, sideboards add 0.92yd3 of volumetric capacity for every inch of height added to the truck body.
Designed in an upside down ‘U’ shape, its sideboards fit over the existing body sides and are securely welded to the body. It also engineers sideboards to fit the specific make and model of
off-highway haul truck, and the front is ‘trimmed to fit’ to ensure it lines up with the front slope of the body. Operations can also use sideboards alone or pair them with Philippi-Hagenbuch Autogate Tailgates to further increase capacity and prevent material from spilling from the back of the body.
Philippi-Hagenbuch’s sideboards are built of Grade 80 steel for trucks ranging from 20 to 150 tonnes and 450 Brinell on trucks 150-plus tonnes for durability. They are also engineered with internal structural gussets to help provide a long service life.
Balancing the cost of production with sustainability needs can be complex. But a miner’s choice in engine is a key part of the equation
CHANGE IS POSSIBLE
How an operator’s choice of engine can successfully reduce the cost of production and enhance sustainability
It is clear that priorities in mining are shifting, enabled by new attitudes and sophisticated technologies. Thanks to both, sustainability has now become an integral part of mining operations. Of course, balancing the cost of production with sustainability needs can be complex, but a miner’s choice in engine can be a key part of the equation. And with several viable pathways to carbon neutrality, it is possible for miners to keep making progressive steps forward without impacting the performance and reliability critical to their success. They can do this in the following ways:
UPGRADE TO TIER 4/STAGE V MINING ENGINES
By upgrading to Tier 4/Stage V technology when purchasing new equipment or through engine rebuilds, miners can achieve improved fuel economy, lower emissions, extended overhaul timelines and reduced operating noise. The typical Cummins engine today emits 90% fewer greenhouse gases than those produced before 2000.
CONSIDER THE OPPORTUNITY WITHIN FUEL MAPS
Less fuel consumption not only saves money but also leads to fewer emissions, and modern technology can bring fuel efficiency that’s calibrated and tailor-made. Cummins is partnering with mining customers to achieve the best fuel efficiency by matching engine technology to the correct horsepower and torque for specific elevations and duty cycles. Through tailored calibration and optimised speed settings, one Cummins mining customer achieved a 7% improvement in fuel economy, saving 17 million litres of fuel annually, cutting costs by US$16 million and leading to a reduction of 45,900 metric tons of carbon dioxide equivalent.
Advanced hybrid mining trucks are a pathway to decarbonisation
MAKE THE MOST OF CLEANER FUELS
Enhanced alternative fuel technologies available today can lead to big carbon reductions. Using hydrotreated vegetable oil (HVO) (EN15940) with all industrial high-horsepower Cummins engines today could see net reductions in well-to-wheels greenhouse gas emissions by up to 90% compared with traditional diesel, depending on fuel feedstock and pathway.
With a similar performance to diesel, HVO is considered a ‘drop-in’ fuel. It can be incorporated into current operations and planned maintenance schedules, without any disruptions to existing technologies, processes, or necessary training for engineers. It is important to look closely at fuel suppliers for HVO fuels as not all are created equal, and for standby power generation applications, operators should ensure that the HVO does not include any blend of biodiesel, regardless of EN15950 compliance.
USE MICROGRIDS TO PRODUCE RENEWABLE ENERGY
Leveraging a microgrid on mine sites presents an opportunity for operators to meet energy demands, reduce greenhouse gas emissions and ensure resiliency. These grids can operate independently from the traditional grid and play a transformative role in powering various
facets of mining operations, including ore processing, powering tethered equipment, general power requirements for lighting, ventilation and heating/cooling, and even charging infrastructure for future EV fleets.
OPTIMISE REPAIR AND MAINTENANCE
Extended service intervals can greatly reduce unnecessary downtime and wasted consumables. Cummins will work with end-users to conduct a TCO analysis for new engine purchases, calculating whole life schedules based on equipment usage and determining recommended service intervals for various components.
Another way that Cummins extends service intervals is through conditionbased maintenance, made possible through advanced digital solutions, PrevenTech for Mining and Fleetguard FIT from Atmus. This allows miners to reduce consumables, such as coolant and filters, which not only saves money but also landfill waste.
WATCH THE HYBRIDISATION SPACE
Advanced hybrid mining trucks, using a combination of internal combustion engine and battery, are a legitimate pathway to decarbonisation. Depending on factors such as the mine profile, advanced battery technology and controls integration, they have the potential to improve fuel efficiency by up to 30%. In China, Cummins recently commissioned its dieselbattery hybrid in partnership with leading rigid mining truck manufacturer, North Hauler Joint Stock Co., Ltd. (NHL). Jenny Bush, Cummins Power Systems President, described the hybrid truck as a “significant milestone in our journey to advance bridge technologies and provide our mining customers with innovative, practical decarbonisation solutions.” Cummins will continue to collaborate with various OEMs to serve the market with the right hybrid solutions, including both firstfit and retrofit options.
THE ROUTE TO SUSTAINABILITY JUST GOT EASIER
With these options now a reality, the route to sustainability just got a little easier. “A miner’s choice in power system can impact many factors for both cost of production and sustainability,” says John Essegbey, Cummins Mining Market Sensing and Innovation Manager.
“We’re always here to help miners explore viable options for increased sustainability without impacting the performance and reliability they require for successful operations.” Leveraging
THE OPPORTUNITY IN THE CHALLENGE
RB 65 Exploration and monitoring wells at a Copper
Ulrich Schoepf from Bauer Machinen tells us how the company is helping miners access deeply-buried resources
Water, energy, and raw materials are essential to life as we know it.
The only way we can overcome the challenges of a rapidly changing world is by successfully generating and supplying these resources in a sustainable manner. After all, even though the demand for water, energy and raw materials is already massive today, it will continue to grow exponentially in the future owing to the major trends of urbanisation, electrification, and digitalisation. Deep below the ground there are still massive resource deposits that have not yet been mined or even explored at all. Bauer Maschinen GmbH, Germany, manufactures mobile multi-purpose drilling rigs for water well and mining applications to help provide access to these resources. Bauer drilling rigs of the RB series provide optimal technical solutions in drilling,
especially for challenging projects such as drilling very large diameters or reaching deep drilling depths in difficult geology.
The latest generation of the RB 65 drilling rig, shows Bauer’s focus on the current and future challenges for mobile drilling rigs in mining, influenced by a combination of technological advancements, environmental considerations, economic pressures, regulatory requirements, and operational needs. As easily accessible mineral resources are depleted, mining operations are targeting more challenging and deeper deposits with more complex geological formations. This requires advanced drilling techniques and equipment.
AUTOMATION AND TECHNOLOGY INTEGRATION
When developing the RB 65 drilling rig, special attention was
paid to the cost-effectiveness of the drilling operations in addition to the straightforward technical requirements such as increased hook load, torque, and drilling diameter. The incorporation of an advanced automated drilling control system helps enhance drilling efficiency, reduce human error, and improve safety. With the available Restricted Operating Mode (ROM), the protective cage, safety control and other features, the RB 65 also fulfils all requirements pursuant to CE/DIN EN 16228 – an important factor for the European market and one that is also of growing importance in mining projects around the world. The Bauer B-Tronic system in combination with the electrical pilot control of the drilling rig forms the centerpiece of the RB 65 drilling rig. By constantly recording and analysing all relevant drilling and equipment parameters, the driller is always informed about the equipment and the
mine site, Chile
drilling progress and receives valuable information for efficient use in realtime. The B-Tronic system automates monotonous and repetitive operations. Automatic control processes increase drilling performance and reduce wear on the equipment. The intuitive and self-explanatory operation of the drilling rig enables even less experienced drilling crews to easily switch from conventional rigs to these new advanced systems. This helps alleviate problems caused by skilled labour shortages.
CHALLENGING OPERATING AREAS AND ENVIRONMENTAL RESPONSIBILITY
Mining operations are pushing into more challenging, remote, and difficult-to-access areas. This is
where the RB 65’s high mobility and all-terrain suitability can help. Despite its maximum hook load of 70t (155,000lbs), the drilling rig is compact with a limited weight of max. 30t and can therefore be mounted on a 3-axle 6x6 truck. The design and selected components also enable high adaptability to challenging site conditions, such as extreme climatic conditions and high altitudes. In such harsh and remote environments, equipment reliability and effective maintenance are crucial for minimising downtime and operating costs. Here the installed B-Tronic system with its equipment monitoring capabilities and the possibility of remote access for trouble shooting also offers a major advantage.
The compactness of the RB 65 also enables a small operational
footprint thereby minimising the environmental impact. Another aspect of environmental responsibility is the energy efficiency of the drilling rig and the reduction of noise and emissions. For this reason, Bauer relies on state-of-the-art truck and engine technology for its equipment carriers and operates the entire drilling rig fuelefficiently via the truck PTOs.
VERSATILITY AND FLEXIBILITY
As drilling projects in mining vary in size and scope, rigs need to be more adaptable to different types of projects and their requirements. This could mean modular designs that can be easily extended and flexible configurations to handle different drilling tasks without having to maintain different types of rigs. Selecting the right drilling method for the relevant geology and drilling requirements is the biggest challenge since it affects quality, efficiency, and cost of the drilling operation. This is the major advantage of the Bauer RB series. With minimal onsite retrofitting (without the necessity of special tools nor a workshop), the same drilling rig can be used to implement various drilling methods, such as direct circulation, RC mud rotary air-lift, RC air-flush, hammer drilling or cable core drilling
RB 65 Dewatering wells at German Coal mine, 1,200mm drilling diameter at 400m drilling depth
RB 65 with pipe handling system in the desert of Kazakhstan
RB RIGS
MULTIPURPOSE TALENTS
We provide mobile multi-purpose drilling rigs for water well and mining applications to help provide access to essential resources. Optimal solutions for drilling very large diameters or reaching deep drilling depths in difficult geology.
TAILINGS TRIUMPH
Sealryt’s Peter Chilton provides two insightful case studies showing enhanced pump reliability in tailings operations
Pump reliability is a critical factor in mining operations, especially when managing tailings, where pump failures can lead to costly downtime and operational inefficiencies. Recent advancements in pump technology have shown significant improvements in the performance and reliability of tailings pumps. This article uses two case studies to highlight how innovative solutions have enhanced pump reliability in tailings operations.
CASE STUDY 1: PROLONGING PUMP LIFE WITH PACKRYT BEARING TECHNOLOGY
The first study involves SealRyt’s intervention in a mine facing persistent issues with a tailings pump. The pump was being repacked twice daily, a clear indication of severe operational inefficiencies and excessive maintenance demands.
To address this issue, SealRyt implemented its PackRyt Bearing technology. This innovative solution combines a bearing system with packing to provide enhanced stability and reduced wear on the pump components. The result was impressive. With the PackRyt Bearing technology in place, the pump operated smoothly for six months without requiring shutdowns, except at the end of the mining season. This significant improvement not only reduced maintenance frequency but also enhanced the overall reliability and efficiency of the tailings pump.
CASE STUDY 2: RESOLVING CLOGGING ISSUES WITH DURAPACK TECHNOLOGY
Another case study involved a mining operation using a Goulds pump that was plagued by recurring clogging problems. Peter Chilton from SealRyt recounts the challenges: “The flush
likely wasn’t sufficient, causing process material to clog the lantern ring in the stuffing box. This situation necessitated frequent maintenance and repacking, significantly affecting the operation’s efficiency.”
To tackle this issue, the operation installed DuraPack, a SealRyt product that combines an SLR (structural lantern ring) and a PackRyt bearing. The DuraPack solution was specifically designed to address the clogging issues by enhancing the flushing mechanism and providing better support to the packing. The results were good. According to Chilton, “It has run uninterrupted for two years without any clogs or maintenance. This was in stark contrast to the previous scenario, where repacking occurred every 60 to 90 days. The transition to packing with the SLR-enabled continuous operation for 24 months without complications, demonstrating the effectiveness of the DuraPack technology in improving pump reliability.”
TECHNICAL INNOVATIONS AND THEIR IMPACT
The success of these case studies highlights the importance of technical innovations in improving the reliability and efficiency of tailings pumps. The PackRyt Bearing technology and DuraPack solutions are prime examples of how targeted technological advancements
can address specific operational challenges in the mining industry. By reducing the frequency of maintenance and preventing common issues such as clogging and excessive wear, these technologies enhance pump performance and contribute to overall operational efficiency. The reduced downtime and maintenance requirements translate to significant cost savings and increased productivity for mining operations.
The case studies presented in this article demonstrate the tangible benefits of adopting advanced pump technologies in tailings operations. Innovations like SealRyt’s PackRyt Bearing and DuraPack solutions have effectively addressed common challenges, improving pump reliability and operational efficiency. As the mining industry evolves, adopting such technical innovations will play a crucial role in ensuring sustainable and efficient operations.
These success stories testify to the potential of innovative technologies to transform mining operations, making them more reliable, efficient, and costeffective. By focusing on continuous improvement and embracing new technologies, the mining industry can achieve greater operational excellence and sustainability.
PackRyt Bearing with Integrated Lantern Ring
DuraPack Bearing System with gland follower
Peter Chilton is with SealRyt.
TOP-TIER TOOLS
This article explores how using high-quality mining tools helps companies avoid downtime
Mined materials are found in a wide range of consumer products, including cars, electronics, jewellery, and energy sources meaning they are are always in high demand. Today’s mining industry is focused on safety, efficient production, cost reduction, and environmental impact mitigation while maintaining high levels of production and quality standards. Crucial to achieving this is the use of advanced mining tools that can withstand harsh conditions to minimise downtime, reduce maintenance needs, and ensure uninterrupted production.
DIXON’S ROLE IN THE LANDSCAPE
Tools manufacturer Dixon plays a vital role in this landscape, since its tools and services are tailored to the specific needs of the mining industry. It claims to be known globally for its quality, safety, and ease of assembly
with products designed for a range of mining operations, from exploration to refining. These products are being used by some of the largest mining companies worldwide. Poor quality and inferior imitation mining tools are prevalent in the market, often leading to inefficiency and frequent downtimes. Companies like Truco in South Africa advocate for Dixon products, supplying them to significant mining operations such as the Anglo American, Mogalakwena platinum mine situated in the northwestern quadrant of the Limpopo Province in South Africa, and the Debswana Jwaneng Diamond mine in Southern Botswana.
GOOD TOOLS HELP PREVENT DOWNTIME
Truco’s managing director, John Tait, liaises closely with onsite mining engineers and says, “every hour of production is important for mining
operations, which is why mines insist on using quality products”. Mines don’t want to be continually fixing their equipment, but want the equipment to work for them, and this is where Dixon comes in. With quality products ensuring production up-time, and a team of experienced technical engineers resolving any problems, such products allows the mine to keep doing what they do best, mining. Together with Truco’s on-site personal and stock holding, Dixon claims to be able to service any mining client’s need in an Africa-situated mine.
Water is fundamental in nearly every mining process, from dust management and drilling to mineral processing. Therefore, the equipment used for water service lines and dewatering applications must be robust and reliable. Pictured is a typical example of an air/ water service system and the essential components which make up a part of an underground mining system.
TRUSTED COMPONENTS
Dixon’s trademarked Minsup and Surelock fittings, Econovalves, and a range of other products, including hose assemblies and ANFO loaders, are trusted components that are used globally. These components are essential for maintaining continuous operation with minimal maintenance. As mining technologies evolve, becoming safer, more efficient, and costeffective, Dixon remains committed to producing durable products capable of meeting the demanding environmental conditions of modern mining. The company’s innovative approach to product development means that the future of mining is likely to be smarter and safer, keeping processes moving in a smooth and efficient manner.
Dixon’s Minsup
Minsup Underground Mining Systems
A HAULER OPERATOR’S GUIDE
Knowing the capabilities and limits of your hauler puts you in control
One ADT manufacturer explains how to become a trusted operator
An efficient articulated hauler operator combines technical expertise, safety and situational awareness with effective communication and a commitment to productivity. Scottish ADT manufacturer Rokbak explains how to master the art of safely operating an articulated hauler.
1) GET READY TO MOVE
Operators must take control of the hauler and their daily work before the ignition has been switched on by making sure they know the truck. It is important to have a thorough understanding of the truck’s controls, capabilities and limitations. This includes knowing how to operate it efficiently and safely in various conditions, such as on gradients, rough terrain or in adverse weather.
2) CHECK THINGS OVER
At the start of the working day, prestart checks are essential. A diligent operator will conduct routine truck inspections to make sure the truck is ready for work. Check for pre-existing damage including leaks and loose parts. In addition, check tyre conditions, fluid and battery levels, that lights and beacons are fully operational and that there is full visibility through the windows.
3) KNOW THE LIMITS
Before starting work, operators must learn worksite boundaries such as speed, ground bearing weight limits, travel direction, passing areas, width
and height restrictions and no-go areas. Know the hauler’s capacity and be aware of the truck’s working limits with regard to payload.
4) SAFE OPERATION
Follow all site operating procedures when driving the truck. Keep under speed and under control on gradients and check grade guides for safe and controlled descent speed. Correctly use differential locks – employ them when operating on soft or slippery ground conditions to maintain traction and control.
5) CORRECT USAGE
Rokbak’s RA30 and RA40 articulated haulers have fully enclosed multidisc brakes on all six wheels plus a retarder to deliver safe, consistent performance. Understanding the correct use of the retarder can prolong the life of the service brakes and reduce maintenance intervals for lower total cost of ownership (TCO).
6) STAY ALERT
A good ADT operator stays alert to their surroundings, including other workers, vehicles and obstacles on site. They anticipate potential hazards and adapt their driving accordingly to maintain safety for themselves and others.
7) KEEP AN EYE ON TARGETS
Operating an articulated hauler requires diligence to ensure proper loading, unloading and manoeuvring
of materials. While an integrated payload system can account for the number of loads moved, manually recording progress in relation to a target keeps productivity proceeding on schedule.
8) DO NOT IGNORE FAULT CODES
Critical information is delivered whenever system fault codes are triggered. If a truck does develop a fault, the operator will receive a warning symbol on the dashboard. Faults should be reported when they occur as continuing to operate could exacerbate the issue. Following the truck’s advice means increasing uptime by avoiding potential disruptions, but necessitates effective communication with site supervisors, co-workers and other equipment operators to ensure ongoing smooth operations.
9) AND AT THE END OF SHIFT...
Follow the correct shutdown procedure. Allowing the truck to idle for a brief period at the end of a workday enables the coolant to circulate through the engine. This helps to gradually lower the temperature, preventing potential damage from frequent ‘hot shutdowns’ over time.
FILTERING YOUR FINDS
A guide to using filter plates in mining
In mining applications, filter plates play a crucial role in the separation of solids and liquids. This process is essential in the production of valuable minerals and metals. Here’s how mining filter plates are typically used and their importance in mining operations:
APPLICATIONS OF FILTER PLATES
1) TAILINGS MANAGEMENT
• Dewatering of Tailings: Filter plates are used to dewater tailings, which are the residual materials left after the extraction of valuable minerals. This process reduces the volume and weight of the waste material, making it easier and safer to handle and store.
• Environmental Compliance: Properly dewatered tailings reduce the risk of environmental contamination and are easier to manage, helping mining operations comply with environmental regulations.
2) CONCENTRATE PRODUCTION
• Concentrate Filtration: After the initial extraction process, the concentrate (which contains the valuable minerals) is filtered to remove excess water. This results in a higher-grade product that is easier to transport and process further.
• Quality Improvement: Efficient filtration enhances the quality of the concentrate, ensuring higher purity levels and better market value.
3) HEAP LEACHING
• Solution Recovery: In heap leaching, the ore is treated with chemical solutions to extract metals. Filter plates help to recover these solutions from the ore, improving the overall recovery rate of the desired minerals.
4) HYDROMETALLURGICAL PROCESSES
• Solid-Liquid Separation: In processes like leaching, precipitation, and crystallisation, filter plates are used to separate the solid impurities from the liquid containing the dissolved metals
• Purification and Concentration:
This separation is crucial for the purification and concentration of metals, ensuring that the final product meets the required standards.
TYPES OF FILTER PLATES USED
1) CHAMBER FILTER PLATES:
• These plates have recessed chambers that hold the solids while allowing the filtrate to pass through. They are widely used for their simplicity and effectiveness.
2) MEMBRANE FILTER PLATES
• These plates have a flexible membrane that can be inflated to press the filter cake, squeezing out additional moisture and improving the dryness of the cake. They are ideal for applications requiring very low moisture content in the final product.
3) PLATE AND FRAME FILTER PLATES
• This traditional design alternates solid plates and hollow frames, allowing the slurry to flow through and be filtered. They are used in applications where thorough washing of the filter cake is necessary.
BENEFITS OF USING FILTER PLATES IN MINING
• Efficiency: High filtration efficiency results in better recovery rates and final products of a significantly higher quality.
• Cost-Effectiveness: Reducing the moisture content in tailings and concentrates lowers transportation and disposal costs.
• Environmental Protection: Proper filtration minimises the risk of environmental contamination, ensuring safer and more sustainable mining operations.
• Operational Reliability: Durable and well-designed filter plates ensure consistent performance and reduce downtime for maintenance.
For optimal results, the choice of filter plates and the specific filtration technology used should be tailored to the characteristics of the ore and the specific requirements of the mining operation.
Pictured: Mining plates size 3200 x 2000 - top feed inlet
HITTING THE HARD ROCK MARKET
How a high-torque drivetrain, optimised tooth configurations, and tungsten carbide extend capacity and lifespan in crushing applications
Mining technology manufacturer TAKRAF has recently seen a significant order from Rio Tinto for six of its X-Treme Class Sizer machines for the Simandou Iron Ore Complex in Guinea. These machines are currently being manufactured at TAKRAF’s Product & Service Centre in Germany.
In another important development, a new overlay solution has been incorporated into the sizer, providing protection of the base material from wear, resulting in an increased lifetime of wear parts. Known as TAKRAF Wolfram Armor, the tungsten carbide overlay was developed in-house over a five-year period to provide the sizing teeth with a combination of hardness and ductility as compared with other overlay types. The high level of hardness protects the sizer teeth from ‘washing’ abrasion caused by freeflowing feed material as the ductility of the base matrix provides protection from impact gouging and flaking.
To obtain the optimal level of protection from the overlay, TAKRAF works with clients to measure wear rates and patterns on equipment start-up. With this feedback, TAKRAF can revisit the design and optimise the placement and thickness of the Wolfram Armor. As a result, clients
have been able to achieve OPEX savings of over 25%.
NEW GENERATION OF SIZING TECHNOLOGY
The TAKRAF X-Treme Class Sizer was developed as a new generation of sizing technology to extend the application window of a sizer into harder and more abrasive feed material. The fundamental design philosophy is to maximise the machine’s grip on large lumps. This is achieved by incorporating primary and secondary teeth, crushing ridges, and tooth pockets that let the lumps drop deep between the rolls where the engagement with the rock can be as aggressive as possible. By maximising grip, the sizer can process oversized feed material and eliminate high wear events where lumps remain, bouncing on top of the rolls for extended periods of time.
For extra-large feed sizes, classified as a feed exceeding 1,500mm, the TCS-X 18 series (TAKRAF’s largest sizer) can be equipped with the patented rhomboid tooth configuration, providing a larger pocket for oversized lumps to fall into.
Other features that aim to ensure extended reliability and increased availability when working on extreme applications include integrally cast tooth holders and shrink fit keys that
transmit the high crushing forces required to break hard rock lumps. The machine’s heavy-duty bearing assemblies are sealed with a triple labyrinth taconite seal for bearing reliability, while the gearbox is designed with high application factors to produce the required torque and withstand shock loads from uncrushable material.
The machine’s modular wear components are easy to handle, according to the company, with change-out procedures actionable in position. The entire unit slides into its maintenance position for safe and efficient maintenance, with quickrelease crushing segments enabling the efficient replacement of individual parts. The bolted tooth system means worn teeth can be replaced quickly while the split housing design enables the easy replacement of entire roll assemblies.
By extending the application window of a traditional sizer into hard rock applications, TAKRAF believes that many more mining operations will benefit from incorporating a sizer into their crushing applications.
X-Treme Class Sizer production in Germany
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A LOGISTICAL FEAT
Using the right drill system is a key element of operations management for all mines, and the operations team at Australian company WesTrac, US-based company Caterpillar, and global mining services provider Thiess at the latter’s Mount Arthur South operation, might well be patting themselves on the back for their recent work. The companies used a fleet of three Cat MD-series drills running with Caterpillar’s MineStar Command Autonomous Drill System (ADS) to drill one million metres autonomously in April this year. The feat was accomplished at the latter’s Mount Arthur South operation where the trio used a fleet of three Cat MD-series drills running with Caterpillar’s MineStar Command Autonomous Drill System (ADS).
Located 5km south of Muswellbrook in the Upper Hunter Valley of New South Wales, Mount Arthur Coal is an open cut mine that produces thermal coal. Thiess has a long history in the Hunter Valley, dating back more than 80 years, where it provides mining services at three mines including Mount Arthur Coal.
WesTrac’s technology solutions manager Nakia Brewer says the achievement not only reflects a highly successful deployment of Cat-built autonomous drills, but the strength of a technology-driven partnership that
developed and rolled out the operation in a cleverly phased approach.
“When implementing new technology, it is crucial that the problem you’re trying to solve is understood – in this case it was to reduce operating costs and increase consistency of drilling,” he says.
TECHNICAL ACHIEVEMENT
WesTrac, Caterpillar and Thiess began the programme in 2019 and following a multi-phase three-year journey, enabled a remotely located operator to control the three drills, a Cat MD6250 and two MD6310s, simultaneously.
The MD6250 crawler-mounted blasthole drill is designed to drill a US EPA Tier 2 equivalent from 152250mm diameter holes in Rotary or DTH (Down the Hole) modes to singlepass or multi-pass depths. Meanwhile, the MD6310 is designed to drill holes of 203-311mm in diameter.
According to Caterpillar, its MineStar Command Autonomous Drill System helps reduce operating costs, increase safety and improve productivity. Command for drilling ensures that every hole is accurately placed, drilled to the proper elevation and angle, and able to stand up until blasting. Furthermore, a range of capabilities lets site managers
configure and automate the drilling system to their budgets and needs.
A COLLABORATIVE APPROACH
Thiess upskilled more than 30 of its people at Mount Arthur South from traditional drill controllers to autonomous operators, and a range of other support functions during the million-metre journey. And more broadly, it has invested in autonomous mining systems training for more than 500 employees.
IMPROVEMENTS IN PERFORMANCE
“Since introducing this technology at Mount Arthur South in 2021, we have recorded a 20% improvement in drilling performance, up to 8% reduction in fuel use, more consistent drill hole quality accuracy and depth, and drill utilisation of up to 23 hours per day,” says Ramesh Liyanage, group executive of Assets, Autonomy and Digital.
“This milestone achieved, safely drilling more than one million metres autonomously at Thiess’ Mount Arthur South, is a testament to this spirit, and we couldn’t be prouder of the team.”
Two autonomous Cat MD6250 rotary drills at Mt Arthur South
CLEARING CONTAMINANTS
A new turbocompressor reduces costs and boosts reliability for smaller treatment works
Sulzer’s range of HST turbocompressors offers energy efficiency and reliability
Municipal and industrial wastewater treatment plants require aeration to remove organic contaminants. Traditionally, noisy blowers have been at the heart of this process, as well as the source of significant operational costs. With the launch of Sulzer’s HST 10, smaller sewage plants processing less than 10,000m3/day (40,000 population equivalent) can take advantage of the benefits of a turbocompressor that will both cut running costs for their facility and provide a huge boost in reliability, according to the company.
In industries such as pulp and paper, food and beverage, chemicals, pharmaceuticals and mining, the HST 10 can provide productivity improvements in both core processes and integrated wastewater treatment facilities.
BOOSTING EFFICIENCY AND RELIABILITY
The HST 10 is a single stage turbocompressor and motor directly coupled to the turbo with no intermediate gears or pulleys. The permanent magnet motor is fed by the integrated variable frequency converter. To reach the high rotational speeds needed with minimum losses, active magnetic bearings are used and the motor and the whole unit are fully air cooled. There are no gears, mechanical bearings, pumps or separate cabinet cooling fans and the absence of these often failure-prone components makes the system more reliable than traditional blowers, according to the company. Combined, the lower energy costs and running expenses offered by the machine are likely to lead to a reduction in operational expenditure (OPEX).
REDUCING COSTS
In the municipal wastewater treatment environment, traditional blowers are the single largest consumer of energy on the site. Their reliability, or lack of it, can lead to considerable downtime for the aeration process, posing a risk to treatment outflow and the environment. Even with spare assets on standby, the blower house is often a cause for costly and extensive maintenance work.
However, tradition has given way to innovation, and the HST turbocompressor has made it possible to have a reliable compressor that doesn’t need constant attention or high energy requirements. Essentially vibration-free and with low noise options available, the HST 10 can be installed in simple structures such as converted freight containers. In addition, the product is compact and easy to install according to the company.
SUSTAINABILITY
The reduced energy consumption is the major driver for the reduced CO2 footprint. However, the lightweight design and the minimal need for consumables and spares also helps lower the footprint.
A huge contribution to the reduced environmental footprint comes from the long service life, as proven by the installed base of HST machines. With this technology, where no two rotating components are in contact with each other, the machine efficiency is maintained at a high level. At the end of service, all mechanical parts are intact and can be re-used or recycled with no worn-off material dispersed in used lubricants or the surroundings.
MAKING THE TRANSITION
Making the transition to Sulzer’s turbocompressor is a simple process, for which assistance will be provided by Sulzer application specialists and the worldwide field service teams. Having determined the most effective
A huge contribution to the reduced environmental footprint comes from the long service life
model and number of compressors for an application, the installation is carefully planned to ensure an absolute minimum of disturbance. Replacing redundant or out of service equipment first, the initial HST unit can be easily integrated with the existing control infrastructure and brought online.
The compact footprint of the HST 10 also ensures additional space is available once the first legacy compressor is removed.
For more information visit: www.sulzer.com
The compact installation includes an internal silencer for low impact operation
THE NEW
AI FRONTIER
Professor Jean S Verhardt explores how AI-driven voice technology can help prevent accidents in industry
The technology uses voice-based AI to predict fatigue with up to 90% accuracy
In his recent Wall Street Journal bestseller ‘The Sound of the Future: The Coming Age of Voice Technology’ (2023), author Tobias Dengel shows us how artificial intelligence (AI)-driven voice technology (voice tech) is on the verge of transforming the world we live in. No part of society and no corner of industry will be left untouched by the voice revolution. What we have already seen with voice assistants such as Siri, Alexa and Google Assistant are just the first gusts of a coming storm.
Together with the mega voice assistants from Silicon Valley, WOMBATT-Voz is one of the early practical applications of the marriage
between artificial intelligence and voice technology. The objective for WOMBATT, in line with non-profit campaign Vision Zero, is to completely eliminate fatigue and sleep related accidents both on the road and in industry. Today, fatigue is the single biggest cause of accidents in mining and accounts for over 20% of all fatal accidents on the roads and highways of the world – an unacceptable 200,000 fatigue-related road fatalities each year.
THE POWER OF VOICE TECHNOLOGY
A growing number of our daily activities involving control of the machines that are an everyday part
of our lives, are already performed by auditory voice communications. A good example is cars and trucks. It is now possible using voice AI to verbally ask your car “Please check to see if I have left the iron on at home, and if so, turn it off”. The car will reply “Very well” and then check via the internet connected house computer whether the iron is on, and if so, turn it off. By the same token, using the new WOMBATT-Voz voice-based AI fatigue prediction technology installed as an app on your mobile phone and connected to the car’s AI system, your voice can be analysed to detect early signs of fatigue, predicting your actual fatigue risk level up to five hours ahead with more than 90% accuracy.
If you have had insufficient sleep to maintain peak driving alertness, the car or truck, using WOMBATTVoz either via the driver’s connected smartphone or integrated into the vehicle’s onboard systems, will immediately alert you and suggest a stop and powernap. Plus, at the same time, sending an email or SMS to anyone else you nominate, such as your supervisor or spouse.
HOW DOES IT WORK?
The human voice is one of the most complex systems in nature and originates from the virtually infinite physical elements and waveform variations of an auditory quantum state. One can think of a wave breaking onto a beach every few seconds for millions of years. Each wave contains information about a vast range of contributory factors such as far off storms, passing boats, swimmers, seabirds, fish and even raindrops, and no wave for the rest of time will ever be exactly repeated. But a wave created by a nearby passing boat has recognisably different elements as it arrives on the beach to one created by a faraway storm in the middle of the ocean.
The same occurs with the voice, which is a window into the entire human neuromuscular system. Each few seconds of voice contains an enormous amount of data regarding the condition of the body, including neuromuscular related diseases and conditions such as Parkinson disease, ALS, MS, the influence of drugs such as alcohol and many others.
One of the conditions which can be detected in the voice is fatigue due to sleep deprivation. Of all the untold millions of elements existing in the voice, many thousands of them can now be detected using the latest microphone and digital processing power contained in modern smartphones and tablets, connected via GSM, Wi-Fi or satellite to the world’s most advanced AI fatigue algorithm.
ELIMINATING FATIGUE
Around 200 voice elements, out of the thousands currently detectable in the human voice, denote tiredness and fatigue due to sleep deprivation. With the release of Apple IOS 6 in 2014 and Android 6 Marshmallow
in 2015, smartphone microprocessor and microphone technology reached a point where these 200 fatigue elements could be detected in everyday life with the consumer smartphones that everybody carries about with them all day every day.
The average smartphone today has 100,000 times more processing power than a personal computer from only a few decades ago, with microphones now so accurate and sensitive that the slightest and most fleeting elements of any sound can be captured, recorded and transmitted.
For the first time ever, a technology exists whereby people can predict their own fatigue risk many hours in advance with more than 90% accuracy, using their own mobile device. Because the AI algorithm
learns each person’s unique individual voice characteristics, accuracy is far higher than older technologies and is continually improving as the algorithm learns and understands more of each person’s individual voice over time.
The huge technological advance of WOMBATT’s voice-based fatigue risk prediction over camera, wearable and vehicle movement fatigue detection technologies means that the objective of Vision Zero – zero deaths due to fatigue, is now within reach in mines, on the roads and throughout industry across the world
Jean S Verhardt is founder and CEO of WOMBATT Fatigue Management. www.wombatt.net
The company’s AI voice-based FRMS app is compliant with a number of industry standards such as the ANSI/API RP 755 and ISO 31000
SMART VENTILATION
Jan Nyqvist product manager from Automation Underground Mining at ABB explores
new ventilation techniques
Creating a safe working environment in underground mines is the primary concern for mining organisations, it is part of their license to operate before a vehicle moves or a person starts their shift. Management must ensure that personnel are not exposed to excessive levels of CO2, nitrous oxide, dust, humidity, temperature, toxic blasting, and strata gases. A constant supply of fresh air is essential throughout the mine. Therefore, ventilation systems are a critical and high-demand part of the underground mining process.
The need to constantly cycle clean air into mines, remove contaminated air, and regulate temperature has led to these systems becoming significant energy consumers, accounting for as much as 50% of resource use and operational expenditure. With increasing pressure on mining organisations to reduce their energy consumption, a new approach to ventilation has gained popularity: ventilation on demand (VoD).
VENTILATION ON DEMAND
VoD systems work by utilising sensors placed around the mine that transmit real-time data on key parameters such as vehicle use, personnel, and information from gas, flow, and temperature sensors to a central control system. This setup enables mine-side control of fans and air regulators. Over time, these systems learn and adapt as more data is collected, maximising air quality and evacuating blast gases faster, allowing workers to return to the face in less time.
For instance, ABB’s VoD system, ABB Ability Ventilation Optimizer, operates equipment according to actual demands. Using a positional tracking system, the technology identifies where people and vehicles are in the mine and their ventilation needs. An algorithm then calculates the optimal set points of the fans and implements this across the mine. The VoD optimiser recalculates airflow every 15 seconds, 24/7, ensuring appropriate levels of airflow
Currently, ventilation systems are heavily relied upon to remove diesel fumes emitted from trucks running underground
are always running. This approach can save large mines up to US$3 million per year and reduce energy consumption by 50%.
VENTILATING THE ALL-ELECTRIC MINES OF THE FUTURE
Currently, ventilation systems are heavily relied upon to remove diesel fumes emitted from trucks running underground. Diesel engines typically waste 60-70% of energy in the form of heat, necessitating additional ventilation to clear continuous tailpipe emissions. This application is coming into
focus as miners plan for, trial, and buy new battery-electric operated vehicles to reduce their emissions. As mining fleets become electrified, the amount of diesel particles that need to be removed will decrease significantly, eventually reaching zero. However, this will only happen once every truck in every mine is electric, and this is some way off yet.
In the interim, sophisticated VoD systems will play a crucial role in ventilating hybrid mines. Many mines will operate mixed fleets for the foreseeable future with both diesel and electric trucks running. Ventilation will
Harnessing innovation for mine ventilation
Innovation has revolutionised many processes in underground mining today, not only ventilation. Robotics are changing the way workers complete vital tasks, such as blasting, while automation is reducing energy and water consumption in mines and improving waste management. The next frontier of innovation is integrating these functions under one planning schedule and production control. Within this system, an automated layer connects daily processes, including ventilation, dewatering,
conveying systems, in-pit crushers, and mobile machines to give the operator a comprehensive view of the process. This holistic overview will enable key activities to be linked. For instance, after blasting, the space needs thorough ventilation to remove the remaining gases and dust before it can be mucked out. Automated production control would enable ventilation to automatically focus on the blasting location as soon as the process is complete, removing the gases as quickly as possible.
need to be distributed based on where different trucks are in the mines. VoD systems will provide the flexibility to adjust the ventilation to supply more air to areas with diesel machinery in operation. Even when the all-electric mine of the future is realised, ventilation will still be crucial. As mines go deeper, cooling and refrigeration become more of an issue, with some mines operating at temperatures of 35 degrees Celsius. Regulating temperature is vital to the efficient operation of electric fleets, ensuring battery charge, health, and capacity are preserved.
TESTAMENT TO THE INDUSTRY’S COMMITMENT
The evolution of ventilation systems in underground mining is a testament to the industry’s commitment to safety, efficiency, and sustainability. As mining operations transition to electric fleets, VoD systems will continue to play a vital role, adapting to new challenges and ensuring optimal working conditions. This integration of automation and innovative technologies promises a future where mines are safer, more efficient and sustainable
For more information visit: https://new.abb.com/mining/ mineoptimize/digital-applications/ advanced-process-control/abbability-ventilation-optimizer
ABB Ability Ventilation Optimizer in place at the Chuquicamata mine in Chile
SENSE YOUR WAY TO SAFETY
A new radar sensor helps mining industry operators avoid collision
Surface and underground mining both involve a lot of heavy vehicles that can pose a threat to personnel in the event of a collision. Such a collision can also lead to costly repairs and downtime. With so many moving parts, and in many cases adverse environments, personnel need help to ensure risk is minimised and one useful sensor can help with this.
Sensory manufacturer OndoSense is currently expanding its sensor portfolio and recently released a compact radar sensor for collision avoidance, vehicle detection and object positioning. With its wide detection range, the OndoSense reach WA (Wide Angle) helps detect obstacles such as vehicles,
people or objects. It can also help position machines and robots – the latter are used increasingly often in mining.
THE SENSOR DETECTS STATIC AND MOVING OBJECTS
The sensor detects static and moving objects even at close range from 0.1 metres and can be easily integrated even in confined spaces, thanks to its very small design. With up to four adjustable sensor zones, the OndoSense reach WA offers flexible monitoring of security areas or collision avoidance of mobile robots or other vehicles. Thanks to innovative radar technology, the radar sensor always reliably detects objects of any nature, even outdoors or in difficult environments with dirt, smoke, steam, rain or poor lighting conditions. And as a result of its high measuring rate of 200Hz, it reliably detects even fast moving obstacles.
The product also has an opening angle of 15 degrees and a measuring precision of ±1mm, making it suitable for precise positioning of machines or robot arms where the target object is tilted – that is, not optimally aligned with the radar sensor.
The radar sensor comes equipped
with a RS485 communication protocol, three digital switching outputs (PNP/ NPN) and an analog current interface (4-20mA). An IO-Link version will be available from 2025. The sensor can operate interfaces such as Profinet or CAN via a gateway.
“Our sensor offers the smallest blind zone on the market for anti-collision radars making the OndoSense reach WA ideal for applications in which objects in close range must be reliably detected. This includes, for example, the detection or positioning of cars in the car wash, the prevention of collisions between aircraft and ground support equipment at the airport or the positioning of drilling machines or washing robots on walls or in tunnels. Our radar system thus enables safe operation without costly unplanned downtimes,” explains Rainer Waltersbacher, Co-CEO of OndoSense.
The OndoSense reach WA is suitable for collision avoidance, vehicle detection, object positioning and limit level control in mining, but is also used in transport and logistics, shipping, mechanical and plant engineering, and agriculture.
Collision avoidance of mining vehicles: Example of possible use of the four sensor zones of the OndoSense radar sensor
The Compact OndoSense reach WA radar sensor helps with collision avoidance, vehicle detection and more
PUNISHING CARGO
Dave Mueller from Martin Engineering explains how the company has transformed the conveyance of raw materials
Mined and quarried hard rock punishes conveyor belts and system components. The demand on these systems can lead to premature equipment wear and excessive downtime. Owing to the varying needs of different applications, raw material is often transported and processed by the end customer. So, beyond the needs of mines and quarries, bulk handlers like ports, cement producers and power plants need heavy-duty conveyors to receive raw materials before loading them onto vessels or sending them to the crusher.
SUPPORTING THE BELT
The force of loading can warp impact idler rollers and the bearings inside, but there are ways to avoid this. One is by restricting the drop height or slowing the descent of heavy bulk
material from a direct impact on the conveyor belt. Operators have found that controlling material loading extends the life of the belt and the conveyor support structure. Another way to extend equipment life is to properly and completely support the belt in the loading zone using a cradle. To help in this respect, bulk handling specialist Martin Engineering devised a heavy-duty impact cradle to support the belt and absorb the impact of loaded material in a consistently sealed environment. Impact cradles are specially designed with a top layer of slick ultra-highmolecular-weight polyethylene (UHMW) molded to a base of impactabsorbing styrene-butadiene rubber (SBR). The belt slides across them easily with little friction while the bars give enough shock support that the belt is not damaged from precise hits on sharp edges. By eliminating the
gaps between idlers, skirting creates a tight seal against bars, further reducing the amount of fugitive dust and spillage for more compliant and safer operations.
Belt speeds above 650fpm (3.3mps) can exceed the limits of impact cradles. For higher-speed conveyors, a specially designed heavy-duty highspeed cradle with four trac-mounted idlers closely spaced to eliminate belt sag can support material impact without excessive drag. Innovative upper connector brackets link idlers throughout the load zone, allowing them to work in tandem as a unified structure. The elastomer bar suspension is engineered to match the CEMA rating specific to the application by absorbing shocks from impact.
SEALING THE TRANSFER
For extra heavy-duty applications,
Martin Engineering’s high-speed cradle helps reduce spillage
Mine in Witbank, South Africa
A coal mine in Eastern South Africa producing 3.4 million tons (3.1 million tonnes) of coal per year was experiencing heavy spillage and system damage along the length of a main conveyor. Impact idlers allowed excessive belt sag, causing high volumes of spillage. Dust, fines fouled idlers, and rocks were being lodged between the belt and the skirt, resulting in unscheduled downtime due to frequent equipment failures. Labour was diverted for cleanup, further raising operating costs.
wearliners can deplete quickly and may need extra protection. A product called the canoe liner is made from durable urethane molded around a rugged steel plate to absorb impact and abrasion. It is an engineered urethane strip molded directly around a protective steel plate. The protective plate being integrated directly into the urethane liner is unique to Martin Engineering and prevents material from fouling the space between the urethane and the steel causing delamination. Separation tests have shown it delivers superior shielding of the skirt sealing system and skirtboard over other designs.
CONCLUSION
Conveyor design engineers recommend taking a holistic view of the system and choosing solutions that address the causes of downtime and workplace hazards from loading to discharge. Investing in modern technology that provides a longer equipment life, better results, and a greater return on investment (ROI) over the long term leads to higher production and a lower cost of operation
Technicians from Martin Engineering South Africa recommended the installation of seven HighSpeed Impact Cradles. The specially designed idlers exceed the operating limits of typical impact bar-type belt support cradles. The rolling components minimise friction on the belt and maximise the life of the belt support structure. Lowfriction polyurethane Martin ApronSeal Single Skirting was also installed to contain material and retain a tight seal on the running belt, further reducing spillage.
Six months after the installation, the volume of spillage has been reduced considerably, and the sealing system remains durable because no material is trapped beneath the seal. The lack of fugitive material has mitigated wear and tear on components and reduced the amount of labor needed for cleanup, maintenance and replacement of broken equipment. The project was so successful that the customer is converting 14 more transfer points.
Large material outdoor transfer
RADICAL RELIABILITY
A new jaw crusher range brings a diesel-electric power line to the aggregates market
Metso launched products from its new EC range at its Lokolaunch event in Tampere, Finland
Working with hard rock aggregates and recycling materials requires raw force in demanding conditions. It is also essential that high-quality products are produced on time, at the right price. To meet these targets, Finnish company Metso’s new Lokotrack EC range claims to boost reliability and performance.
Metso recently launched the first two products of its new EC range (at the Lokolaunch event in Tampere, Finland in April this year), the Locotrack Mobile Cone Crusher LT350C and the Locotrack Jaw Crusher LT400J. The LT400J comprises a 68-tonne mobile jaw crusher designed for the primary crushing of hard rock and recycled aggregates. The LT350C is a 50-tonne mobile cone crusher for secondary and tertiary crushing. To reach high capacity, LT350C comes equipped with the new Nordberg HP350e cone crusher, while LT400J relies on the proven Nordberg C120 jaw crusher. Both units can be seamlessly combined with each other as well as with the Lokotrack mobile screens to
produce high-quality aggregates.
“When external electricity is available, the new electric power transmission provides high capacity with minimised operational cost and CO2 emissions. When not available, the onboard diesel gensets allow maximum independent operation time. In addition, auxiliary units, such as mobile screens and stackers, can be powered from the same gensets, which will further reduce the needed power to run the complete plant,” says Jarmo Vuorenpää, director of the new Lokotrack offering at Metso.
A MODULAR DESIGN
The Lokotrack EC range has been developed using new, modular architecture, which reduces the number of components and provides scalable solutions that can be adapted for different applications and capacities. “This modular architecture enables a faster, more agile way of creating products and meeting changing customer needs. Furthermore, it enables more efficient support for the machines with fewer parts needed and easier feature upgrades,” says Renaud
Lapointe, senior vice president of Metso Products business line in the Aggregates business area.
SAFETY STANDARDS
All the components of the new EC range are designed and tested to perform in demanding conditions and reach maximum uptime for the customers. Safety and usability have been given special attention. The LT400J and LT350C meet the latest safety standards while being user friendly. The units can be operated safely from the excavator and be quickly set from transport to operation. The concept of track-mounted crushers and screens was developed in Finland in 1985 to minimise cost and energy use, and the associated Lokotrack units help process both natural aggregates and recycled materials. Lokotrack EC, the new diesel electric range (launched at the company’s recent event) complements the company’s existing offering.
artin’s broad variety of both primary and secondary conveyor belt cleaners are the industry leaders in minimizing costly carryback and related issues.
SQC2S™ is our most efficient and versatile platform of secondary belt cleaners and offers five unique blade cartridge options to match the needs of your specific application. Each configuration features a compact design allowing for simple blade replacement and installation.
With more than 80 years of bulk material handling experience around the world, Martin stands ready to provide you with factory-direct sales and services—including expert assistance on all of your belt cleaning problems and concerns.
A BUYER’S GUIDE TO INDUSTRIAL CONVEYOR BELT SELECTION
Conveyor belt specialist Jeremy Clark shares his essential dos and don’ts when buying industrial conveyor belts
Always
Conveyors are indispensable but expensive pieces of equipment. With operating budgets under continuous scrutiny from senior management, it is all too easy to make a costly mistake when buying conveyor belts. Here, conveyor belt specialist Jeremy Clark shares what he considers to be the most important dos and don’ts when buying industrial conveyor belts.
CHECK THE SPECIFICATIONS
Never assume that the specifications of your conveyor belts are correct. Most conveyors have been in operation for a number of years. During their lifetime they are likely to have been operated by several different managers and maintenance personnel. It never fails to surprise me to find that mistakes have been made by the original builders of the conveyor when calculating the belt specification best suited to the conveyor. Likewise, subsequent attempts to solve problems such as rapid wear and ripping and tearing, may have resulted in the wrong specification of belt being fitted. The same applies if the material mix or volumes have changed significantly. It is imperative that the belt specification always matches the conveyor design and the materials being conveyed.
Too soon on the scrapheap – the price of the belt will invariably be reflected in the length of its working life
For example, belts that are too thick for the design of the application can cause problems such as excessive rigidity (lack of troughability) and steering and handling difficulties. The same applies to tensile strengths that are too high. It is important to remember that for every step increase in tensile strength, the pulley and drum diameters need to be increased by 25%. The belt carcass may fail due to dynamic stress if this action is not taken. Quality belt manufacturers and their service partners who supply and fit their belts, will have experienced engineers. When provided with sufficient information, they can verify the belt selection.
SELECT BELTS BASED ON DURABILITY
Always select belts based on their durability, suitability and longevity (whole life cost) rather than for shortterm ‘economic’ or budgetary motives. Experience shows, without doubt, that the price of the belt will invariably be reflected in both its quality of performance and the length of its working life. I regularly see cases where a good quality belt can produce a working life of more than five years compared to low-grade belts that have been purchased on the basis of their low price but need regular repairs and then have to be replaced after only a year or two, often less.
The biggest source of low-price, low-grade belting is, of course, the
Far East, primarily China. Their prices may be very tempting, but it is important to understand how those prices are achieved. The ‘lower labour costs’ argument is a fallacy because the labour element accounts for as little as 5% of the production cost. The true reason for the difference in price is that raw materials make up to 70% of the cost of producing a conveyor belt. Consequently, the only way to manufacture a low-price belt is to use low-price (low grade), unregulated raw materials. There simply is no other way. Cost-cutting practices include using cheap, low-grade carbon black made by burning old car tyres, the use of ‘bulking fillers’ such as clay instead of good quality polymers and using low-grade inner synthetic plies. The two best indicators of poor quality rubber are its low price and its pungent smell. Good quality rubber rarely has any smell at all. As the old saying goes, price is what you pay but cost is what you spend.
CHOOSE BELTS IN THE STANDARD STOCK RANGE
Always (unless significant quantities are involved), choose belts from within the manufacturers standard stock range whenever possible Any deviation from the standard specification of a belt held in stock means that the belt would have to be made to special order, invoking higher production costs and potential
The first signs – small cracks appear in the surface of the rubber
MATERIALS HANDLING
minimum length order quantities. It also increases the delivery lead time, which can be especially bad news if a belt needs to be replaced in an emergency.
Only buy belts when you are totally confident of their provenance (manufacturer’s origin) and where the manufacturer clearly states the level of anticipated performance rather than simply claiming to have been tested to a certain standard. Unfortunately, in today’s market, with the exception of Fenner Dunlop in The Netherlands and North America, nearly all manufacturers now supplement their production with imported belting, mostly from the Far East. My advice is to always ask for certified confirmation of the actual place of manufacture.
CONSIDER THE BELT EDGE
Avoid over-specifying the type of belt edge. This may surprise you, but it can have a very significant impact on belt costs, repairs, maintenance, lost production and lead times. Many years ago, moulded edges (fully covered in rubber) were the standard because cotton was used as the reinforcing fabric in multi-ply belts. A moulded edge was therefore essential to prevent moisture penetrating the cotton fabric and causing it to rot. Since the introduction of synthetic ply fabrics using polyester and polyamide, this problem effectively no longer exists. Despite this, many conveyor operators and their buying departments continue to specify moulded edges, even though they do not provide any structural or performance advantage and can actually be susceptible to damage if the belt wanders off-track.
Nowadays, the most commonly used type of belt edge is the ‘cut & sealed edge’ or simply ‘sealed edge’, which is sufficient to prevent moisture being drawn into the carcass from the edge by capillary forces. Although the synthetic fibre plies are barely affected, moisture can ultimately cause vulcanising problems when making splice joints. A sealed edge also enables a belt to be used in very wet conditions and makes it better suited to long-term storage outdoors. The reason why it is important
The Ultra X fabric provides up to five times better tear resistance than conventional multi-ply conveyor belts
Super-tough belts like Fenner Dunlop UsFlex can last up to five times longer than conventional belting
Conveyors in the cement industry are indispensable but costly pieces of equipment
not to over-specify the type of belt edge is that manufacturers need to manufacture belts at the optimum width and length for cost and production efficiency. Consequently, standard width stock belts are usually made as wide as the manufacturing machinery will allow, creating huge rolls known as ‘slabs’. These are then cut and sealed to create a range of narrower widths. For example, using metric measurements in this case, 400 meters of 2,200mm wide belt ‘slab’ would be manufactured and then be slit (cut) to produce 400m of 1,000mm wide belt and 400m of 1,200mm wide. This is why the vast majority of rubber multi-ply belting held in stock by manufacturers, distributors and traders has sealed edges. Moulded edges can only be created when a belt is manufactured in isolation and to an exact width. Consequently, the manufacturer is unable to achieve optimum production line efficiency, the cost of which has to be reflected in the selling price.
ENSURE THE BELT IS UV AND OZONE RESISTANT
Never order a conveyor belt without first obtaining written confirmation from the supplier/manufacturer that the belt being supplied is fully resistant to ozone and UV. As every manufacturer of rubber products will know only too well, at high altitude ozone (O3) acts as a protective shield by absorbing harmful ultraviolet rays but at low altitude, it becomes a pollutant that attacks the molecular structure of rubber. Ground level ozone increases the acidity of carbon black surfaces with natural rubber, polybutadiene, styrene-butadiene rubber and nitrile rubber being the most sensitive to degradation. The reaction that occurs is known as ozonolysis.
The first visible sign is when cracks start to appear in the surface of the rubber. Further attacks then occur inside the freshly exposed cracks, which continue to grow steadily until they complete a ‘circuit’ and the product separates or fails.
Ultraviolet light from sunlight and fluorescent lighting also has a seriously detrimental effect on rubber because it accelerates rubber deterioration by
SOME THINK THAT RAW MATERIALS TRANSPORT REQUIRES TRUCKING. WE THINK DIFFERENT.
producing photochemical reactions that promote the oxidation of the rubber surface resulting in a loss in mechanical strength and wear resistance. This is known as ‘UV degradation’. The combination of ozone and UV has a seriously limiting effect on the operational lifetime of a rubber belt, regardless of geography or type of climate. Fortunately, ozone and ultraviolet damage is easy to prevent. Unfortunately, laboratory testing consistently reveals that some 90% of belts tested according to EN ISO 1431/1 procedure B static ozone resistance test are not resistant. In fact, the vast majority typically start to crack within the first 6 to 8 hours of the 96-hour test duration. This is because the anti-ozonants needed to
protect the rubber have been omitted from the rubber compound mix because of cost so always insist on ozone & UV resistance when selecting any rubber conveyor belt.
CHOOSE SPECIFICALLY ENGINEERED BELTS
Choose belts that are specifically engineered for the conditions they are required to cope with. This is especially important on sites where rip, tear and impact damage problems occur. Attempting to solve the problem by fitting belts with thicker covers and heavier carcasses is invariably a mistake. Simply using more of the same material will not provide the solution. As mentioned earlier, thicker, heavier belts can also cause other problems including lack of troughability, steering and
It is important to have a supplier that will readily provide a high standard of professional technical support and who has a good reputation for quality
handling problems and dynamic stress due to the pulleys and drums now being too small.
The most economical solution is to fit a conveyor belt that has been specially designed for the purpose, such as Fenner Dunlop’s UsFlex, Nova X and Ultra X range belts that are proven to last up to four or five times longer than conventional multi-ply conveyor belts. The initial buying price might be appreciably higher, but the cost will be substantially less over the working life of the belt, with the added benefits of far less repairs, change-out costs and disruption to output.
CHOOSE THE RIGHT BELT SUPPLIER
Always choose a belt supplier who you can rely on to be accountable in the event of a problem. It is important to have a supplier that will readily provide a high standard of professional technical support and who has a good reputation for quality. This, I feel, should always be an essential part of the criteria when choosing a supplier. A tall order perhaps, but they do exist.
Words by Jeremy Clark
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With a milling drum width of 2,750mm and a maximum cutting depth of 650mm, the 280 SMi is an efficient rock mining tool
BANGING THE DRUM
A clever design in one manufacturer’s Surface Mining equipment enhances operational stability
There are many innovations in the mining industry, but arguably at the forefront is the central drum design built into the Surface Miners (SM) made by manufacturing company Wirtgen. The placement of the cutting drum at the centre of the machines, known as the Middle Drum Concept, uses the machine’s weight to enhance cutting effectiveness and operational stability.
MAXIMISING CUTTING EFFICIENCY
Wirtgen’s Middle Drum Concept allows nearly the entire weight of the machine to be utilised for the cutting process. This design ensures that the machine’s weight force rests directly on the drum, pushing it firmly into the ground and enhancing the cutting action.
In practical terms, this means a Wirtgen SM can operate using very high cutting forces, according to the
company, translating into greater productivity and less wear on the machine. For instance, in a 60-ton Wirtgen 220 SM, nearly 88% of the machine’s weight is used for cutting, providing a higher cutting factor compared with a heavier 120-tonne machine using a different design, which uses only about 45% of its weight.
ENHANCED STABILITY AND PRECISION
The central placement of the drum also provides superior stability and precision, according to the company. By maintaining the center of gravity close to the drum, the machine achieves a balanced load distribution, reducing the likelihood of tipping or instability during operation. This stability is important for maintaining a consistent cutting depth, which is essential for producing a clean, even, and stable surface post-extraction.
POWER AND PERFORMANCE
Wirtgen Surface Miners’ Middle Drum Concept delivers excellent power and performance, according to the company. The efficient transfer of power from the diesel engine through the clutch, power belts, and planetary transmission directly to the cutting drum ensures that the machine operates at peak efficiency. Approximately 80% of the machine’s power can be used for the cutting process, compared with around 67% in alternative designs, thus enabling faster and more efficient rock-cutting operations.
PRACTICAL ADVANTAGES IN SURFACE MINING
The design facilitates direct loading of crushed aggregate, minimising the need for additional equipment and handling, thus streamlining the mining
process. Furthermore, the clean and stable surface left behind after cutting reduces the need for subsequent leveling or grading, saving both time and resources.
In applications where precision is crucial, such as road construction or
maintaining a stable cutting depth can be challenging.
In conclusion, Wirtgen Surface Miners offer an advantage based on physicsThe Middle Drum Concept allows for an excellent distribution of the machine’s weight, optimising the cutting process and ensuring efficiency and stability.
The practical benefits are: a 60-tonne Wirtgen 220 SM surpasses the cutting factor of most 120-tonne machines, and a 110-tonne Wirtgen 260 SX outperforms many 180-tonne machines. This efficiency and performance delivered by Wirtgen’s central drum design leads to outperformance in productivity and precision when extracting primary resources and realising large-scale infrastructure projects, according to the company.
TOUGH BELTS FOR TOUGH APPLICATIONS
Bulk material handling and heavy mining operations that use Fenner Dunlop Conveyor Belting benefit from maximum uptime, less belt maintenance, higher productivity, and lower total cost of ownership.
Since the center of gravity is located close to the drum on all Wirtgen SM‘s the maximum amount of weight force can be used for the cutting process Visit our booth at this year's Minexpo to speak with our conveyor belt experts! North Hall, 2633 www.fennerdunlopamericas.com
site preparation, the ability to maintain a precise cutting depth without additional stabilising mechanisms ensures that Wirtgen Surface Miners deliver high-quality results. This precision is particularly beneficial in complex geological conditions where
For more information visit: www.wirtgen-group.com/ surface-mining-wirtgen
Fenner Dunlop designs and manufactures premium quality conveyor belting for bulk material handling applications. We are known for our expertly engineered belt constructions that are extremely resistant to rip, tear, and impact damage. With over 150 years of industry experience, Fenner Dunlop is proud to be an innovator in conveyor belt manufacturing- with a commitment to safety and the environment at the core of everything we do.
Contact us for more information and/or to schedule a meeting in advance at Minexpo.
DIAMONDS DEALING IN
How one global diamond producer uses sorting technology and digital solutions to recover unbroken diamonds
Global diamond producer Lucapa Diamonds owns 70% of Mothae Diamonds, an open-pit mine located in the Maluti Mountains of Lesotho, Africa. The mine started commercial operation in 2019 following the commissioning of its kimberlite processing plant. The mine is known for producing large, high-quality diamonds, and has had significant gem-quality recoveries including a 215 carat D-colour Type IIa, a 204 carat Type IIa, and rare pink, blue and yellow diamonds.
DELIVERING SORTING EFFICIENCY
When planning the recovery plant, Mothae turned to TOMRA Mining for a solution: “We wanted to recover large diamonds at the highest sorting efficiency with the highest throughput, and TOMRA met Mothae’s requirements with its modern and innovative technology,” says Macobone Semelane, recovery superintendent. The recovery plant operates two
TOMRA COM Tertiary XRT 1200 sorters: one for fine materials from 10mm to 20mm, and the other for coarse materials from 20mm to 45mm. The ore extracted from the mine is treated through primary crushing, scrubbing and screening, then transferred to the recovery area: “That’s where the TOMRA sorters separate diamonds from the ore,” explains Kothalo Matoli, a recovery mechanician at the mine. “TOMRA sorters help us to recover large diamonds prior to secondary and tertiary crushing, hugely reducing the risk of breakages, and our throughput is high, with 98% efficiency.”
UNLOCKING THE POWER OF DATA
The two TOMRA XRT sorters at Mothae are connected to the TOMRA Insight cloud-based data platform that turns the machines into connected devices generating valuable data and helping operators to control the sorting process. They also feature the TOMRA ACT user
interface, which helps optimise the workflow and improve productivity.
Macobone Semelane explains: “As a relatively small and low-grade mine, we are always investigating the latest technologies. With our sorters operating 24 hours a day, seven days a week, we wanted to ensure they were connected to the latest compatible software and hardware.”
“We also wanted to ensure our operators could interact with the sorters and so needed a user-friendly portal. The TOMRA ACT user interface provides a clear view of events and alarms as well as images of belt occupancy. It also shows ejection activity, which is useful.”
“TOMRA Insight has changed the way we run our production because we can monitor our sorters remotely as well as access reports from both machines in one interface,” says Kothalo Matoli. “All the alarms and events are logged on the sorter in real time, allowing us to troubleshoot very fast. My troubleshooting skill has improved a lot.”
Mothae Diamonds is an open pit mine located in the Maluti Mountains of Lesotho, Africa
STORAGE AND BACK-UP OF DATA
TOMRA Insight also stores and backs up all the data generated by the sorters so that the operator can analyse the complete history of each machine.
“Digital data is crucial. TOMRA Insight has exceeded my expectations because I can access data whenever I want, wherever I am. I have all the learnings about my sorters, their operation and maintenance. We can also see the belt occupancy and our ejection rate, and understand if a machine is overejecting owing to foreign objects in the material, for example. The utilisation of the sorters has improved, enabling us to process more tons and recover more carats.”
“In addition, I can monitor the sorters’ operational and health status from the office or offsite since TOMRA Insight captures and compiles all the data in one interface, generating reports and data analyses, as well as improving data management and analytics.
The utilisation of the sorters has improved, enabling us to process more tons and recover more carats
IMPROVED COLLABORATION
The technology also enables a smooth production process since it fine tunes many parameters at the same time. Planning, productivity, quality management and logistics can be accessed by all teams and departments, and staff will be looking at the same near real-time information.
CUSTOMER SUPPORT
Macobone Semelane is also impressed with the support TOMRA offers. He says: “The team have been very supportive and their service is excellent.” Kothalo Matoli agrees: “They are available whenever we need them. They help us remotely and if we need somebody on site, they will send someone along.
With TOMRA Insight, I expect to see advanced sorting solutions and automated recovery plants in the not too distant future,” adds Macobone Semelane.
For more information visit: www.tomra.com
TOMRA sorters help operators to recover large diamonds prior to secondary and tertiary crushing
AGILE INDUSTRY
Customised solutions from Caterpillar promise to help with technology integration and the energy transition
Experts in material handling, are, like all other segments of the mining industry, keen to balance technology that will help with the energy transition and their customers’ need to increase efficiency and productivity.
Industry leading manufacturer, Caterpillar, has brought several new innovations to market that aim to both advance the industry’s green credentials and streamline their operations.
One example is a 372-tonne (410ton) Cat 798 AC mining truck. The vehicle is configured for autonomous haulage with Cat MineStar Command for hauling. Marc Cameron, senior vice president, Caterpillar Resource Industries says of the truck: “Autonomous technology will help monitor and orchestrate the complex balance of onboard energy, available charging assets and production targets to achieve the lowest operating costs.”
In addition there is the underground Cat R1700 XE load-haul-dump (LHD) loader which aims to contribute to industry-wide energy transition efforts by featuring battery-electric propulsion producing zero exhaust emissions and generating less heat than a reciprocating engine powered model. The Cat R2900 XE LHD provides a high-efficiency switch
reluctance electric drive system that meets the mining industry’s needs for bigger payloads, faster loading and lower emissions, according to the company. The loader’s PGS 1260 HD Energy Storage System (ESS) module offers energy storage for charging battery electric machines, and the MEC500 provides mobile equipment charging for the underground mining industry.
Brian Weller, vice president of electrification, Caterpillar Resource Industries says: “We have been working alongside select customers to accelerate the deployment of Caterpillar’s first battery-electric haul trucks. These machines will soon be operating at our customers’ sites where they will be tested and validated across a variety of applications.”
OPTIMISING THROUGH TECHNOLOGY
In addition, Caterpillar provides scalable building block technology packages to meet the mine operators’ needs as they move along their technology integration journey.
Caterpillar is also planning to launch two new technology offerings to its ‘MineStar’ ecosystem at the MINExpo trade show on 24-26 September in Las Vegas, Nevada. The ecosystem comprises a suite of
technology products and solutions related to health, fleet, terrain, command, detect, and edge. The elements of the ecosystem aim to track, monitor, manage, and sometimes automate different types of assets including production machines, light vehicles, and personnel.
The first technology offering at the show will be the Collision Awareness System (CAS). A site-wide solution using technology advancements to enhance situational awareness by warning operators of potential machine interactions before they happen.
Second will be a new office application for Terrain Payload Management that expands the payload tracking technology to Cat Electric Rope Shovels and Draglines. A virtual reality experience at the show will allow attendees to ‘get into the cab’ of the Cat 7495 Electric Rope Shovel and 6060 Hydraulic Mining Shovel to showcase the capabilities of Cat Command technology via two remote operating stations that will give visitors the chance to operate a dozer or rotary blasthole drill located hundreds of miles away from the Caterpillar exhibit. For
EXPANDING INFLUENCE
How one hauler manufacturer is targeting the West African market
Scottish articulated hauler manufacturer and member of the Volvo Group, Rokbak, has partnered with Heavy Machinery Dealership (HMD), a premier provider of construction, mining and quarrying equipment in West Africa.
Founded in 2003, HMD has established a strong reputation as a specialised distributor of premium heavy machinery and parts and is dedicated to contributing to the developent of Africa’s infrastructure. HMD, as an experienced local partner, will help bring Rokbak Articulated Dump Trucks (ADTs) to an established customer base in Nigeria, Ghana, Senegal, Benin, Guinea and Cote d’Ivoire. HMD claims it assists the growth and success of its customers through reliable, tried and trusted equipment together with strong spare parts availability and aftersales support.
“Rokbak has an excellent reputation, and our customers know and trust the Volvo brand,” says HMD CEO Mathew Khouri. “Rokbak haulers will complement our product portfolio well, offering the thriving mining, quarrying and construction industries
in West Africa a reliable and efficient ADT. With Rokbak we will deliver high-quality trucks alongside our exceptional service and support.”
ADVANCEMENTS IN AFRICA
The construction market in Africa is currently estimated to be worth US$58.42 billion and is expected to reach US$74.81 billion by 2029. West Africa’s construction industry is, in particular, experiencing substantial growth, driven by urbanisation, infrastructure development and mining activities. Nigeria and Ghana have the biggest mining markets in the region, with the global push for green energy solutions meaning reserves of critical minerals such as lithium, manganese and nickel are in high demand. The Nigerian mining sector alone is estimated to have 44 different types of commercially viable minerals worth an estimated US$700bn.
The demand for reliable, highperformance machinery is at an all-time high and Rokbak offers two hauler models. The RA40 is the largest with a gross power of 331kW (444 hp), a maximum torque of 2,225
Rokbak’s haulers are a good fit for the region’s challenging terrains
Nm and a 38 tonne (41.9 US ton) payload. It is a popular choice for major infrastructure and mining projects, with its effective power to weight ratio enabling the fast movement of heavy materials.
Like the RA40, the 28 tonne (30.9 US ton) RA30, with a gross power of 276 kW (370 hp) and a maximum torque of 1880 Nm, benefits from a transmission retardation system, a fully adaptable drivetrain and easy maintenance to suit a variety of different job sites.
A POWERFUL PARTNERSHIP
“Our partnership with Rokbak represents a significant advancement for our customers in West Africa and continues our vision to become the leading supplier of heavy machinery in Africa through customising solutions to customers’ needs,” says Khouri “Rokbak’s robust and reliable haulers are perfect for the region’s requirements. We look forward to working closely with the company to enhance the capabilities of our customers and contribute to the development of the local infrastructure.”
Rokbak’s articulated haulers are renowned for their durability, efficiency and ease of use, according to the company, making them a good fit for the region’s challenging terrains and demanding projects. HMD’s local expertise and infrastructure will provide support and training, ensuring optimal use of Rokbak equipment.
IMARC: MAKING MINING SUSTAINABLE
The International Mining and Resources Conference (IMARC) will take place on 29-31 October at the ICC Sydney Australia. It is billed as an event that fosters “collaboration between mining, investment, and innovation towards a sustainable future.”
IMARC is one of the biggest mining shows in the southern hemisphere and will see more than 600 mining leaders and resource experts participating in the conference and more than 500 leading companies exhibiting. The conference centre comprises 200,000 square metres of floor space.
Seven concurrent conferences are being held with a program covering the entire mining value chain. Delegates will be able to choose from approximately 340 technical talks, panel discussions, and strategic keynote presentations all taking place over the three days.
Attendees can expect to gain
strategic insights from c-suite executives on progressing ESG and environmental resilience, with the aim of accelerating mining’s energy transition as well as the ongoing digitisation of mines.
Delegates will see demonstrations of the latest innovative technology and be exposed to vivid showcase of all the elements that make the mining industry great. According to the organisers.
Manufacturers across the globe have committed to achieving net zero targets by 2050, while some have more ambitious goals, aiming for 2030. The mining sector and its extended value chains, play a crucial role in the transition to net zero. Miners should be fast-tracking the extraction of critical minerals vital for low-emissions technologies, but as an energy-intensive industry, the entire value chain bears the responsibility of reducing their
carbon emissions to reach this net zero goal.
IMARC 2024 will explore how the industry can accelerate the pathway to net zero in both a critical and responsible way, while also being efficient and effective. This approach acknowledges the importance of mining’s role, while ensuring that responsible mining and ESG standards and obligations are also met. The conference will cover various aspects of the mining value chain, including investment and developments for mining projects across all commodities and decarbonisation strategies, commercialisation and applications of innovative technologies, alongside case studies from companies working towards this transition.
YOU NEED TO BE HERE
WANT TO FUTURE-PROOF YOUR OPERATION?
Don’t miss MINExpo INTERNATIONAL® 2024 in Vegas! More than 1,900 suppliers are waiting to introduce you to 800,000 sq. ft. of mining products and solutions. And you’ll have exclusive, firsthand access to major product announcements. This is how you get ready for what lies ahead.
Register Now at MINExpo.com
MIF IT’S MINING IT’S AT MINEXPO
INExpo International, the world’s largest mining event, is back this year at the Las Vegas Convention Center from 24-26 September.
Owned and produced by the National Mining Association, MINExpo brings professionals, experts and decisionmakers from the global mining industry together to collaborate, learn and engage.
With a focus on all things mining, this event will provide insight into new trends and the direction of the industry, it will also be an excellent opportunity for mining operators
to find out what they need to know. Delegates will have access to technical staff that can answer questions on key issues to help them make smart purchasing decisions.
At the event, attendees will be invited to peruse cutting-edge technology, including sensors, AI, robotics, Internet of Things (IoT) technology and purchase equipment, as well as other parts and services from a global network of suppliers and manufacturers. There will be several networking events at which attendees will be encouaraged to share ideas with people facing the same operational issues.
Expect to meet spealialists in industry sectors such as precious metals, coal, industrial minerals, stone mining and quarrying, as well as sand and gravel. The show floor will also feature mining products for areas such as safety, drilling, engineering, materials handling, and training and HR. Every element from exploration, planning and processing to safety, sustainability and reclamation will be there.
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