The May issue of International Mining Engineer has a particular emphasis on artificial intelligence, predictive maintenance and digitalisation.
The special feature (page 8) examines how miners at the mercy of the weather can leverage AI to generate more precise weather reports from millions of climate data points.
As current mines are depleted and miners are pushed toward lower grade deposits in more remote areas, our Q&A with Earth AI (page 21) explores the Australian startup’s algorithm for pinpointing untapped reserves. If its current discoveries are anything to go by, Earth AI could hold one of the keys to the future of efficient mining.
Efficiency is also the focus of an article by Flender (page 20), which emphasises how geared mill drive systems save companies time and money by taking a holistic approach towards their practices.
Cleaner mining is another vital consideration for most mining operators, and the magazine addresses this too. An article from TLX Technologies (page 26) explains the value of selective catalyst reduction thermal management systems for offroad logging vehicles, and their role in reducing Nox emissions.
Having had the opportunity to assist editor Nicola Brittain with this issue of International Mining Engineer, I am delighted to become the magazine’s editor beginning with our upcoming August issue.
We always aim to provide meaningful and informative content to our readers, and should you have any ideas for articles you wish to see in future issues, please reach out to shenn@setform.com
Saskia Henn Deputy editor
Weather the storm
An innovative AI solution to help miners manage difficult weather
Global industry insights Your round up of global news for the mining industry
Advanced analytics How digitalisation is boosting efficiency 14
Out with the old A rigid dump truck promises durability
COVER STORY
LOAD & HAUL
A case study of Dellner Bubenzer’s work in Mongolia
The importance of coolant control valves for off-road vehicles
trails Earth AI’s transformational impact on mining
How a 5G tablet connects miners in hazardous environments
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
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A look at some impressive safety-enhancing AI solutions
How lantern rings help run rotating equipment smoothly
&
A reagent from Nasaco that manages pyrite depression
A deep dive into conveyancing, surveying and factory direct partnerships
Electric Mine A Santiago-based show aimed at Net Zero
Mining Asia Conference Celebrating 10 years
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's portfolio focus on Process, Design, Transport, Oil & Gas, and Power.
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GLOBAL INDUSTRY INSIGHTS
Your roundup of world news from the mining industry
KODAL MINERALS CLEARS WAY FOR LITHIUM PROJECT
Kodal Minerals has transferred the Foulaboula exploitation permit to its subsidiary Les Mines de Lithium de Bougouni (LMBL) to enable its lithium project in Mali. This ensures the validity of the permit and clears the way for a final export approval of spodumene concentrate, starting as soon as next quarter.
The permit is a key mining licence required to ensure compliance with Malian government and legislation, playing into the country’s new mining framework. It was introduced in August 2023 to increase the country’s revenues from mining by scrapping tax exemptions. The Malian government owns a 35% stake in the company, with the rest owned by Kodal Mining UK.
The move means Bougouni will become the country’s second operational lithium mine; one which will operate using Dense Media Processing (DMP), a method that sorts particles primarily on the basis of their density - a highly efficient sorting method.
BLUE MOON UNDERGROUND EXPLORATION PROGRAMME
Mining company Blue Moon Metals has received congressional support and Bureau of Land Management (BLM) approval for an underground exploration programme at the Blue Moon Critical Minerals Project in the state of California.
“With this approval, all three of Blue Moon’s critical metals projects have permits for underground exploration and development activities,” said Blue Moon CEO Christian Kargl-Simard.
A portal and tunnel will be built at Blue Moon volcanogenic massive sulphide (VMS) deposit in Mariposa County to provide access for infill and exploration drilling.
Engineering for this decline has begun and a request for a
proposal process to select a mining contractor has been initiated, with decline construction expected to begin late in the third quarter of this year.
Infill and exploration drilling allows for the examination of geology, rock mechanics and underground mining conditions. Once the mine moves into production, the decline will be used as the main haulage route.
Another aim of the programme will be to evaluate the potential addition of barite, pyrite, gypsum, aggregates, gallium, germanium and indium.
The approval allows for immediate commencement of the underground exploration programme.
New gold ore processing plant in Mexico
Precious and base metal resource company Asia Broadband (AABB) has unveiled its gold and silver ore processing facility in Etzatlan, Mexico.
“We are very proud and excited to have reached this pivotal point in our company’s mining operations,” said AABB president and chief executive Chris Torres.
The company’s on-site laboratory and testing programme aims to accelerate the processing facility’s operations while significantly reducing costs. The plant is designed
to use advanced automated mining equipment to further minimise costs while maximising throughput.
After initial production levels are established, the plant’s expanded processing capability will be implemented by management.
The first line of production will a mineral flotation process which the company predicts will be able to produce up to 500 tonnes per day. The second line of production, projected to start in September 2025, is a cyanidation process.
CC EXPLORATIONS UNVEILS AMRT TECHNOLOGY
Remote mineral sensing company
CC Explorations has unveiled its Atomic Mineral Resonance Tomography (AMRT) technology, which uses satellites to locate land and sea-based mineral resources.
“We are proud to disclose our capabilities and make our satellite-based AMRT Technology services available to the broader market,” said a CC Explorations representative. “We believe that our methods can significantly contribute to the efficiency and sustainability of exploration efforts across a wide
variety of industries.”
The satellite-based mineral detection service locates each targeted mineral’s unique atomic resonance frequency using the company’s satellites.
CC Exploration’s AMRT technology can be used for rare earth metals, gold, silver, copper and lithium.
The time-saving technology limits the impact on the environment and supports informed decision-making based on concrete data.
Epiroc to deliver autonomous vehicle fleet
Epiroc AB has been awarded a £178 million contract to deliver a major fleet of fully autonomous and electric surface mining equipment to Fortescue, Australia, over the next five years. Equipment such as Epiroc’s blasthole drill rigs, the cable-electric Pit Viper 271 E, and the battery-electric SmartROC D65 BE are expected to be included in the order.
The driverless machines will be deployed across Fortescue’s iron ore mines and overseen from the Integrated Operations Centre in Perth, over 1,500km away. This is possible owing to the self-directed capabilities of the machines.
The move marks a major step towards using electrified equipment over traditional equipment for the company.
Around 35 million litres of diesel consumption annually are likely to be cut with the new additions, helping to reduce operating costs and improving the carbon impact of the site. This plays into Fortescue’s emissions objectives, as it aims to achieve ‘real zero’ emissions by 2030.
WEATHER THE STORM
Platform Resilience will ultimately comprise a hybrid constellation of 30 satellites
A satellite-backed AI solution promises to help mining operators navigate extreme weather. Nicola Brittain reports
Climate change means much of the world is suffering from more erratic weather than it once did. This might include increased rainfall, higher winds than expected or extreme drought. Such unpredictable weather is causing safety and other problems for a variety of industries. In fact, the World Economic Forum’s 2024 Global Risks Report paints a harrowing picture, with these changes meaning potential financial losses to the global economy of $350bn with profound implications for safety and continuity. This landscape demands not just awareness but action.
THE MINING INDUSTRY’S VULNERABILITY
The mining industry is particularly exposed to such weather. For example, extreme rainfall can cause polluted rainwater to run from a mine into a nearby village if precautions are not taken; high winds can blow debris onto nearby farmland; and drought or very hot temperatures might impact machinery for example. That mines are often situated
in parts of the world with a less developed infrastructure than might exist in the US or Europe, for example, makes mining operators and communities around mines particularly vulnerable to the impact of extreme weather.
It is clear then how mining operators will benefit from accurate weather-related information to help with operational planning.
TOMORROW.OI’S TECHNOLOGY EXPLAINED
In 2016 a Boston-based group of technology entrepreneurs recognised that the business need for weather information was acute and becoming more so and therefore launched Tomorrow.io - a proprietary software and AI weather company to help businesses manage these issues. The company has since been featured in TIME magazine as one of its 100 most influential companies.
Chief marketing officer for the company, Dan Slagan, explained how the company came about: “We realised that changes in weather were
significantly impacting business but that most weather companies were repackaging publically available information, and that meteorologists were acting as account managers for these companies. The business element was missing. We therefore decided to automate weather information for businesses and build software as an API that included all a company’s operating protocols. We then calculated this against their risk threshold. This has basically delivered a system that manages weather 24/7.”
Tomorrow.oi’s automated system therefore provides a mining company with a level of foresight that allows for the adjustment of work schedules, maintenance, and transportation plans, ensuring that operations run smoothly, regardless of the weather.
More specifically it will provide a company with information detailing when it can and can’t blast for example using the information provided.
Slagan explained: “Blasting at the right time is absolutely critical for mine operators. One of our customers had previously been shut down for blasting during high winds and
subsequently polluting a neighbouring village, there was considerable legal fallout from this. You can see then how useful our solution is.”
Slagan added: “The software might also take into account high winds for example, or when an essential road might be closed because of heavy rains, this is extremely important information for mine operators looking to minimise downtime.”
The company is currently working with a handful of big-name mining companies to provide weather insights that will improve decision making, staff scheduling optimisation and supply-chain resilience.
RESILIENCE PLATFORM
This original proprietary modelling
The company is currently working with a handful of big-name mining companies to provide weather insights
combined with AI was enhanced in 2023 when Tomorrow.oi launched the first of a series of satellites. A further seven have been launched since, and the constellation, called Platform Resilience, will ultimately be made up of a hybrid mix of more than 30 satellites, all operated by the company. The importance of these is that the data is more accurate than that delivered by other satellites and that this weather information is owned by Tomorrow.oi.
HOW DO THE SATELLITES WORK?
The satellites have active (radar) and passive (microwave sounders) sensors which deliver very accurate and detailed pictures of weather formations. The platform constellation satellites
both carry a Ka-band Software Defined Radar which uses backscatter to profile precipitation in the atmosphere, and scatterometry to measure relevant parameters of the ocean surface.
PERFORMANCE SPECIFICATIONS
The Ka-band radar sends and receives radio waves with a frequency of 35.75 GHz. This radar is observing over a 400 km field of view with a horizontal spatial resolution of 5 km and a vertical resolution of 250 m. The company’s satellites span the entire globe.
CONCLUSION
In the mining industry, every minute of operation counts, and weather-induced downtime can lead to significant losses. Tomorrow. oi’s advanced weather forecasting combined with predictive analytics offers a powerful way of mitigating problems associated with climate change to maximise operating time and efficiency for mine operators regardless of where they are situated in the world.
Tomorrow.oi
ADVANCED ANALYTICS
How advanced analytics are boosting efficiency and productivity for mine operators
Without access to real-time data minor issues can go unnoticed
One of the most important but often overlooked developments in engine technology in recent decades is the dawn of digital connectivity. Whether it’s in cars, buses, or even large haul trucks, operators can take immediate access to performance data for granted.
Cummins has over 100 years’ experience manufacturing engines for a range of sectors and has been at the forefront of incorporating remote analytics capabilities. Over this time, Cummins has found that while some sectors have been quick to embrace digitalisation, others have lagged.
With the high cost of mining equipment and the critical impact of downtime, the mining industry has the most to gain through using advanced analytics. To maximise these potential advantages, professionals across the sector need to understand how they can best utilise this modern, advanced analytics technology.
THE FUNDAMENTALS – WHAT ARE DIGITAL SOLUTIONS?
Starting from the basics, connected diagnostic systems are technologies often incorporated within an engine to gather performance data. This collected information on engine outputs can then be remotely shared with engine manufacturers, original equipment manufacturers (OEMs) and mining engineers and operators, and assessed to inform changes to operations.
What these changes are depends on what information is shared. This can range from implementing additional training for operators on how to best use equipment, to taking machinery out of use for servicing if there are early signs of a potentially costly fault.
STATE OF PLAY IN MINING
While a lot of engines in mining today are equipped with connected diagnostics systems, many operators still rely on outdated IoT systems that offer limited insight into efficiency or early warning signs of failure. Without access to realtime data, minor issues can go unnoticed until they escalate. In mining, where engines are large both in size and cost, this lack of visibility can have critical consequences.
Many operators still rely on outdated IoT systems that offer limited insight into efficiency or early warning signs of failure
THE BENEFITS
Cummins Preventech technology captures proprietary datasets, only interpretable by Cummins, to provide detailed breakdowns of in-service equipment health. This function enables precise, proactive intervention, that maximises uptime and cuts down on expensive breakdown costs.
Through the latest technology advancements, Cummins is enhancing the accuracy and interpretation of its collected information. Machine learning capabilities allow the company’s systems to learn more quickly, assessing large live data sets to share dynamic information and inform operations. These innovations ensure equipped applications can operate at peak performance, paving the way for a more intelligent, efficient, and sustainable mining industry.
THE PROOF
A benefit of connected diagnostics is that you can easily see when and where they are working. Cummins PrevenTech equipped engines are in operation across many mining sites around the world, with mining engineers reporting real-life efficiency savings every day.
For example, in a case study of 50 equipped engines in a mining truck fleet operating over rough, mountainous terrain, Cummins PrevenTech was used to assess an issue regarding variable speed inefficiencies.
The technology analysed over 80 million records, with 200 plus variables, to identify correlated components and systems that were responsible for causing
Connected diagnostics means you can see when and where they are working
LOAD & HAUL
speed discrepancies. Through this assessment, a new targeted maintenance plan was implemented across the fleet, increasing average truck speed by 3%.
The result of this gain was a 2% improvement in annual production per truck, leading to a US$800,000 increase in productivity per truck, amounting to an overall $40m annual productivity increase across the full fleet.
ASSESSING REAL-TIME AND HISTORICAL DATA
In another example, a large operator was frustrated by an inability to measure the usable life of filters and oil across a fleet of over 100 trucks, each hauling 320-ton loads in extreme operating conditions. To address the problem, Cummins PrevenTech learning models, integrated with Fleetguard FIT, assessed real-time and historical data, captured from advanced sensors in oil and filtration systems, to generate
early servicing alerts where needed.
As a result, service intervals across the fleet went from 42 to 50 days, with shortened inspection times owing to remote diagnostics, extending engine life owing to limited progressive damage.
THE FUTURE OF MINING
The benefits of productivity, servicing and efficiency improvements from connected diagnostic systems are clear. Products like Cummins PrevenTech can, and have, made mining sites around the world more productive, safer and more profitable with digital integration. As mines around the world look towards an energy transition, realtime monitoring of fuel usage and performance of power solutions will be increasingly important. By being more connected in this changing landscape, we can make more informed decisions, ensuring that the mining industry as a whole
can strike a critical balance of TCO and profitability while achieving decarbonisation strategies.
THE ELECTRIC MINE SHOW
The mining industry needs to meet the world’s demand for raw materials but it is also under increasing pressure to make environmental commitments. Cummins is working hard to meet both objectives; the company’s mining engines are designed to be considerably cleaner than many in the industry, with technologies such as alternative fuels and advanced monitoring. As such the company is exhibiting and presenting at The Electriic Mine, a show that will take place in the Las Condes Region of Santiago in Chile. For more information read our preview on page 40.
As mines around the world look towards an energy transition, real-time monitoring of fuel usage and performance of power solutions will be increasingly important
LOW COST OF PRODUCTION SUSTAINABLE OPERATIONS
POWER: BALANCED
Can mining satisfy the world’s hunger for raw materials – and meet environmental targets too?
With Cummins’ help, it can. Our range of mining engines, made even cleaner and more e icient through technologies like alternative fuels and advanced monitoring, are helping mining explore a future that can be both sustainable and profi table. It’s power: balanced.
Visit Us at Booth G04! Don’t miss our speaking session: Wed, May 14 | 10:00 – 10:30 AM - Surface Mining Stage
OUT WITH THE OLD
A sustainable rigid dump truck promises improved durability for mine operators
Japanese heavy industry manufacturer Komatsu Europe has added the HD605-10 rigid dump truck to its extensive line up of vehicles. The company claims that this large class machine – a beast at 10.68 metres in length and 5.45 metres in width - sets new benchmarks in safety, productivity, durability, and environmental responsibility.
The machine was demonstrated at Bauma, a leading trade show recently held in Munich, Germany.
STAGE V ENGINE
At the heart of the HD605-10 vehicle is a 610 kW Stage V engine which the company claims boosts productivity and provides operators with the flexibility to tailor performance to their worksite needs with three selectable power modes: economy, economy light, and power.
The machine also features advanced fuel-saving technologies such as a high-efficiency cooling system and a lightweight body design option. These elements work together
to trim fuel consumption and slash operational costs.
The vehicle weighs 50.3 tonnes, considerably less than other products with similar power output. The standard tyres are 24.0 R35, and the dump capacity is 26.3 m3
DURABILITY AND UPTIME
Durability and uptime are critical in the mining and quarrying business, as such the HD605-10 features reinforced components from top to bottom. These include a robust main frame, upgraded differentials, final drives, a more resilient torque converter, and a heavyduty transmission which all help to ensure the truck is able to move through tough terrain.
A care programme offered with the vehicle protects operators with an maintenance plan, reducing unplanned downtime and extending the life of the equipment.
SAFETY CRITICAL
There are several important safety charactistics of the vehicle. These
include an LED lighting package to boost night-time visibility and illuminated stairways to provide safer access to the operator’s cabin.
PUTTING THE OPERATOR FIRST
Operators will benefit from cruise control, hill start assist, and a spacious, ergonomically designed cab. These enhancements aim to reduce fatigue and improve overall productivity, making life easier for people spending hours in the driving seat.
SUSTAINABILITY CONSIDERATIONS
Environmental considerations were paramount when designing the HD605-10, according to the company. The truck has an efficient engine cooling system; selectable power modes to reduce unnecessary fuel burn; and lightweight body components to reduce overall weight.
THE PERFECT PAIRING
The HD605-10 will be paired with its on-site partner: a wheel loader –the WA700-8. Built with the same attention to productivity, safety and environmental impact, the WA700-8 has been designed to complement the dump truck well. They provide an integrated loading and hauling solution and have been designed to work together, reducing idle time and increasing material movement.
A POWER MOVE FOR PROGRESS
The Komatsu HD605-10 rigid dump truck is an innovative machine designed for modern quarries. With smart engineering, customer-led design, and a commitment to sustainability and safety, operators are likely to be impressed by this vehicle.
The HD605-10 was demonstrated at Bauma
INERTIAL SENSOR SOLUTIONS
Precision Drilling: from Mining to Geothermal Energy
Drilling down several thousands of meters requires high-tech tools and equipment. Equally crucial is the appropriate sensor technology, to keep to the exact drilling path for precise results. So are shock and heat resistance to prevent strong vibrations and high temperatures from skewing measurement outcomes while drilling through the rock strata.
For the geothermal energy industry, this is enabled by ASC inertial sensor technology. Our portfolio includes high-end JAE quartz-based JA-5 and JA-25 accelerometers particularly suitable for this purpose.
In addition, MEMS-based ASC OS-series accelerometers conduct accurate, stable vibration analyses on machines like hydraulic deep drilling vibrators for soil inspection and preparation, to keep them running smoothly and prevent damage.
SUCCESSFUL
SONIC drilling ensures deep, straight and continuous near-in situ core samples, enabling accurate lithological representation and more statistically significant data.
Terra Sonic rigs drill quickly through all types of overburden and provide clean, stable boreholes. TSi SONIC Technology is the ideal choice for mineral and aggregate investigations, tailing piles, leach pad drilling and much more.
PREDICTIVE POTENTIAL
Saskia Henn finds out how predictive maintenance and other technologies are boosting operational efficiency in mines
The mining industry is at a pivotal stage, with current mining conditions prompting many challenges.
A recent webinar titled ‘Upgrades in Mining: Increasing Efficiency and Productivity’ highlighted some of these challenges, as well as potential strategies for overcoming them.
Pressure to identify new mining opportunities is mounting as current mines are being depleted. To accommodate increasing global demand for resources, miners are pushed toward lower grade deposits in more remote areas.
Remote deposits mean further trips to move the ore, and because ore grades are declining, the volume of material that needs to be moved for each ton of ore is increasing.
MINING LABOUR
At the same time, mining labour is declining as safety risks underline difficult-to-fill vacancies. Although mining encompasses 1% of the working population, it accounts for 8% of accidents.
These challenges have led to an increase in use of technology in mining that could not only offer respite from current difficulties but pave the way towards a new era of mining. Such digitalisation technologies include artificial intelligence (AI), virtual and augmented reality (VR and AR), as well as predictive maintenance and automation.
These technologies are already being implemented around the world, with the last ten years showing a considerable increase in technology investments.
GLOBALDATA SURVEY
Last year, a GlobalData survey of 150 mine sites worldwide found that digitalisation of the mining process had been moderately progressed or was considered well advanced at 77% of mines.
“Sizable shares of technology spend is being directed to areas such as cloud computing, networking, communications and IoT, all helping sites to operate more efficiently and safely,” said webinar host and GlobalData research and analysis director David Kurtz.
The introduction of predictive technologies could have a positive impact on company expenditure, time spent on equipment replacements and safety of miners.
METHODS OF EQUIPMENT REPLACEMENT
Traditionally, there have been two methods of equipment replacement: Condition-based replacement, where components are replaced when they stop working, and time-based replacement, where components are placed consistently after a certain period of time.
The introduction of predictive monitoring technologies has introduced a third, more fluid option, where the condition of components is monitored to find the most appropriate point in time to replace it.
Predictive maintenance through real-time monitoring enables the collection and analysis of data to assess the condition of components and replace them before they break. This saves not only time and money, but also potential injuries. It also positively impacts the labour market, as the number of jobs related to predictive maintenance has increased tenfold over the last five years.
One way in which this technology can extend the life of mining equipment is the use and monitoring of high-performance synthetic lubricants, which can reduce the need for costly overhauls or replacements, even more than standard oils.
Monitoring the condition of lubricant and equipment wear through techniques such as oil analysis, vibration monitoring and thermography, can identify patterns of wear and degradation. This considers extreme conditions such as high temperatures and pressures during operation, which accelerate oxidation, diffusion and thermal fatigue.
By identifying issues early, such techniques reduce the risk of sudden failures and malfunctions that lead to safety incidents.
“Mining doesn’t have the best track record with safety and safety really does start with each one of us and the little decisions that we make,” said webinar speaker ExxonMobil lubricants field engineer Jonathan Leland.
A company-wide cultural shift appreciating the importance of predictive maintenance is key to extending the life of mining equipment, according to Leland. To obtain useful results analysing the
Predictive maintenance through real-time monitoring enables the collection and analysis of data to assess the condition of components and replace them before they break
status of lubricants, everyone in the company must take the same approach to sampling.
“Quality sampling practices are the foundation for oil analysis,” he said. “There are inconsistencies that can be driven just by how you take your sample that can skew your data.”
A detail-oriented approach is also vital. Although automated and predictive technologies have taken over much of the work that used to be entirely manual, operators can still monitor the results that come in and apply them to each unique situation.
“Using data to recognise failures and drive reliability initiatives is really helpful because you can detect small
failures as they start to happen with oil analysis,” said Leland. “If you’re not watching it closely or you’re not heeding those cautions and alerts that come into the lubricant analysis platform, you’re missing an opportunity to catch a failure about to happen.”
Catching these failures allows users to replace components before they break, minimising downtime, money spent on emergency parts and potential injuries from unreliable equipment.
For more information visit: www.globaldata.com
Predictive maintenance is key to extending the life of mining equipment
GOOD VIBRATIONS
A look at how piezoelectric accelerometers can prevent downtime and production issues with hard-to-reach mining equipment
Vibration monitoring is critical to the preventive maintenance of mining and quarrying machinery. Not only do sensors leveraged in mining applications have to be precise; they must be extraordinarily robust, shockresistant and stable. ASC tailors its P31x industrial grade IEPE (Integrated Electronics Piezo-Electric) sensors for customers across mining, quarrying, drilling and related methods.
VIBRATION MONITORING
In the mining industry, it is typical for technical equipment to run 24/7. This often operates under extreme environmental conditions, with high levels of heat, dust, moisture, wet soil or crushed rocks affecting it.
Add cooling emulsions, grease and other substances that are meant to keep tools and equipment going longer and the difficulties are compounded. The combined effects produce a tough environment, both for the machinery in question as well as the sensor technology installed to protect it. Typically, all this comes to a head where access for maintenance or repair is difficult, if not impossible.
To prevent expensive machine downtime and to avoid significant safety risks, it is crucial that the rotating parts of machinery are continuously monitored to predict and prevent material fatigue, damage and failure. Beyond causing excessive wear and tear, undetected issues may lead to deviations from the intended drilling path, misalignment of shafts and other out of balance working patterns.
ACCELEROMETERS EXPLAINED
Piezoelectric accelerometers are based on PZT ceramic and feature IEPE circuitry to convert the charge to an analog output voltage signal. ‘Piezo’ is from Greek, meaning to squeeze. When input acceleration causes the piezoelectric material to
stress, it produces an electrical charge proportional to the acceleration. The IEPE circuitry converts this charge to an analog voltage output signal.
HIGH FULL SCALE OUTPUT VOLTAGE
ASC P31x industrial accelerometers feature a very high full-scale output voltage of ±8 V and low broadband noise of <100 µg. They come with a broad measurement range from ±16 g to ±800 g while covering a wide frequency response of 1.5 Hz to 16 kHz (±10 %) and a scale factor of 10 mV/g to 500 mV/g. Of extremely robust design – with shock resistance of up to 5,000 g and operational temperatures stretching from -55 °C to +150 °C – these uniaxial or triaxial sensors come in a robust stainlesssteel housing with protection class IP68 and an integrated cable of configurable length with connectors. This compact housing and overall robustness means the ASC P31x series can help manage the challenges of monitoring and maintaining a wide range of machines used in quarrying, mining and drilling, including engines, gearboxes, pumps, screens,
crushers and conveyors. Other tough applications such as geothermal energy drilling, other deep and surface drilling, high-frequency sheet pile vibrating/driving, ramming, pressing, hydraulic hammering, trench cutting or soil mixing techniques will also benefit from ASC’s flexible, costeffective sensor innovations.
INERTIAL SENSOR TECHNOLOGY
In recent years, inertial sensor innovations have been transforming the capacity, safety and productivity of global industries including structural engineering, automated vehicles and machines, railway and sensitive infrastructure like bridges, tunnels, dams or power stations. The mobility, commercial vehicle, aerospace, agricultural engineering, transport and general shipping sectors all benefit from this innovative sensor technology, just as much as wind turbine, geothermal and other sustainable energy operators do.
Two ASC piezoelectric accelerometers
MODERN MILLS
The mining drive expert Sankar Singha tells us how geared mill drive systems are reshaping the grinding circuit
Mill drive systems are essential in mineral processing plants, particularly for commodities like copper and gold, where ore must be reduced in size for extraction. As demand for larger and more efficient grinding solutions grows, the industry is re-evaluating drive technologies.
THE RISE OF ADVANCED GEARED SOLUTIONS
Geared drive solutions are reshaping industry preferences. As mining companies seek efficient, costeffective, and reliable solutions, the latest geared drive innovations are gaining traction. With recent advancements such as enhanced scalability, improved torque distribution, and self-aligning pinion technology, they are poised to play a key role in the next generation of mineral processing plants.
A SHIFT IN DRIVE TECHNOLOGY
Historically, mills up to about 30 feet in diameter were driven by ring gear and pinion systems, powered by motors and gearboxes. As torque demands increased, engineering challenges in designing high-power gearboxes and large-diameter ring gears led to the rise of gearless mills in the late 1970s. These systems eliminate traditional mechanical components, relying on magnetic torque transmission via an air gap between the stator and rotor. However, over the past few decades, metallurgy, precision gear manufacturing and computational engineering have improved significantly. Leading gear manufacturers like Flender have developed next-generation geared solutions, such as the DMG series, enabling mill drive configurations up to 30 MW. These improvements offer
The Flender DMG Series - geared mill drive system
a cost-effective and operationally flexible alternative to gearless drives.
ENHANCING POWER DISTRIBUTION AND RELIABILITY
Modern geared drive systems now feature quad-pinion girth gear engagement, effectively distributing mechanical power across multiple pinions for optimal torque control and load sharing.
The Flender DMG series incorporates self-aligning pinions, which automatically adjust alignment, ensuring consistent contact patterns and reducing uneven wear. This extends component lifespan, minimises unplanned maintenance, and enhances operational efficiency. Additionally, integrated inching drives improve safety and operational flexibility, while locked charge detection adds extra protection.
EFFICIENCY AND COST COMPARISON
While gearless drives have been favoured for their mechanical efficiency, a more holistic analysis of total system efficiency, including electrical components and auxiliary losses, shows that modern geared drives offer comparable efficiency. A detailed study on large mills shows around 90% overall efficiency for
both gearless and quad-pinion geared drive, considering all peripheral and auxiliary systems.
COMPARED WITH GEARLESS MILL DRIVES, FLENDER’S GEARED MILL DRIVE SYSTEM OFFERS THE FOLLOWING ADVANTAGES:
A 50% reduction in capital expenditure
Equivalent overall drive system efficiency
Faster delivery and easier installation
Simplified maintenance and far less operational downtime
No additional cooling units
Minimised long-term operational risk
Flexibility in procurement
DIGITAL MINING
The mining industry is undergoing a gradual but consistent transformation through the integration of automation, data analytics, and the Internet of Things (IoT) to enhance efficiency, safety, and sustainability. In line with this global trend, Flender has developed its proprietary AIQ monitoring system, now embedded into the DMG series gearboxes. This intelligent solution can be fully integrated into a plant’s automation pyramid, enabling optimised mill utilisation while significantly improving system reliability and operational transparency.
TECHNOLOGY TRAILS
Business exploration company
Earth AI is shaking up the mining industry. Saskia Henn gets the low down on the company’s business model and outlook
Recent exponential advancements in artificial intelligence mean that the technology is leading most industries by the nose – and mining is no exception. Australia-based EarthAI, an AI-driven mineral exploration company, is arguably one of the best know AI companies in mining. It uses a precise metal detection technology, fundamental geology and responsible drilling to find and deliver difficult to excavate resources.
International Mining Engineer’s Saskia Henn caught up with EarthAI’s CFO Monte Hackett to find out more about the company’s practices and operations.
HOW
DO
YOU USE AI
TO IDENTIFY MINERAL DEPOSITS AND THEN DECIDE ON A DRILL SITE?
The model learns from 400 million training cases around the Australian continent. In each case, it passes raw data through the neural net and characterises the geological environment for each site. The neural net changes and evolves as it learns from the data. Once trained, the AI can scan any area on Earth and identify fertile geological environments yet to be discovered.
WHAT KIND OF DATA
DOES THE PREDICTIVE TECHNOLOGY TAKE INTO ACCOUNT TO LOCATE UNTOUCHED RESERVES?
In Australia all exploration work since the 1970s has been entered into a central archive. This includes, with coordinates, drill results, geochem,
geophysics and soil samples. Our algorithm organises this large 50-year data set into predicting new prospective greenfi eld sites. We leverage these data points along with remote sensing and geophysical imaging to pick up subtle anomalies that are unable to be detected by the human eye. We run this analysis across the continent which then creates targets, typically 2km2 sites that we thereafter evaluate and drill using more traditional exploration methods.
IN WHAT WAYS DOES EARTH AI’S TECHNOLOGY IMPACT THE DISCOVERY PROCESS OF NEW MINERAL
DEPOSITS?
Earth AI’s technology drastically improves the discovery process because our algorithm does the heavy lifting for site selection. When we get to the site, we are looking at a 2km2 area, this is significantly smaller than your typical tenement (which might be greater than 50x that size). This allows our team to be much more efficient in finding the concentrated deposit.
HOW
DOES EARTH AI’S ROLE IN LOCATING UNTAPPED AREAS IMPACT MINING COMPANIES AND IN WHAT WAYS
ARE THEY AFFECTED?
Our company vision is ultimately to partner with miners. We recognise the value in extraction, financing, construction and selling, we also view this as a completely different skill set from our core competency. Our goal
is to be the organic growth engine to the mining industry, leveraging technology to find exciting new projects that we then sell to mining partners who can more efficiently tackle the subsequent steps once feasability tests have been done.
TELL
ME ABOUT SOME NOTABLE EARTH AI DISCOVERIES AND PROJECTS SO FAR THIS YEAR
We have made several exciting discoveries. Perhaps one of the more interesting was at Fontenoy on the east coast of Australia. This is a partnership with publicly traded company Legacy Minerals. Fontenoy has been interesting because there was geological consensus that the east coast was not a good site for magmatic nickel deposits. Our AI predicted the opposite and shortly thereafter we indeed found magmatic nickel and platinum group elements. An exciting case showing that technology can disprove convention.
WHAT PLANS DOES EARTH AI HAVE FOR 2025 AND BEYOND?
We have recently purchased two additional rigs, bringing our current fleet to three. Our near-term focus remains in Australia and will be balanced between adding new sites to our portfolio with continuing to drill and develop the sites for which we have already have success.
TOUGH TOOLS
Kathrin Geisler of i.safe Mobile explains how the company’s explosionproof 5G tablet helps connect miners in hazardous environments
In today’s rapidly evolving mining landscape, digital transformation is no longer optional, but essential, for operational excellence. As mining operations increasingly rely on edge computing, predictive maintenance, and real-time data analytics, the need for resilient, explosion-proof mobile technology is becoming ever more important. i.safe Mobile addresses this demand with its IS940.M1, the industry’s first 5G 10.1inch tablet specifically engineered for hazardous mining environments.
BRIDGING THE DIGITAL DIVIDE
The digital revolution in mining faces a unique challenge: how to deploy advanced technology in potentially explosive mining environments. The IS940.M1 tablet offers a comprehensive solution for knowledge workers involved in data-driven predictive maintenance management within digitalised mining operations.
This tablet integrates with existing 4G/5G campus networks and Wi-Fi 6 infrastructures, enabling mining professionals to access critical data in real-time from anywhere on site. The device transforms into a versatile operator station for process control and Manufacturing Execution Systems (MES), creating application possibilities in explosion-hazardous areas.
ROOTED IN TECHNOLOGY
Despite its robust explosion-proof design, the IS940.M1 remains lightweight and user-friendly, according to the company. The device features a 10.1-inch full HD display protected by Corning Gorilla Glass, making it suitable for visualising complex operational data even in challenging underground conditions.
The tablet is powered by an energyefficient chipset optimised for IIoT/edge computing applications. With 8GB RAM and 128GB internal memory (expandable via microSD), it delivers the processing
ADDITIONAL FEATURES INCLUDE:
Android 14 operating system with long-term support
Replaceable battery for extended operations
Front and rear cameras for documentation and remote collaboration
Comprehensive wireless capabilities including Wi-Fi 6, Bluetooth 5.2, NFC, GPS
Programmable red key for lone worker protection/SOS
IP68 waterproof/dustproof rating and MIL-STD-810H compliance
Operating temperature range of -20°C to +55°C
capability required for demanding mining applications. The 16-pin ISM interface ensures secure connection to approved accessories, enhancing functionality for field operators.
THE 5G CATALYST
The implementation of 5G technology in mining environments offers transformative benefits. The IS940.M1 leverages this potential with reliable, low-latency communication for remote maintenance, augmented reality applications, and mobile machine data visualisation. Mining operations can now deploy advanced IoT sensor networks with the IS940.M1 serving
as the central hub for monitoring critical infrastructure.
The IS940.M1 complements i.safe Mobile’s existing 5G portfolio, which includes the IS540.1 smartphone and IS440.M1 radio, providing a complete communication ecosystem for the digitalised mining industry. For mine operators navigating the transition to Industry 4.0, the tablet offers the balance of rugged durability and advanced technology.
The IS940.M1 can visualise complex operational data even in challenging underground conditions
You’re looking at the first XNO® powered hybrid vehicle.
Unveiled by Switch Technologies, this pioneering development gives mining operations high performance electrification with a low total cost of ownership.
XNO®, Echion’s uniquely robust anode material, performs in the toughest environments.
www.echiontech.com/landcruiser
Off-highway vehicles need components that stand up to harsh conditions. TLX Technologies delivers custom solutions for the most challenging applications.
+ Engineered to withstand debris, vibration, & extreme temperatures
sales@tlxtech.com | tlxtech.com CONTACT US WITH YOUR CHALLENGE.
BREAKING CONVENTION
Dellner Bubenzer’s recent work for a large mining company in Mongolia helps demonstrate the importance of brake technology
A Mongolia-based copper mine
Mining puts considerable demand on its equipment, not least the disc and drum brakes used for pulley systems, cranes and other severe duty applications. The equipment must be able to weather heat, contaminants, vibration, heavy load and extreme production demands while maintaining ‘always on’ operations. The equipment must therefore be outstandingly durable as well as safety critical.
Provider of disc and drum brake equipment Dellner Bubenzer is currently providing such safety critical equipment to companies operating in Mongolia, north of China, one of a number of mining hotbeds in the region.
The company recently supplied brakes for three gearless conveyor systems with an installed capacity of 2 x 5,500 kW each for 7100 t/h for a copper mine in the region.
The full scope of work included floating calliper brakes (model SFR50), brake discs, hydraulic power units, UPS, BCC3000 closed loop control systems, and complete encoder technology.
BRAKING SYSTEMS IN MINING
There are a variety of braking systems used by mine operators. These include hydraulic brakes commonly used in mining trucks and other heavy equipment. They rely on hydraulic pressure to actuate the system, offering good stopping power and control. Hydraulic systems can be enclosed and run in oil, protecting them from the corrosive elements of a mine. Secondly, there are wet multi-disc brakes, These are immersed in oil to prevent overheating and brake fade, making them ideal for heavy machinery like mining trucks. Electric brakes are also widely used, and these offer a smooth, wear-
free braking experience. Dellner’s product comprises disc brakes which offer precise control and good heat dissipation and finally drum brakes which are less common in modern mining equipment but still used in severe duty applications.
HOW DOES THE BRAKE SYSTEM WORK?
The main parameters of the brake system including pad wear, stroke (air gap), and brake pad temperature are now continuously monitored. The brakes stop the conveyor within ten seconds in loaded or unloaded condition. Depending on load, speed, etc., the HPU and control unit provide different braking levels and scenarios. The controlled braking process minimises the conveyor belt tension and reduces stress in the connected equipment. The system is also able to perform the pre-programmed
Right: A Dellner Bubenzer brake stand
ramps and stopping curves after a power outage.
REDUNDANT CONTROLS HELP SYSTEM AVAILABILITY
Redundant controls and HPUs guarantee system availability. The environmental conditions need a compact set-up of the brake units. The spring applied, hydraulically released, fail-safe brakes are able to equalise axial movement of the connected shafts.
Communication between the main PLC and BCC3000 goes via a PROFIsafe protocol integrating the relevant safety features while also monitoring the sub-functions.
High-end hydraulic cylinders and accumulators are central to the company’s mining portfolio,. These cylinders generate a pulling or pushing force, and are found, among other places, in earth moving equipment at surface mines. Steering, bucket and lift cylinders can be found on a single wheeled loader. Accumulators, meanwhile, are a type of pressure storage hardware where an incompressible hydraulic fluid is held under pressure and applied mechanically.
THE PROBLEM OF CONTAMINATION
An overarching concern with technologies that are required to work in dirty, heavy-duty environments – is contamination. These systems have multiple components and contamination can lead to downtime and increased costs. In fact, over 70% of failed cylinders have broken down owing to contamination and Dellner claims that it is contacted daily about inferior systems breaking for the same reason.
All weld details must be optimised for high fatigue strength and to eliminate the risk of contaminating internal parts of the cylinder. Metalto-metal gaps at welds must also be avoided, as unfortunately dirt can be trapped and released when parts expand at high pressure.
Dellner says it recently improved the 800-hour lifetime of a cylinder by five times, ‘simply’ by removing the risk of contamination.
OTHER PARTS OF THE WORLD
Further demand for this braking equipment is being generated by China itself, India, and South America, where a wide variety of raw materials are mined — from rare earths to precious metals. Africa, meanwhile, represents a more embryonic marketplace.
In each case, the requirements are different. The projects range from being underground, to being at an altitude of 5,000 metres. Then there are projects with above-ground conveyor belts that descend and then rise sharply. Conveyor belts and elevators present a clear and obvious need for braking solutions. Belts must come to a safe standstill in the event of a drive failure, depending on the load and speed. Especially during power outages, the belts must stop in a controlled manner with longer braking times. An immediate stop by directly applying the brakes would lead to destruction of the conveyor belt and, in the worst case, wrecking of everything surrounding it.
The mining sector continues to sharpen its focus on health and safety surrounding conveyor belts and elevators. The controlled stop prevents the belt from being destroyed along with the load but, importantly, this also prevents human injuries if people are near the band.
LEAD TIME FOR EQUIPMENT SUPPLIERS
Where a manufacturer of container handling equipment might complete
production on a crane every day, the largest mining companies — BHP Group, Rio Tinto, Glencore Plc, Vale SA, and China Shenhua Energy Co. Ltd., for example — might be working on a site with a mine start date a year from Dellner Bubenzer first being consulted. However, that point in time is nonnegotiable and everyone has to deliver on schedule and budget.
It is not uncommon for component manufacturers to have service engineers on site for months at a time, which wouldn’t be the case in other markets. And, while a lot of industries work to high duty cycles, mines are expected to be operational constantly. This requires considerable specific expertise. Dellner Bubenzer provided this long-term consultation work to its Mongolian client.
CONCLUSION
Dellner locates its product development and manufacturing facilities across the globe. Presently, the company maintains manufacturing and service facilities and operational bases across Europe, Asia, and North America. These global facilities are positioned to ensure proximity to major mining markets, facilitating streamlined production processes and prompt delivery of braking solutions to mining operations, according to the company.
For more information visit: www.dellnerbubenzer.com
Dellner’s visualising monitoring system
A hydraulic power unit from Dellner
COOLANT CONTROL
Chad VanRens from TLX Technologies explores the use of coolant control valves for off-road vehicle SCR thermal management systems
In the 1970s, countries across the globe began a decades-long process of implementing mandates intended to improve air quality. Reducing emissions from power plants, industrial facilities, vehicles and heavy equipment have played a crucial role. This includes reducing nitric oxide and nitrogen dioxide (Nox) emissions, a key contributor to smog and linked to cardiovascular and respiratory disease.
REDUCING NOX
Increasing pressure to meet targets for reducing NOx emissions drove manufacturers of diesel vehicles to adopt selective catalyst reduction (SCR) systems. First developed in the 1950s, SCR technology proved effective at reducing NOx and saw its first application in power plants. Now these systems are the standard means of reducing NOx in diesel vehicles. SCR systems can reduce NOx by
as much as 90%. In diesel engine applications, urea, also known as diesel exhaust fluid (DEF), is sprayed into the exhaust stream where it breaks down into ammonia. The ammonia and NOx then flow into a catalyst composed of base metals where they chemically react, reducing NOx to nitrogen and water vapour.
THERMAL MANAGEMENT MATTERS
DEF freezes at temperatures below -11ºC and degrades if it gets hotter than 30ºC. Depending on the specific vehicle, SCR systems may use different thermal management systems for heating and cooling DEF to keep it within its optimal temperature range, between 12ºC and 30ºC.
For certain applications, engine coolant is used for both heating and cooling DEF. Depending on the
Valve used for control of coolant in DEF multi-function head unit
DEF multi-function head unit. Includes coolant valve, heat exchanger and sensors
conditions, hot or cool coolant is circulated through a heat exchanger inside the DEF tank, providing enough heat to keep DEF from freezing, thawing it if it has already frozen or cooling it if the temperature is in danger of getting too high.
OPERATING IN HARSH CONDITIONS
TLX Technologies was approached to design a coolant control valve for an SCR thermal management system for off-road logging vehicles. The valve needed a maximum flow rate of 0.5 L/s to be able to handle operating pressures up to 500 kPa, as well as be reliable in harsh conditions like vibration, submersion and debris.
TLX developed two versions of this valve: one with an IP65 rating, making it dust-tight and water resistant, and a second with an IP67 rating, making it dust-tight and fully submersible to one metre for 30 mins. The higher-rated version was needed for vehicles operating in circumstances
where the valve could be submerged in water, such as during flooding or when crossing a stream.
MANAGING FLUID CONTAMINATION
Because logging vehicles are subject to so much dirt and debris, fluid contamination is always a challenge. TLX designed this valve with a custom diverter to route debris in the coolant away from critical internal valve components, ensuring reliable operation in difficult conditions.
Increasing regulatory pressures sometimes drive innovation, as has the complexity introduced to diesel vehicles by emission control systems. As such engineering ingenuity is required for optimal performance and reliability. As environmental standards evolve, robust engineering becomes not just a compliance requirement but a competitive advantage.
For more information visit: www.tlxtech.com
Schematic of a DEF system with active heating and cooling
SAFE AI
Although mining accidents overall are on the decline, a troubling trend shows fatalities are still prevalent enough to warrant attention.
Last year, there were 11 fatalities in the Australian mining industry, as reported by SafeWork Australia, nearly double that of last year’s six. The USA Mine Safety and Health Administration has reported 10 fatalities from 3rd January to 5th March, over triple the number for the same period last year. In March, five people perished in a coal mine explosion in Spain. Eurostat found the highest incidence of fatal accidents at work in the EU was observed in mining and quarrying in 2022.
AID FROM AI
With the recent surge in AI technology, safety features have the potential to develop rapidly and in unique ways, anticipating dangerous events and even learning on the job.
Real-time surveillance can help to identify potential hazards and equipment upgrade requirements before accidents occur. Unstable structures, gas leaks, exposed electrical wires, inconsistent traffic flow, loose rocks, temperature changes and tremors are all hazards that could be identified using AI.
COLLISION PREVENTION
As usual, safety was a significant topic of discussion at Bauma 2025, where mining industry players gathered in Munich to explore some of the latest developments for safe and smart equipment.
Safety solutions company Brigade Electronics featured its range of safety equipment at the April show.
“Brigade’s mission since 1976 has been to prevent collisions and save lives, and as shown by statistics, the construction and mining industries need considerable input to maintain safe sites,” said Brigade regional director Maurizio Cagno.
“All our products are rigorously
Exploring some of the most interesting AI safety technology solutions for mining
tested to withstand harsh working environments, enabling operators to drive with confidence.”
Brigade’s Backeye 360 was one item on display, featuring multiple highresolution view options, including a 360-degree view with four cameras. These cameras provide a bird’s eye view of a vehicle in operation to eliminate blind spots and warn drivers verbally and visually when a person is detected in the vehicle’s path.
Additionally, Brigade’s AI camera and Backsense Radar Detection was showcased. Brigade’s AI camera has been trained to recognise people based on algorithms, reducing the number of false positives when warning the driver of a risk of collision. The camera is suitable for the harsh weather and terrain associated with mining, as it is protected against the ingress of dust, high temperatures and high-pressure water.
A SMART SERIES FROM DEVELON
Another organisation focusing on safety at Bauma 2025 was safety
solutions company equipment manufacturer Develon which unveiled its Smart Crawler excavators. The Develon 9 Series includes safety features such as virtual fences, these create a digital boundary around the machine, preventing it from moving beyond a specified limit, they also prevent potential problems with user error or machine malfunctions.
Another safety feature of the smart crawlers is the Smart Around View Monitor, which is an AI-based object detection system using cameras, radar sensors and machine learning to provide a 360-degree view of the machine’s surroundings.
Develon’s Transparent Bucket 2.0 was also launched at the Bauma show. The bucket, which increases visibility, is now equipped with object detection and object recognition to help prevent accidents.
Top: Develon Smart Crawler Bottom left and right: Brigade’s Backeye 360
Control dust and spillage.
For over 40 years, the largest mining companies in the world have put their confidence in Richwood’s innovative material handling solutions.
When it comes to solving problems with dust and material containment, Richwood achieves success with engineered passive dust containment systems. Application-specific solutions optimize efficiency through sealed and protected load zones without the need for vacuums, filters or other additional equipment. The reduced wear and tear on equipment and controlled dust and spillage create a safer and more productive work environment. Worry free load zones are designed and built by Richwood every day.
What would it mean for your productivity if dust and spillage issues were eliminated? Contact Richwood today for a review of your application.
Rely on Richwood!
RING OF LIGHT
Sealryt looks at the crucial role that lantern rings play in the smooth running of rotating equipment
Lantern rings are essential to the successful operating of rotating equipment, since they are specifically designed to deliver flush water to the shaft surface when used with mechanical packing.
TYPES OF LANTERN RINGS
There are various different types of lantern rings and they can be manufactured from materials such as steel, aluminum, brass, and Teflon.
Shaft sealing technology specialist SealRyt, produces its own unique lantern rings, tailored to address specific challenges in the industry.
INNOVATIVE DESIGN
SealRyt lantern rings SLR (Structural Lantern Rings) are distinct from the standard ones on the market since they were developed to ensure the delivery of water to the shaft as efficiently as possible.
The design not only achieves this but also boasts a robust structure capable of withstanding higher pressures within the stuffing box, this arises from the mechanical action of tightened packing.
Additionally, the design mitigates clogging issues - a common problem with conventional lantern rings where small ports and shallow channels on either the outer diameter (OD) or inner diameter (ID) often lead to blockages.
COMMON INSTALLATION ISSUES
Despite their essential role, lantern rings can encounter issues owing to improper installation, including: Incorrect sizing: If the lantern ring is not correctly sized for the equipment, it will not function effectively.
Poor configuration matching: Installers must ensure the packing set configuration matches the actual stuffing box setup. Failing to do so can lead to poor performance.
By way of illustration consider a typical pump model number indicating a configuration such as ‘2L3’. This means there are two rings of packing at the bottom, followed by the lantern ring (denoted by ’L’), and then three more rings extending to the atmosphere – they might be configured wrongly during the installation process.
THE IMPORTANCE OF PROPER PLACEMENT
It’s important to carefully inspect the stuffing box and take accurate measurements to ensure the correct placement of the product. Placing the lantern ring incorrectly can cause problems such as reduced performance and ineffective sealing. Proper positioning is crucial to avoid these issues and maintain optimal function.
A SLR PRODUCT VIDEO LINK
For more insight, a video at this following link https://tinyurl.com/ zrnder9a explains various aspects of the product, their materials, and functions. Remember, correct placement of the ring inside the stuffing box is crucial.
The company has been sealing shafts in all types of industries for over 20 years. Sealryt urges anyone who has any rotating shaft sealing questions or wants to learn more about pump seals, mechanical packing or failure points, or to contact a Sealryt engineer.
Pump packing utlising the SLR in a 2L3 configuration
A glass and moly filled PTFE lantern ring
Standard PTFE versus an SLR
SAFE SMART &
How a reagent from Nasaco tackles pyrite depression
Pyrite is one of the most common sulphide minerals found in a variety of geological settings. It contains valuable materials such as gold and lithium. However, extracting these precious metals can be challenging,
THE PYRITE FLOTATION PROCESS
Pyrite flotation is the process of separating pyrite from other minerals in ore, improving the quality of the minerals. The flotation process contains many steps, beginning with ore preparation, where the ore
Pyrite depression changes the surface properties of the minerals and enables the separation of valuable materials from tailings
containing pyrite and other materials is crushed to reveal individual particles of minerals. The ore is then mixed with water to form a slurry, and depressants are added to selectively depress pyrite, thereby preventing it from floating alongside the other materials.
PYRITE DEPRESSION
Pyrite depression changes the surface properties of the minerals, enabling the separation of valuable materials from tailings. Various reagents can be used to depress pyrite. High Ph levels, for example, can do so by separate it from
Pyrite depression changes the surface properties of minerals
other minerals by inhibiting its ability to float.
NASACO’S SOLUTION
A solution from chemical specialist Nasaco is a reagent called Nasmin 1032, The product is engineered for safety, performance, and sustainability, and tackles depression by stripping copper from pyrite surfaces – like cyanide, restoring it to ‘normal pyrite’.
YOUR PYRITE CONTROL CHECKLIST:
Operate at high pH, especially in the mill
Use high-chrome steel grinding media
Avoid overdosing xanthate and consider combining xanthate with a more selective collector such as NASCOL 201 (thionocarbonate)
Tailor oxygen conditioning times to your pyrite’s reactivity
Use a cure method like Nasmin 1032 to remove copper-activation
For use in layouts where the logo will be placed on a dark color eld such as technical services gray.
Check for locking with mineralogical services
It also reduces pulp electropotential, which limits oxygen’s role in dixanthogen formation. In addition, Nasmin 1032 is non-toxic and non-volatile.
LOCKED PYRITE
If the pyrite is locked in Cu-sulphides, Ni-sulphides or similar value minerals, it will float with the host mineral. Where pyrite recovery is still an
issue after optimising pH, grinding media and reagents, an operator should check for pyrite locking using a scanning electron microscope. Nasaco helps its clients determine the level of locking and find possible solutions.
For more information visit: www.nasaco.ch
PACK™ System PUMP PACKING
SIMPLE SCHEDULING
Sue Griffith, a field support supervisor for Martin Engineering, provides a deep dive into conveyancing service, maintenance, and factory-direct partnerships
Wear parts like air cannon valves can be reconstructed and sent back for less waste and better cost savings
Unscheduled downtime of belt conveyors in bulk handling operations can be calculated in cost per minute. For sanity’s sake, operators should not calculate this. It’s likely to reveal the severe logistical and scheduling inefficiency of service contractors and equipment manufacturers as well as seriously raising the respective operator’s blood pressure.
Generally, when operators install retrofitted conveyor solutions, they focus on the up-front price with little consideration for the cost of ongoing service, maintenance costs, and supply chain. But down the road, when critical service or parts are needed, the cost per minute difference between days and weeks of downtime or keeping the system limping along at 25-50% production can amount to an entirely new equipment retrofit.
Research published by the Australian Coal Association indicates the cost of downtime is in the order of five times (5x) the cost of replacing the component. When the root cause of downtime is related to the basic conveyor design, the downtime cost is approximately two times (2x) the cost of the redesign.[1]
At first, these ratios may seem to be erroneous or even backward but consider that a component failure often involves maintenance with a relatively short downtime window for replacement, whereas a basic design mistake often involves a significant capital expense and a prolonged outage for correction.
This is why having a close relationship with equipment manufacturers and/or their certified contractors that offer responsive ‘factory direct’ products and services is important to the cost of operation. The main factors to consider are service availability, technical expertise/safety, and supply-chain logistics.
SERVICE AVAILABILITY
The mystery of the ‘disappearing manufacturer’s representative after installation’ is an old one. However, reliable and timely site visits are a hallmark of a solid partnership between the operator and the factory-direct manufacturer. Service technicians and certified
representatives who are available during problem-free uptime are likely to be responsive during panicinducing unscheduled downtime.
Site visits are also not arbitrary. A reputable equipment manufacturer representative will examine not just their components but the entire conveyor system, offering preventative maintenance support. The goal is to find indicators of the causes of
downtime and offer practical and timely solutions. For example, Martin’s Walk the Belt program is specifically designed for predictive maintenance. A Martin Service Technician (MST) or certified contractor will physically examine the entire system with an extensive checklist and then write a report, often with photos, observations, recommendations, and solutions to improve safety and efficiency.
Trucks specially equipped with the necessary tools and parts arrive to offer service and solutions
Walk the Belt checklists are accompanied by tests, results, and solutions to improve conveyor performance
Technology provides real-time status updates remotely, allowing for scheduled changes or adjustments
TECHNICAL EXPERTISE AND SAFETY
Experts have ‘seen it all’ until they haven’t, and that’s when their expertise is tested and safety becomes an issue. Outside service contractors may be generally familiar with systems and maintenance procedures but often face a steep learning curve when servicing new equipment designs. The top equipment manufacturers consistently iterate on previous designs, seeking to improve safety and efficiency. Factory-direct technicians and certified contractors from these reputable equipment manufacturers respond quickly to calls and arrive equipped to diagnose and solve issues, minimising downtime.
Most operational site managers strive to maintain the highest workplace safety standards. If external contractors don’t operate to the same level, they risk being ejected from the site. In addition to stringent conveyor and flow equipment maintenance training, MSTs undergo comprehensive safety training. With regular visits, factory-direct MSTs quickly learn the latest standards and procedures of each production site,
staying up to date with the needs of their customers and ensuring compliance and safe working.
SUPPLY CHAIN LOGISTICS
Often, during the installation of retrofitted equipment, some creative engineering is required to make components fit, secure, and operational. Maintenance crews can’t have a replacement part for every bolt in their operation, especially if storage space is limited. This becomes acutely apparent when specialised parts are needed for repair. Equipment designs should have standard, easy-tounderstand parts and procedures.
In addition to providing a solution, this engineering design should prioritise safe inspection and maintenance access. Whether it’s replacing wear-parts or engaging in routine service, getting the proper manufacturer parts in a timely manner is imperative.
Factory direct means that wear parts can be predictively scheduled and delivered by simply monitoring the speed at which they wear, especially for processing plants
SUE GRIFFITH, FIELD SUPPORT
SUPERVISOR, MARTIN ENGINEERING:
Sue has more than 20 years of management experience with a successful record in project planning, sales coordination, and logistical scheduling at varying levels. With a degree in business management and marketing, in 2009 she implemented an ROI policy for trade show effectiveness. She has extensive knowledge of creating service routes for a fleet of vehicles plus monitoring costs for sales/service completed within the routes. Sue has been the backbone of the company’s dispatch of service teams and logistics for over a decade, helping make it a trusted name in the bulk handling industry.
making use of remote monitoring systems. If the wear timeline is somehow shortened, this can be an indicator of downstream issues causing more wear. It can also mean that an unexpected rapid early delivery is required. Factory-direct MSTs and certified contractors usually have the proper equipment in the service truck. If they don’t, depending on the remoteness of the site, the MST simply calls, and these parts can be procured and delivered rapidly.
RESOURCES
[1] Roberts, Alan. Conveyor System Maintenance & Reliability, ACARP Project C3018. Published by Australian Coal Association Research Program Centre for Bulk Solids and Particulates, University of Newcastle, Australia. Nov, 1996. http://www. acarp.com.au/abstracts.aspx?repId=C3018
At Cirrus Research, we specialise in the design, manufacture, and distribution of high-quality noise measurement instruments and solutions.
T +44 (0)1723 891655
E sales@cirrusresearch.com
W www.cirrusresearch.com
HILLIARD
Hilliard offers a diversified product line for industrial applications in a wide variety of industries. Hilliard products are designed, manufactured and sold according to our customers' applications.
T +1 607 733 7121
E rdoud@hilliardcorp.com
W www.hilliardcorp.com
CONN-WELD INDUSTRIES, LLC.
Conn-Weld Industries, LLC is an engineering firm and 400,000 sq. ft. manufacturing facility providing a full product line of vibrating screening equipment, sieves, and various components serving the mining industry.
T +1 304 487 1421
E sales@conn-weld.com
W www.conn-weld.com
J.H. FLETCHER & CO
Celebrates their 80th anniversary of serving the underground mining industry. Fletcher world renowned roof support, is accompanied by an entire product line, which serves the coal, industrial mineral, metal, and construction industries.
T +1 800 543 5431
E sales@jhfletcher.com
W www.jhfletcher.com
DIEMME FILTRATION
Diemme Filtration has the widest range of filter presses available on the global market in terms of size, design and technical characteristics. The equipment is tailor made and designed according to the needs of the specific application.
T +39 0545 20611
E info@diemmefiltration.com
W www.diemmefiltration.com
RICHWOOD
Richwood designs innovative solutions for the worldwide bulk material handling industry. Clean conveyors and sealed and protected load zones from site specific solutions mean lowered maintenance costs, safer work areas and more productive operations.
T 304-525-5436
E info@richwood.com
W www.richwood.com
family of primary belt cleaners deliver industry-leading performance in the most demanding and varied mining environments. QC1+™ Cleaners effectively discharge material from the belt while minimizing the carryback that can lead to conveyor system damage. Our patented Continuous Angle Radial Pressure blade-to-belt technology, our long-lasting application-specific urethane blades, and our rugged mainframes ensure superior cleaning power throughout the blade’s service life.
Easy to maintain and quick to service, these robust QC1+™ Cleaners protect belt components from premature wear and minimize fugitive material issues — keeping your operation running smoothly, safely and more productively.
THE ELECTRIC MINE: FOR OPERATORS ON THE ‘NET ZERO’ JOURNEY
The mining industry is at a pivotal point in history with most if not all companies looking to move from powering their operations with fossil fuels to electricity. Such a move requires new thinking, collaboration and an openness to technology adoption that the industry has not previously had.
As such, The Electric Mine exhibition and conference series was established five years ago and has run every year since then. The fifth in the series will take place on the 13th to 15th May 2025 in Santiago, Chile.
HISTORY OF THE SHOW
In the five years since it started, the show and conference has become a lightning rod for innovative technologies and adoption case studies. The event is also designed to offer insights and
expertise from first movers, and to provide guidance on how solutions can be practically applied at individual operations and highlight the direction of travel in the sector.
The Electric Mine is aimed at OEMs, mining companies, service suppliers, consultants or mechanical engineers on the net-zero journey.
CONFERENCE PANELS
Conference panels and keynotes span the three days of the event and include the following sessions: Open pit and underground mine electrification; Pathways to a sustainable future: and Fostering opportunities in the transition to zeroemission vehicles.
ATTENDANCE
Attendees will not be able to purchase day-only events, however they will be able to attend online as the conference will be streamed for those not at the event.
The big-name headline exhibitors include Cummins, Komatsu, Epiroc, Caterpillar and Hitachi.
CELEBRATING 10 YEARS: MINING ASIA CONFERENCE AND EXHIBITION
The Mining Asia Conference and Exhibition will be held 18th June and 19th June at the Marina Bay Sands Expo & Convention Centre in Singapore. This will be the 10th event of this sort.
Although the show is Southeast Asia’s largest strategic mining investment, capital raising, technology and clean energy convention, attendees are expected from all around the world.
At least 450 attendees from global organisations and 150 or more investors, as well as decision-makers, stakeholders and regulators from over 30 countries are expected to attend the event.
A range of topics will be covered, including exploration opportunities, precious, base and bulk metals, sustainability goals, technological innovations, commodities forecasts and mining investment trends.
Numerous opportunities for
networking will be available, with mining CEOs there to discuss the feasibility of projects and financing options and opening doors for industry
players of all sizes. The team will be on site to match attendees in 1-2-1 meetings according to their business profiles and objectives.
In addition, free-roaming and organised opportunities for conversation will be plentiful, with talks by over 50 speakers scheduled to share vital industry information from the past year. Panel discussions and keynote and premium presentations aim to foster the exchange of ideas and viewpoints.
The exhibition floor will be packed with 35+ exhibitors featuring new technologies, discoveries and projects.
Key themes such as the shifting geopolitical climate and opportunities for junior miners aim to both reflect current circumstances and support industry players experiencing them.
Over 50 speakers are scheduled to talk
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