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COMMENT

A MINING AND CONSTRUCTION EXHIBITION TO BEHOLD BEN CREAGH

Ben.Creagh@primecreative.com.au

THE ATTENTION WAS ON MINING MACHINERY MORE THAN EVER BEFORE AT THE USUALLY CONSTRUCTION-FOCUSED BAUMA EVENT IN GERMANY THIS YEAR.

A

ustralia has a strong selection of high-quality mining events, but none are remotely near the scale of the Bauma trade fair in Munich, Germany.

The Australian Mining team was fortunate to attend the world’s largest construction and mining machinery exhibition during April.

Bauma may traditionally be a showcase for construction machinery, but it did have a growing focus on mining equipment and technology across the record 614,000 square metres of exhibits in 2019.

There were several mining trucks and excavators displayed by the leading equipment manufacturers, including Liebherr, Caterpillar, Komatsu and Hitachi.

Manufacturers of minerals processing and materials handling equipment also featured prominently in a hall of exhibits set up specifically for mining.

These companies were supported by a bevy of technology developers that are tapping into the digitisation of the industry.

And while Australia may be a long way from Germany, the understanding of the growth and trends that are shaping the industry here was strong.

Equipment manufacturers from across each expertise of mining all seemed aware of the opportunities in Australia and had plans to establish a niche in the marketplace.

At the 2019 edition of Bauma, Canada was a designated partner country of the event for its place as one of the largest and most diverse mining markets in the world.

Despite the distance from Europe, there is

MANAGING DIRECTOR JOHN MURPHY MANAGING EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALISTS EWEN HOSIE Tel: (03) 9690 8766 Email: ewen.hosie@primecreative.com.au VANESSA ZHOU Tel: (03) 9690 8766 Email: vanessa.zhou@primecreative.com.au ALEX GLUYAS Tel: (03) 9690 8766 Email: alex.gluyas@primecreative.com.au

no reason why Australia couldn’t target a similar role to what Canada had at the 2022 Bauma, such was the awareness of our marketplace.

Australia looks like it is already one of Bauma’s major international growth markets in terms of visitors, with organisers reporting that we were a leader from international countries in this regard.

When Bauma came to a close it had this editor pondering the coming events season in Australia.

Once again, Australia’s events cross the country from coast to coast. At the time of publication, Austmine’s 2019 Innovation Conference will have just been staged in Brisbane.

To name a few others, the annual Diggers & Dealers Conference in Kalgoorlie and AIMEX in Sydney both return in August, before attention turns to IMARC in Melbourne in October.

What can Australia’s events learn from Bauma? In 2019, Bauma attracted 620,000 visitors, who viewed around 3700 exhibitors from 63 countries.

This logistical feat was something to behold and how the organisers managed an exhibition of this magnitude is an aspect that all event holders could appreciate as they target growth of their own.

FRONT COVER

In this edition, we look at the role of batteries and electric vehicles in the future of the Australian mining industry.

This issue reviews the Bauma trade fair in Germany, including the new products launched and analysis of the Australian mining marketplace from abroad.

In our commodity spotlight, we explore the next opportunities for growth in the iron ore industry outside of the major miners.

We also look at National Group’s acquisition of Wolff Mining and how the move will bolster its autonomous capabilities.

An as usual, we review the latest mining equipment and technology in our regular products spread.

Cover image: Sandfire Resources.

Ben Creagh Editor

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CONTENTS

CRUSHING AND SCREENING

FUTURE OF MINING

12-13 A BOOM FOR BATTERIES The evolving opportunity in mining

A REPEAT WINNER Lincom Group delivers Premiertrak in a time of need

AUTOMATION

48-49 MINING INFRASTRUCTURE

NATIONAL GROUP’S NEW PUSH Wolff acquisition opens up autonomous opportunities

50 WASTE INTO WATER Hydroflux’s successful clarifiers last decades

14 MAINTENANCE

16-17

RIO TINTO’S CALIBRATION NEEDS Thermo Fisher meets the massive challenge

DRILL AND BLAST

51 EASY SHOT Dyno Nobel ties in familiarity with innovation

BAUMA 2019 WORLD’S LARGEST CONSTRUCTION FAIR Highlights from the leading mining exhibits

19-34

BAUMA PRODUCT SHOWCASE

MINING EQUIPMENT

52-53 A SAFETY BREAKTHROUGH The experts at Nivek Industries speak up

EXHIBITION OF MINING SOLUTIONS The event’s showcase of new products

36-37 COMMODITY SPOTLIGHT

MINING EQUIPMENT

THE RACE FOR IRON ORE Mount Gibson, Havilah and Carpentaria seize opportunity

KEEP THE WHEELS ROLLING Partners ACS and ifm raise standards

40-41 PROSPECT AWARDS

42-43

54-55

SANDFIRE RESOURCES’ LONG LIFE Expansion within and beyond DeGrussa

PRODUCTIVITY AND EFFICIENCY

57

MAINTENANCE

57 TENDING TO REPAIRS Tennant keeps maintenance priorities straight

44

SMOOTH PRODUCTION McLanahan removes bottlenecks

INDUSTRY COMMENT MATERIALS HANDLING TRANSFORMATIVE DECADE Fenner Dunlop strengthens Kwinana plant

INDUSTRY BODIES MAKE A POINT Voices of Austmine, METS Ignited, AusIMM

46-47 58-62 REGULARS

NEWS 9-10

PRODUCTS 64-65 AUSTRALIANMINING

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EVENTS 66

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13 73 23 / blackwoods.com.au

“You’d never know all this used to be a mine.”

Australian miners and farmers are working together towards a common goal.

Mining land is being rehabilitated to graze cattle and grow crops. When the mining is gone, the rehabilitated land will be here to stay – preserving it for future generations.

There’s more to Australian mining.

ZZZ PLQHUDOV RUJ DX

NEWS

THE LATEST MINING AND SAFETY NEWS AUSTRALIAN MINING AND SAFE TO WORK PRESENT THE LATEST NEWS FROM THE BOARDROOM TO THE MINE AND EVERYWHERE IN BETWEEN. VISIT WWW.AUSTRALIANMINING.COM.AU AND WWW.SAFETOWORK.COM.AU TO KEEP UP TO DATE WITH WHAT IS HAPPENING. RIO TINTO DISCOVERS RARE WHITE DIAMOND AT ARGYLE

AUSTRALIAN MINING GETS THE LATEST NEWS EVERY DAY, PROVIDING MINING PROFESSIONALS WITH UP TO THE MINUTE INFORMATION ON SAFETY, NEWS AND TECHNOLOGY FOR THE AUSTRALIAN MINING AND RESOURCES INDUSTRY.

THE RARE DIAMOND WEIGHS ALMOST 29 CARATS.

Rio Tinto has revealed one of the largest gem-quality white diamonds in the 35-year history of its Argyle mine in the Kimberley, Western Australia.

The diamond, which was found at the mine in March, weighs 28.84 carats and will be sold in Antwerp, Belgium later this year.

Dubbed Argyle Octavia, due to its octahedral shape, the find

comes six months after the mine unveiled its largest ever Fancy Purplish Red diamond, the 2.28-carat Argyle Muse.

Such discoveries are exceedingly rare at Argyle, which is better known for its coloured diamonds, particularly pink and purple varieties.

The company did not give a price estimate for Argyle Octavia, but due

to its shape, size and rarity it can safely be expected to command a large value at auction.

“We are delighted with this discovery which is a testament to the extraordinary Argyle orebody that continues to deliver these miracles of nature, even as it nears the end of mine life,” Rio Tinto Copper and Diamonds chief executive

Arnaud Soirat said.

Since launching operations in 1983, the mine’s output of gem quality white diamonds weighing more than 20 carats has amounted to the equivalent of fewer than one in every 14,000 gems, or “0.00007 per cent of Argyle’s production”, according to the company.

“Argyle Octavia is unique in its size, shape and beautiful provenance and will take its place in Argyle’s history as one of a few special large white diamonds ever to be produced from the mine,” Argyle general manager Andrew Wilson said.

Rio Tinto is expected to close the Argyle mine next year.

CAMEBY DOWNS COAL MINE GETS STATE NOD FOR MASSIVE EXPANSION Yancoal Australia has received approval from the Queensland Government for its planned expansion of the Cameby Downs thermal coal mine.

The Darling Downs-based mine started production in 2010. It consists of an open cut mine, coal handling and preparation plant (CHPP) and related infrastructure.

The operation was previously approved to extract up to 2.8 million tonnes of run-of-mine (ROM) coal a year over a 45-year period, but this has now been increased to

3.5 million tonnes a year over a 75-year period.

Queensland Mines Minister Anthony Lynham referred to the extension as a “vote of confidence” in the state’s resources by Yancoal.

“For Western Downs communities like Miles and Chinchilla, it means greater opportunities for the current and future generations of locals to benefit from a strong resources sector in their region,” Lynham said.

The Queensland Resources Council (QRC) stated the extension of

AUSTRALIANMINING

the mine life helped to confirm a long-term role for coal in the Surat Basin, with the resources sector accounting for about 10 per cent of the Western Downs Regional Council area’s gross product.

“Whether it is the governmentowned Kogan Creek mine, Cameby Downs, other existing mines in the Surat and Bowen basins or those proposed in the Galilee Basin, Queensland depends upon them,” QRC chief executive Ian Macfarlane said.

“Coal currently delivers $43.4

9

JUNE 2019

billion or 13 per cent of the state’s gross regional product and more than 215,000 or nine per cent of full-time equivalent jobs in Queensland.”

Cameby Downs’ new production target of 3.5 million tonnes a year — a 25 per cent increase on the previous annual rate — is expected to be achieved within the next year.

Yancoal Australia manages the mine, which is operated by Syntech Resources, a subsidiary of Yancoal Australia shareholder Yanzhou Coal Mining Company.

NEWS

GOLD PRODUCTION ON TARGET TO REACH GLOBAL RECORD IN 2019 Global gold output is expected to grow to a record 109.6 million ounces by the end of 2019, according to S&P Global data.

The increase from 2018 to 2019 is anticipated to be 2.3 million ounces, S&P Global found, representing the largest growth in the past three years.

Gold production reached 107.3 million ounces worldwide in 2018, capping off a decade of consecutive growth.

S&P Global reported that more than half of the 2.3 million ounce increase will come from new operations in 2019, with the Gruyere joint venture project in the Yamarna Belt, Western Australia being listed as the largest new Australian operation contributing to this figure.

The Gruyere project is also in second place on the list of the five largest new gold projects, just behind Agnico Eagle Mines’ Meliadine project in Canada.

Gruyere, which is split evenly between Gold Fields and Gold Road Resources, is on track for a June quarter start.

The companies produced an updated

mine plan for the project in December 2018 that estimated an average annual production of 300,000 ounces a year over the project’s 12-year mine life.

S&P Global’s findings are consistent with a March report from Surbiton Associates that found Australia broke a 21-year-old record for gold production last year after producing 317 tonnes.

Newcrest Mining’s Cadia operation in New South Wales led the pack at nearly 752,000 ounces.

The production records are not expected to continue for long, however, as depletion from operations will outpace growth as early as 2021, according to the S&P Global report.

This will contribute to an expected fall in gold production of over three million ounces in 2023 and five million ounces in 2024.

This is particularly evident in Australia, where gold production will be hit hardest among major producing countries, falling from its current second place position (behind China)

AUSTRALIA WILL REMAIN A LEADING GOLD PRODUCER THIS YEAR.

to fourth place by 2024, when it is expected to be overtaken by Canada and Russia.

“The underlying reason for Australia’s fall is the depletion of several long-lived assets such as St Ives, Paddington, Telfer, Edna May,

Southern Cross, Agnew/Lawlers and more,” the report said.

“The expected commissioning of Mt Todd and reactivation of Union Reefs Operations Centre will partly mitigate the loss from those aforementioned closures.”

MINERALS COUNCIL STUDY IDENTIFIES MOST SOUGHT AFTER MINING JOBS A Minerals Council of Australia (MCA) study shows that mining job demand has risen considerably over the past three years.

Organised for the MCA by tech firm CoverCard, the study found that in the three months ending November 2018, 16,000 positions were advertised, a 120 per cent lead on the 6000 jobs reported for the three months ending November 2016.

The MCA used information sourced from CoverCard’s database of over four million mining jobs and skills.

CoverCard applied an algorithm to 140,047 job advertisements in order to identify employment trends in the industry.

An analysis of licence requirements

identified a strong interest among employers for “skilled Australian workers able to operate in high-risk environments”, according to the MCA. CoverCard’s algorithms identified five industry roles that were particularly sought after.

The roles included forklift operators, employees who could work safely at heights, employees who could work safely in confined spaces, construction induction cards, and boom-type elevating work platform (EWP) roles. Following these five roles, dogging and rigging were the next most-referenced qualifications.

The Northern Territory recorded the highest incidence of FIFO jobs as a percentage of all mining jobs in the

territory at 46.5 per cent of jobs, followed by Western Australia at 32.5 per cent and South Australia at 24.2 per cent.

At the other end of the scale, New South Wales and Queensland both recorded a relatively low percentage of FIFO jobs, at 4.9 per cent and 12.9 per cent, respectively.

The Queensland figure is lower than anticipated, according to the report.

“However, further exploration has revealed many references to DIDO (drive-in, drive-out) and BIBO (busin, bus-out), which are not within the scope of CoverCard’s current algorithmic assessment,” the report added.

Western Australia attracted the

majority of mining job demand over the past three years according to the report, representing 33 per cent of advertised jobs in the period, closely followed by Queensland at 29 per cent, and New South Wales in third place at 22 per cent.

“This analysis not only shows an industry continuing to grow and employ people in regional Australia, it will also help people wanting to work in mining to target their choice of qualification,” MCA general manager – workforce and innovation Gavin Lind said.

“Training institutions will also now have better information on which qualifications are most in demand across mining regions.”

WORLEYPARSONS ACQUIRES JACOBS RESOURCES DIVISION WorleyParsons has acquired Jacobs Engineering’s energy, chemicals and resources division in a $US3.2 billion ($4.55 billion) deal.

The acquisition will create a merged business known as Worley, which employs a 57,600-strong workforce across 51 countries.

WorleyParsons anticipates cost synergies of around $130 million to be delivered at a cost of $160

million within two years.

The company is undergoing a transition process and will mobilise four business units under the new structure – advisian; energy and chemical services; mining, minerals and metal services; and major projects and integrated solutions.

Further benefits will be achieved from optimisation and AUSTRALIANMINING

revenue synergies, according to WorleyParsons.

“This merger is about more than capacity and capability,” WorleyParsons chief executive Andrew Wood said.

“It’s about opportunity. The opportunity to become the partner of choice for our customers, the employer of choice for our people and to deliver enhanced returns

10

JUNE 2019

for our shareholders.”

Both WorleyParsons and Jacobs boast a number of high-profile projects across Australia, including a contract win by WorleyParsons at Rio Tinto’s $3.8 billion Koodaideri iron ore project in the Pilbara, Western Australia, and Jacobs at Newcrest Mining’s $598 million Cadia expansion project in New South Wales.

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FUTURE OF MINING

BATTERIES INCLUDED: HOW AUSTRALIA IS CHARGING UP FOR A REVOLUTION AUSTRALIA IS SITTING ON A GOLDEN MINING OPPORTUNITY. AND IT’S NOT GOLD, BUT MATERIALS NEEDED FOR BATTERIES. EWEN HOSIE REPORTS. LITHIUM STOCKPILES AT THE BALD HILL MINE SITE.

T

he rise of Australia’s battery metals sector over the last few years — particularly in Western Australia — is proving indicative of a wealth of potential that is yet to be fully tapped.

A surge in battery mineral mining activity has coincided with a growing need for materials to service the increasing popularity of electric vehicles (EVs) and on- and off-grid energy storage solutions.

Lithium is the big dog in the race, with Australia responsible for about 60 per cent of the world’s output in 2018, according to statistics from the United States Geological Survey (USGS).

The material is sought after for its use in rechargeable lithium-ion (Li-ion) batteries, which are used to power electric vehicles (EVs), mobile phones and tablets, laptops, games consoles, power tools and a host of other applications. The exact composition of the batteries varies by

application, but they tend to feature lithium cobalt oxide cathodes and graphite anodes.

In particular, the rising popularity of EVs, which includes cars, trucks, rail, planes and even spacecraft, is expected to fuel demand for these batteries as countries around the world look to meet their emissions targets and combat climate change.

Several lithium projects in Western Australia are set to start or expand production in 2019.

Albemarle launched first earthworks at its $1 billion Kemerton lithium hydroxide conversion plant in January, for example.

The United States-based company is also developing the Wodgina lithium project in a joint venture with Mineral Resources. The two companies will split the costs down the middle, providing $US1.15 billion ($1.65 billion) each to design and construct a lithium hydroxide plant capable of producing up to 50,000 tonnes of battery-grade lithium a year.

AUSTRALIANMINING

Talison Lithium, a JV between Tianqi Lithium and Albemarle, also secured environmental approval from the Western Australian Environmental Protection Authority (EPA) for the latest expansion of the Greenbushes lithium mine in May. Wesfarmers, meanwhile, has proposed a takeover of Kidman Resources to gain access to the Mt Holland lithium project.

In fact, the Western Australian lithium space looks crowded over the next few years, with Altura Mining, Galaxy Resources, Pilbara Minerals and Alliance Mineral Assets others vying for a slice of the battery pie.

Due to the sector’s burgeoning presence, the Western Australian Government launched the Future Battery Industries (FBI) cooperative research centre (CRC) in April.

Funding for the CRC includes $25 million from the federal government, $5.5 million from the Minerals Research Institute of Western Australia (MRIWA) and $28 million

12

JUNE 2019

from other state governments and research partners, in addition to $82 million of ‘in-kind’ funding.

According to the program’s initial prospectus, it will “provide leadership for Australia to participate meaningfully in the future battery industries value chain”.

The Commonwealth grant supports a six-year period for the program, with an aim towards providing something bigger throughout the program period, rather than winding down at the end, explains FBI CRC chief executive officer Stedman Ellis.

He says the genesis of the CRC’s proposal came from growth centre METS Ignited, which identified a significant paradigm shift in terms of renewable uptake and the ways in which energy was being stored and deployed. Curtin University took leadership of the idea as the CRC’s host university.

“Western Australia hasn’t been the home to many cooperative research centres when compared to the number on the east coast,” Ellis explains. “Curtin has played a very significant leadership role in putting together a consortium of 58 participants.”

Ellis says sustainability is of key importance to the CRC in keeping with the environmental benefits large-scale battery production could bring to society in future.

“The scale of the shift in the use of batteries is going to be really important that we sustain and manage the environmental benefits that come from the greater use of batteries in storing and deploying energy,” Ellis says.

“Part of that involves doing the research that can assist in understanding how we can construct batteries with the end in mind, including how they might be recycled rather than ending up in landfills.”

Alliance Mineral Assets managing director Mark Calderwood backs the idea to form the CRC. The company started producing

FUTURE OF MINING

A VSUN ENERGY’S CELLCUBE VANADIUM REDOX FLOW BATTERIES.

at Bald Hill in the Eastern Goldfields in July 2018, five months before completing a merger with Tawana Resources.

Bald Hill has reached nameplate capacity and continues to ramp up in 2019. The company achieved a production record in the March 2019 quarter and signed an agreement with Chinese company Jiangte to sell its product for downstream battery cathode production.

“It’s good for driving research together with corporates and getting them to work together,” Calderwood tells Australian Mining.

“We’ve been looking at proposals for the CRC and while we haven’t done anything yet, there’s lots of research that the industry can do to really improve downstream processing.

“CRCs have been going for a while but to have a more focused one involving battery materials is a very good idea.”

Australia is no one trick pony when it comes to battery metals, either.

Commodities such as vanadium, rare earth elements (REEs), nickel, cobalt, graphite, zinc and manganese are all well-represented by various projects across the country, something that will also be reflected by the CRC. Australian Vanadium stakeholder engagement manager Sam McGahan says lithium is an important metal, but the CRC could give a “louder voice” to other battery metals through a process of democratisation.

Where lithium has been vaunted for its EV applications, vanadium occupies a different space, being better suited to large-scale energy storage projects.

“I think the CRC will give us a much louder voice internationally.

There are different strands for each mineral (including a vanadium subgroup) within the CRC,” McGahan says.

“The vanadium wing of the CRC has got two remits we’ve decided to go with. One is the uptake of vanadium redox flow batteries in Australia, which will help to grow that market here.

The other involves researching how to process the mineral in the cheapest way to get the highest possible grade of vanadium electrolyte.”

McGahan says another benefit vanadium has over lithium is its stability. One of the downsides of lithium-ion batteries is the flammability of their electrolytes, a trait also known as thermal runaway.

This is a property that led to highprofile incidents such as Samsung’s

2016 recall of the Galaxy Note 7 phablet, which was prone to catching fire. McGahan says vanadium’s high heat tolerance could lead to new chemistries for rechargeable batteries in future.

“There’s a lot of research going on around the world about who can crack that perfect chemistry first,” she explains.

“Producers started to move away from cobalt because of child labour issues in the Congo, and regarding lithium there’s the search for that combination that will make the best possible solution. Everyone is keeping their cards quite close to their chest.”

Australian Vanadium managing director Vincent Algar says the company sees an opportunity to

AUSTRALIAN VANADIUM MD VINCENT ALGAR. AUSTRALIANMINING

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JUNE 2019

place vanadium on the map by being involved in the CRC. “Our ability to offer (cash) funding to the CRC was limited at the beginning, but what we’ve decided to do is offer a lot of ‘in-kind’ knowledge,” Algar explains.

“This includes our internal vanadium knowledge internally, as well as our knowledge around vanadium flow battery implementation and marketing through our subsidiary, VSUN Energy.

“We have also shared our knowledge of electrolyte development, which is the fuel in the vanadium flow battery if you like.”

Ellis says the CRC has the potential to not only promote Australia’s raw commodities strength in the battery metals sector, but also serve as a stepping stone towards sustainable domestic battery production down the track.

This includes taking the next step in the value chain from mining and refining to precursor production of advanced battery components.

Calderwood believes Australia’s capacity as a battery producer is limited by the high costs associated with working in the country, but also adds the addendum, “never say never”.

“There’s a lot of downstream potential here in WA to take spodumene and turn it to a cathode material or something similar,” he says. “I think building the batteries in WA is a fair way off but at least producing the cathode materials and all that stuff is an area that can really be encouraging for the conversion of the product in WA.” AM

AUTOMATION

NATIONAL GROUP LEADS THE WAY INTO AN AUTONOMOUS FUTURE NATIONAL GROUP IS MAKING MOVES IN THE MINING INDUSTRY WITH THE ACQUISITION OF AUTOMATION-FOCUSED WOLFF MINING. EWEN HOSIE WRITES.

NATIONAL GROUP SHARES MANY CULTURAL SIMILARITIES WITH WOLFF.

T

he National Group has continued to experience exponential growth in the mining industry and has historically taken an organic approach to its growth agenda.

But with the recent acquisition of Wolff Mining, which is well-known in the industry for autonomous operations such as dozer push, National Group is set to enter the rapid growing innovative technology market as a front runner.

National Group’s acquisition of Wolff Mining will provide a mutually beneficial boost to both companies that will keep them ahead of the game when it comes to mining’s ever-expanding automation push.

Wolff Mining, a Queensland-based company owned by husband-andwife team Terry and Wanda Wolff, had already received considerable industry attention for its technology before the National Group entered the scene.

Terry Wolff says the two companies share a lot of values that make the decision a natural choice for Wolff Mining.

“National Group met all of our foundations and culturally aligned with the way we already do business here at Wolff, so that made this

decision a lot easier for us,” Wolff says. “We couldn’t think of a better company to pass on the baton to.

“The acquisition brings together two family owned and operated businesses, both with an excellent reputation in the mining industry.

National Group values our people, autonomous expertise and our ability to operate in the segments where we have a depth of knowledge and experience.”

Wolff Mining is known for implementing Caterpillar’s Command for Dozing technology at a pilot trial using three semiautonomous Cat D11T Dozers at Coronado Coal’s Curragh coal mine in Central Queensland. This pilot resulted in improved dozing hours, safety and increased efficiency through reduced dozing costs per bank cubic metre at the operation.

“Once we looked into the company, we identified market opportunities and cultural similarities,” National Group managing director Mark Ackroyd tells Australian Mining.

“Their story is similar to that of the National Group, in that they are a small, private company that has grown substantially over the years. They possess a very similar organisational culture to us in the AUSTRALIANMINING

sense that they are a family business with good values and work ethic.”

“Adding Wolff Mining to the National Group will allow us to deliver additional services in the autonomous operations space that complements our current service offering, so it was a logical choice for us.”

“With our range of autonomous dozers, everything including the speed, direction and blade position can be fully controlled using Wolff’s technology by remote operators on site,” National Group chief operating officer Julian Cook continues.

“Currently, operators control the dozers during a dozer push at another location on site.

“Going forward, we plan to take this technology even further to the point where operators will control equipment off site.”

National Group’s expertise will be employed to support Wolff’s ongoing fleet expansion – its current semiautonomous fleet stands at seven machines – while Wolff will in turn open up a previously unexplored market sector for National Group.

Ackroyd suggests the company has plans to expand on its semiautonomous fleet using its own dozers across Australia in order to cultivate the two groups’ shared interests.

Wolff Mining offers a variety of dozer push, excavation and rehabilitation services in Queensland and New South Wales.

Its semi-autonomous dozing services provide a quick and costeffective alternative to excavators, creating an effective pairing with dragline, truck and shovel operations.

“Wolff’s technology can allow the dozers to operate with absolute precision. This is a particularly effective method for open cut earthmoving operations, including tailings. It’s moving to more technologically-driven and efficient methods for moving material from point A to point B,” says Cook.

“It’s fair to say that most, if not all, open cut mining operations require some form of rehabilitation, prestripping and ground disruption,

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so anything that helps you do that more quickly and safely has to be a good thing.”

This safety application also extends to areas where it’s not safe to send people, such as areas of high temperature (including fires), high levels of gas or under swinging draglines, for example.

The dozers were used at a site near Moranbah in late 2018 just for this purpose, performing push operations in the mine’s exclusion zone via remote control operation to help extinguish a fire.

“We believe that we’re in a good position to capitalise on that and deliver what the market needs and will indeed want over the years to come, especially around personal safety,” adds Ackroyd.

“I think there is a growing spotlight on personal protection and safety within the mining industry and that is only going to continue as things move forward.

“The opportunity for National Group going forward can’t be underestimated as the industry, like Wolff, continues to evolve with automation technology. This trend began with Tier 1 miners around a decade ago with the rise of the autonomous haul truck.

“It’s a big focus of ours going forward to position ourselves in a market that is increasing its push with technology and innovation.” AM

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CALIBRATING AUSTRALIA’S LARGEST NETWORK OF IRON ORE SITES RIO TINTO’S NETWORK OF PILBARA OPERATIONS IS ONE OF THE MOST SUBSTANTIAL FOR ANY REGION IN THE WORLD OF MINING. SO HOW DOES THE MINER MANAGE THE SIGNIFICANT CALIBRATION RESPONSIBILITIES IT HAS AT THE OPERATIONS? BEN CREAGH FINDS OUT.

R

io Tinto Iron Ore’s operations in the Pilbara, Western Australia cover an area roughly the size of England.

The company’s assets in the region include 16 mine sites, 1700 kilometres of rail and four port terminals.

Rio Tinto supports these operations with a substantial number of utilities, such as four gas laterals, four fuel hubs, four power stations and 14 bulk supply stations.

The network runs around the clock alongside five towns, 3500 houses, 500 commercial properties, 38 villages, 16,000 beds and three aerodromes.

Rio Tinto’s calibration activities for the massive amount of equipment it requires in the region are, therefore, considerable and an important task that ensures the high level of productivity it targets.

Up until three years ago, each Pilbara operation had individually

managed processes like calibration.

For this reason, Rio Tinto assumed that no two sites were conducting these activities in the same way.

Rio Tinto endeavoured to change this approach and engaged Thermo Fisher Scientific to establish a single process across all Pilbara sites that would be made available to each company department.

The process Rio Tinto envisioned has since developed into a vendormanaged calibration program where Thermo Fisher visits every site across the region twice a year to maintain the miner’s compliance requirements.

Thermo Fisher provides flexible on site and off site services to ensure Rio Tinto maintains compliance, focusing on fast turnaround times for the repair and replacement of equipment and the delivery of instruments.

The program is then backed by an online database that manages the information generated during the calibration of equipment.

AUSTRALIANMINING

Thermo Fisher Scientific Australia and New Zealand general manager Stephen Pickering believes the extensive workload throughout the massive area could not be managed effectively unless the two companies developed a strong relationship from the beginning.

“The thing that has driven us forward is in the collaboration we have as organisations,” Pickering tells Australian Mining.

“It is the ability for us to understand what their requirement is and then to be able to match what we deliver for their requirement. And make sure that we both have the goal in sight and that we are working towards the same thing.”

Rio Tinto has included its major contract partners in the calibration program so they can also use Thermo Fisher’s services while on site.

The electrical test instrument calibrations cover analogue and digital multimeters, current clamp meters, insulation resistance testers up to 10 kilovolt, micro ohm meters,

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earth loop testers, process loop calibrators, RCD testers, portable appliance testers, installation testers (multifunction testers), and resistance decade boxes.

Rio Tinto Iron Ore core services engineering manager Bradley Edwards says Thermo Fisher has been flexible in its delivery of these on-site calibration services and others.

“The important factor was for us to get the calibrations done on site and also to be able to manage all of the geographical spread of our operations,” Edwards says.

“The key aspect of why we believe it has been successful is the relationships that have been established with each of the site operations in order to be able to make the calibrations and service work smoothly and efficiently.”

Thermo Fisher aims to strengthen the relationship by offering additional feedback on how efficiencies can improve further through its services.

“They are always continually

MAINTENANCE

RIO TINTO’S PILBARA OPERATIONS INCLUDE 16 MINE SITES. COPYRIGHT © 2018 RIO TINTO.

looking for extra pieces of equipment that they can calibrate to add to the register, making life a bit easier for us,” Edwards says.

“It’s pivotal that we do have strong partnerships with vendors that are able to prove that they can deliver and have the capability.

“These partnerships do evolve over time and I believe in this case we have got strong bonds with Thermo Fisher in terms of the services they are currently providing and for future services.”

Thermo Fisher’s data management provides Rio Tinto with calibration information and an asset register, which has benefited the miner’s auditing activities, both from an internal perspective and for those undertaken externally by regulatory bodies.

“At a click of a button an operator or maintainer on the shop floor can access that information easily,” Edwards says.

Pickering, who has worked for Thermo Fisher around the world over the past 15 years, has been involved with the Australian resources industry specifically for the past year since starting his current role.

He has quickly become aware of the growing importance of data for resources businesses over this time, particularly during his

AUSTRALIANMINING

A PARTNERSHIP APPROACH HAS PROVEN TO ENSURE EFFICIENT CALIBRATION ACTIVITIES.

experiences in the Pilbara.

“A lot of (data) comes from our high-end instrumentation, it is helping customers understand how to use that and how to consolidate all of that information to give them an output that they can execute against,” Pickering says.

“We have companies with a lot of data and the capturing of that data is happening, but I still think people struggle to understand how to execute against the information that is available.

“I think as we move forward

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understanding how we work with our clients in this industry and enabling them to get better at what they do by utilisation of data is going to be an incredibly important space.”

Pickering believes the journey that Thermo Fisher and Rio Tinto have started in this way will continue to develop through the calibration partnership.

“I think as we continue to work together and we continue to evolve together in process and instrumentation that journey will flourish,” Pickering concludes. AM

BAUMA LIEBHERR’S BAUMA EXHIBIT WAS DOMINATED WITH CONSTRUCTION MACHINERY BUT ALSO INCLUDED SEVERAL MINING PIECES.

LIEBHERR LINKS THE AUSTRALIAN MINING LANDSCAPE WITH EUROPE MANAGING EDITOR BEN CREAGH TRAVELLED THROUGH EUROPE WITH LIEBHERR AHEAD OF BAUMA 2019 IN GERMANY TO DISCOVER THE ORIGINS AND FUTURE DIRECTION OF THE EQUIPMENT MANUFACTURER.

T

he Bauma trade fair in Munich is a big deal for Liebherr.

It is easy to miss a company name or two at a fair that covers around 614,000 square metres, or close to the size of 90 soccer pitches, but it is impossible to miss Liebherr’s brand at Bauma.

No company goes all out at the event like Liebherr, which puts on the largest exhibition of all at the world’s biggest construction and mining machinery show, in the country where it originates.

Liebherr spends tens of millions of dollars on a mammoth display and 14,000-square-metre threestorey pavilion that takes six months to setup at the Messe

München grounds.

The company squeezes in hundreds of products from several of its divisions, including mining, earthmoving, cranes and even domestic appliances.

It takes until the Liebherr exhibition is experienced firsthand to realise that simply calling Bauma a ‘big deal’ is, in fact, an understatement of the company’s efforts.

For its global offices, too, Bauma is clearly more than just a seven-day trade fair for Liebherr, as a touring party of Australian and international mining professionals found out in April during the company’s factory tours that accompany the event.

In the days leading up to and then during Bauma, Liebherr hosted six AUSTRALIANMINING

factory tours that rolled the touring party through four neighbouring European countries – Switzerland, France, Germany and Austria.

The tours provide insights into the global direction of Liebherr’s mining division. They also give the travellers an in-depth look at the company’s cranes, engines and components areas, while bringing them up close with the history of the family-owned company.

Liebherr-Australia managing director – mining Trent Wehr says the tours offer an opportunity to strengthen the link between the company’s European origins and the Australian market.

“The focus was really about building the depth of relationship, instead of having

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just a relationship based purely on business transactions,” Wehr tells Australian Mining.

“I think it is important for when these companies make large capital transactions that they know there is a bit more substance behind the deal.”

Liebherr’s mining expansion

Liebherr has become a wellknown supplier of excavators, haul trucks and crawler tractors in the Australian mining industry since it started building a presence in the country in 1981.

For a company founded in 1949, however, Liebherr’s growth as a mining equipment manufacturer remains a relatively new venture on a global scale in comparison with other divisions.

BAUMA

For example, Liebherr has only manufactured large mining trucks at Newport News in Virginia, United States since the 1990s.

To parts of the world, Liebherr remains primarily recognised as a manufacturer of earthmoving and construction equipment, such as cranes.

Liebherr’s latest annual results, released during the tour, provide a reminder of where the mining division sits in the broader company picture alongside its various divisions.

The Liebherr Group’s annual turnover reached €10.551 billion ($16.8 billion) in 2018 to push the company through the €10 billion barrier for the first time in its 69-year history.

Liebherr’s mining division achieved sales revenues of just over 10 per cent of this total with €1.07 billion, less than half the turnover of the earthmoving (€2.772 billion) and mobile cranes (€2.243 billion) business units.

Despite this, Liebherr’s mining division contributed the most growth of any division compared with 2017 at 16.1 per cent, as demand in Asia and Oceania, Africa, and Central and South America increased.

Liebherr’s growth in Australia was represented in the touring party, which included equipment suppliers, mining services companies and even an international copper miner.

Most of these companies have

THE ASSEMBLY LINE FOR THE D98 SERIES ENGINE.

started working with Liebherr in the past two or three years, according to executive general manager – sales and marketing Tom Juric.

“If you look at the mix of companies there is not much crossover in terms of what they are competing for,” Juric says.

“There might be some competition here and there, but they are quite a diverse group. All of the companies are slightly different across the board with their own

unique value drivers.

“It is about being sensitive to what it is that they are working for. Ultimately our machines and services are only as good as what they can demonstrate or return to the client and their business.”

Liebherr’s mining equipment has most often been found at bulk commodity sites in iron ore and coal, something its Australian team has focused on diversifying in the past two years.

The emerging line-up of mining partners on the tour reflected this strategy with their exposure to precious and base metals.

Vertical integration

The Liebherr Mining Equipment Colmar SAS and Liebherr Components Colmar SAS factories in France drew the most direct interest from the mining-focused touring party.

It is, however, Liebherr’s company-

LIEBHERR’S D98 MINING ENGINE BEING TESTED AT THE COLMAR PLANT. AUSTRALIANMINING

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WAT E R

SCIENCE

TECHNOLOGY

BAUMA

LIEBHERR’S T 236 TRUCK ON DISPLAY AT BAUMA.

wide approach to vertical integration that emerged as the key theme in not only Colmar, but also at the facilities in Bulle (Switzerland), Biberach (Germany), Ehingen (Germany) and Telfs (Austria).

Liebherr focuses on designing and manufacturing a significant percentage of its components in house to ensure the high levels of safety, performance and reliability it targets.

The company’s personnel spoke of Liebherr’s aspirations to produce up to 90 per cent of its own components in the coming years to consolidate the model.

Liebherr plans to achieve this while continuously developing new equipment that increases

performance, facilitates ease of maintenance and lowers operating costs for the end user.

For mining and other industries, Liebherr’s vertical integration practice promotes the company’s willingness to design and build components that meet specific requirements for customers.

“In Australia, we can say Liebherr has this vertical integration model, but it doesn’t become a reality until you tangibly see it and touch it,” Wehr says.

“It’s about being able to understand how that dovetails into their businesses but more importantly how that affects and makes a positive spin on the productivity of their machines.

AUSTRALIANMINING

“They know if there is an issue with the machine, we can contact our brother and sister companies in Europe to influence that in a much timelier fashion.”

Liebherr is convinced the vertical integration model also gives the company a competitive advantage over third party suppliers from a customer support perspective. The model generated positive feedback from the touring party in this regard.

First Quantum Minerals consultant – group procurement Steve Poulter says Liebherr’s plan to produce a high percentage of its components supports the modular designs it develops for equipment.

He questions why the modular practice isn’t more common amongst

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original equipment manufacturers (OEMs).

“The idea of modularisation is absolutely first class and why someone hasn’t done it before like this I have no idea,” Poulter says.

“It makes good sense to me. You will have spare parts and inventories that are going to be highly reduced because cylinder one is the same as cylinder 12, for example.”

Colmar commitment

Liebherr’s current and future developments at the Colmar factories are prime examples of the commitment to vertical integration.

For almost six decades, the company has been regarded as a major driver of the local economy

BAUMA

IN AUSTRALIA, WE CAN SAY LIEBHERR HAS THIS VERTICAL INTEGRATION MODEL, BUT IT DOESN’T BECOME A REALITY UNTIL YOU TANGIBLY SEE IT AND TOUCH IT.” in Colmar, a quaint French city that also relies heavily on tourism.

Liebherr has manufactured hydraulic excavators in Colmar since 1961, including mining diggers for more than 30 years.

It bolstered this presence when the Liebherr Mining Equipment Colmar SAS factory was established in 2011 to cater specifically for the requirements of surface mining operations.

The OEM develops, produces and services its hydraulic mining excavators at the site, ranging from the R 9100 up to the R 9800.

Liebherr’s tour party included owners of excavators across the range, from Blue Cap Mining’s two R 9150 diggers at gold sites, to MacKellar Mining’s R 996 excavators and up to the R 9800 excavator that National Group supplied to a New South Wales coal mine last year.

The company also developed the 100-tonne T 236 mining truck at Colmar, a product it launched in 2017 after a concept first appeared at the 2016 Minexpo in Las Vegas.

Liebherr’s T 236 truck, also one of the key mining products at Bauma, highlights the vertical integration model by heavily featuring the company’s own components and technology.

The rigid-frame dump truck, Liebherr’s entry into the 100-tonne class, includes a diesel-electric drive system that takes advantage of the company’s vertically integrated Litronic Plus Generation 2 technology.

Wehr believes the unique electricdiesel truck will find its place in a competitive 100-tonne truck marketplace as mining continues to move towards becoming a more socially responsible industry.

Diesel power

Next door to the mining factory is the Liebherr Components Colmar SAS facility, a plant built in 2014 to develop, design, assemble and test large diesel engines.

Liebherr has developed the D98 diesel engine series at the components factory, a range that will include three cylinder variants – V12, V16 and V20.

The D98, which first premiered in Australia in late 2017 and is in the testing phase, is designed to meet the needs of the mining industry,

but is also planned for use in other industries.

Liebherr claims the D98 diesel engine will provide the best specific power ever, reaching up to 43.5 kilowatts per litre displacement across the range.

The company revealed details of how the D98 engine will be tested in Australia, including in a R 9400 hydraulic excavator at a Pilbara iron ore mine and in a mining truck at an east coast coal operation.

“Those are two bits of equipment we are hoping will help prove that we know what we are doing with a high horsepower engine product,” Juric says.

“The trials will last a couple of years – we want to get to the first mid-life at least. As a conservativelydriven engineering company we have conservative targets even though we know deep down that our products will be able to go for longer.”

The D9812 engine has already been tested over the past 18 months in excavators and trucks in France and the United States, respectively.

The testing of the D9816 will start during 2019, before trials of the D9820 begin in the following years.

“It is still early days for the engine and like anything we need runs on the board,” Juric continues. “We’re progressing with some forwardlooking clients that are prepared to take risks. If everything goes to plan there is no reason why we won’t progress the engine further with them.”

The D98 engines, which are built from start to finish on a single assembly line by the same personnel, typify Liebherr’s modular mindset.

Liebherr is taking this approach with the engines so it can develop them exactly to the requirements of mining companies. Depending on the application, the engine consists of scaled components to provide machines with optimised power when it is required.

Customer first

Liebherr’s modular approach, combined with the focus on vertical integration, has emerged as a key focus of how its customer service division in Australia will develop.

In the same way Liebherr has pushed for diversification of its Australian client base in the past two years, the company has

BAUMA LIEBHERR MANUFACTURES ITS MINING EXCAVATORS, INCLUDING THE R 9800, IN COLMAR.

also prioritised establishing a stronger service model.

Liebherr continuously improves the capabilities of its Australian service people by having them visit the European factories for training on new or updated equipment and components.

The D98 engine, for example, is expected be a major part of this training in the coming years as the product evolves and is eventually rolled out across mine sites.

Liebherr Australia executive general manager, customer service Tony Johnstone regards the vertical integration model as a positive opportunity, but is under no illusions about what it means from a customer support perspective.

“I think that vertical integration is of great value to the organisation, but it also comes with challenges because you essentially only have one supplier,” Johnstone says.

“When we need improvement in component life or have some sort of technical problem, we need to have close relationships with the components division and the supplier for what goes into

the equipment so we can have that resolved.”

The Liebherr factory tours do, however, importantly educate the OEM’s customers about the supply chain that extends from Europe to their mine sites in a way not possible in Australia.

“It gives them a view of our capability as a manufacturer and what goes into manufacturing components and machines,” Johnstone says.

“When we take customers from an operational point of view what it gives them is a sense of comfort that we are a professional manufacturer.”

The reassurance and focus on aftermarket service didn’t go unnoticed by the touring party.

Poulter says having that direct link with customer support in Australia, which in turn communicates directly back to the factories, is an advantage for mining organisations.

“If the machine has been on the market for a few years, and is proven, it will sell itself,” Poulter says. “But what you can’t buy these days is the service that goes with it.

“The service component, as AUSTRALIANMINING

in technical assist, spare parts inventories, managing modifications and upgrades for software, that is paramount. Without that don’t even bother talking to us.”

Strengthen mining together

The relationships that developed during the tours, and into Bauma, demonstrate the growing collaboration between mining companies and OEMs. Liebherr is challenging OEM norms with its vertical integration model and latest mining solutions.

Blue Cap Mining general manager Paul Allen believes OEMs also have an opportunity to work closely with mining partners to challenge the impact of industry volatility to help guide sustained prosperity.

“Collectively, you look at OEMs and us, and say, how are we challenging paradigms in the industry? We have got to make it a sustainable industry economically despite commodity price variation in the markets,” Allen says “We employ people, we want people to have security and we want people to come into mining.

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“Conversely, in the Australian context, mining is the biggest contributor to the GDP, we have got a responsibility to ensure the future success of the industry.

“We would like to see that consistently delivered through us and the OEMs; and look closely at how we can do that together.”

From the Colmar factories, to the magnitude of the Ehingen crane facility and complexities of the components supply chain, Liebherr portrayed a bigger picture view of how its operations will be sustained.

Wehr hopes the experience of bringing each of these facilities together translates into the potential for Liebherr to work with each company in the tour party on a deeper level to benefit the industry.

He says Liebherr’s wrapup meetings with the mining organisations at Bauma indicate that a more personal relationship has been achieved.

“If they can understand the depth and capabilities of our business better then hopefully that augers well for future opportunities,” Wehr concludes. AM

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BAUMA

METSO BREAKS NEW GROUND AT BAUMA THE EQUIPMENT MANUFACTURER MOVED INTO A NEW PRODUCT AREA AND STRENGTHENED AN EMERGING CRUSHER RANGE WITH ITS LATEST RELEASES IN MUNICH. AUSTRALIAN MINING WRITES.

M

etso used its presence at Bauma 2019 to reveal a number of innovative solutions for mines and quarries that reinforce its focus on increasing productivity and driving down costs for its clients.

Two new products stood out in particular, including what Metso believes is a ground-breaking innovation for off-highway trucks – the Metso Truck Body.

Metso also expanded its innovative Multi-Action cone crusher range, with the addition of the MX3, which is said to bring improved productivity and lower operating costs to mid-sized operations.

Australian Mining examines both of the solutions.

Metso Truck Body

Metso has extended its range of solutions to the mining and aggregates industries with the launch of the Metso Truck Body.

The truck body has been designed to combine the benefits of rubber and high structural strength steel to help mines and quarries “haul more with less”.

For several decades Metso has supplied rubber lining for haul trucks that have successfully reduced maintenance needs and improved the

THE METSO TRUCK BODY OFFERS A LIGHTWEIGHT OPTION FOR MINING COMPANIES.

work environment for drivers.

The benefits of Metso’s rubber linings have included up to six times more wear life compared to traditional steel lining, a reduction in noise of up to 50 per cent, and 97 per cent less vibration.

THE TRUCK BODY BUILDS ON METSO’S EXPERTISE WITH RUBBER LININGS.

AUSTRALIANMINING

Metso’s truck body takes this concept to another level by combining the wear protection and working environment benefits of rubber with the payload maximising abilities of a lightweight body.

The company has taken note of an industry trend towards using lightweight bodies on haul trucks when developing the innovative product, according to vice president, wear lining and screening solutions, mining consumables, Lars Skoog.

“I think this opened our eyes and made us start to understand that if we do our homework right and figure out how to absorb energy, then we can take this a step further,” Skoog explains during the Bauma launch.

“We are here now and we feel there is a new space in the market with this product.”

Hauling is one of the most costintensive components at a typical mine or quarry’s operations due to the fuel, labour and maintenance involved. At the same time, haul trucks are required to carry as

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much payload as possible to ensure cost efficiency.

Metso set out to tackle these demands by designing a truck body that requires minimal maintenance while also maximising payload.

The truck body has been developed as a specialised lightweight, rubber-lined alternative to those supplied by major off-highway truck manufacturers (OEMs).

Metso’s elastic rubber absorbs the energy of every impact, preventing it from reaching the frame and allowing for a lighter-than-usual, high structural strength steel frame beneath the rubber.

This combination of features means the body can absorb maximum shock at the lowest possible weight.

“What we have understood and what experience has taught us is the actual amount of energy absorption that the rubber can take,” Skoog says.

“We have done a lot of research in order to understand how much that actually is. The application of this knowledge has allowed us to use less

BAUMA

METSO UNVEILED THE MX3 TO ACCOMPANY THE MX4 IT RELEASED IN 2017.

high-strength steel.”

“Utilising the combination of high-strength steel with the energy absorbing rubber lining enables us to shave off weight in the steel structure.”

Metso claims that one of its typical truck bodies has up to six times the wear life, with 20 to 30 per cent lower weight than a traditional steellined truck body. Depending on the application, this translates into a payload increase of several tonnes.

Skoog says many mining companies prefer lightweight truck bodies because they carry a higher payload. However, the problem with traditional lightweight bodies is a lack of durability.

“They often have to be replaced or repaired every one-to-two years, which gets expensive,” Skoog says.

The Metso Truck Body provides an unprecedented solution for the mining industry that is both light and durable, Skoog adds.

“The rubber lining and high structural strength steel frame have been engineered in a seamless process, utilising the best qualities of both materials,” he says.

Metso is offering several lining options to ensure application-specific fit, even in operations that struggle with problems such as carry-back.

Responsible for the product locally, Australian screen media and lining product manager – Peter Lundberg says that preparations for the commercialisation of the product are under way in Australia.

“Our first application of the new truck body at a Finnish mine are already delivering great results. At Bauma we booked orders for two more bodies for a mine site in Sweden.

We will shortly commence our first Australian field trial of the product,” Lundberg says.

Metso MX3

Metso also unveiled MX3 at Bauma, the latest addition to its Multi-Action cone crusher family.

MX3 is designed by Metso to bring improved productivity and lower operating costs to mid-sized quarry operations. It follows the 2017 launch of MX4 – the first model of the MX cone crusher series.

Metso developed MX4 to redefine cone crusher performance with claims of previously unimagined efficiency, wear parts utilisation, safety and automation.

According to Metso representatives, around 50 MX4 crushers have been sold worldwide, with some already operating successfully at Australian quarries.

Metso’s Australian vice president – aggregates Shaun Fanning says quarry operators in Australia are already experiencing the benefits of the company’s unique Multi-Action technology.

“Our customers are getting some remarkable results with MX4. Some of our industry’s major players have really embraced this unique technology, we currently have several MX4 crushers in operation and being AUSTRALIANMINING

commissioned,” Fanning says.

The newly-released MX3 is a scaled down version of the MX4, sharing the same design principles and technology.

Like the MX4, it delivers very high reduction ratios with a refined, in-spec end product shape and consistency critical in aggregate applications.

The machine’s engineering team says MX cone crushers are designed with one objective in mind – to make the machine owner’s business more profitable than ever before.

Metso states that MX3 has the potential to reduce the total cost of ownership while supercharging productivity.

Fanning says the company’s patented Multi-Action technology is an innovative way to automatically optimise crusher operation.

MX crushers can simultaneously adjust their settings with a rotating bowl above their cavity and a hydraulic piston inside the machine’s fixed shaft.

Dynamic setting adjustments can be made when the crusher is operating under full load conditions without the need to stop production.

Both rotating bowl and piston adjustments are fully automated, so no human intervention is required. The MX series also provides a maximised tramp release distance, delivering high levels of protection against uncrushable objects and overloading.

Metso claims the MX series is the most cost-efficient crusher range on the market. It delivers cost savings

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of 10 per cent or more compared with traditional cone crushers, according to Metso.

Savings in wear components, coupled with effective and continuous crushing action, provide a valuable starting point to bring down the cost per tonne.

Metso also claims the uptime of MX crushers is significantly higher than traditional cone crushers. The MX’s Multi-Action design allows dynamic setting adjustment and wear compensation using a highpressure hydraulic piston, minimising interruptions to production.

MX crushers are designed for the most challenging operating conditions with very hard and abrasive material.

From the start, Metso engineered the MX series to minimise downtime and allow 24/7 crushing in the harshest applications.

Fanning says the MX series delivers highly effective wear parts utilisation rates, with up to 25 per cent longer liner life achievable compared to conventional crushers.

Optimal cavity design, stroke direction and an effectively distributed crushing action are combined to provide a highly optimised rock on rock crushing motion.

Together with the machine’s Multi-Action technology, this results in extended intervals between maintenance and higher production rates. Quality characteristics of all sized end product fractions stay consistent throughout the lifetime of the wear parts.

The smart optimisation of Metso’s Multi-Action technology is the key to reaching the desired end product shape and particle size distribution while eliminating waste.

Metso included a pre-launch field testing period as part of its MX3 development program.

French aggregate producer Durance Granulats has been testing a preproduction prototype of the MX3 along with a new MX4 at its Peyrolles quarry since April 2018.

Durance Granulats director of operations Mathieu Kasprzak says that he is very satisfied with the performance of both machines. The MX4 is achieving the company’s production targets while delivering around 12 per cent in energy sayings compared with the machine that it replaced.

Commenting on the Durance Granulats experience and feedback from Australian MX crusher users, Fanning says, “Our prospective customers can be confident that our new machines already have a proven track record in some really challenging applications.” AM

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BAUMA

THYSSENKRUPP CUTS CRUSHING CHALLENGES DOWN TO SIZE

THE ERC ON DISPLAY AT BAUMA 2019.

THYSSENKRUPP HAS DEBUTED THE ECCENTRIC ROLL CRUSHER (ERC), AN INNOVATION FOR THE PRIMARY REDUCTION OF HARD ROCK AND ORE IDEAL FOR UNDERGROUND AND SURFACE MINES. BEN CREAGH WRITES.

A

decade of research and development led to the global launch of thyssenkrupp’s eccentric roll crusher (ERC) in Munich.

While the core vision for a revolutionary underground crushing system has remained intact over this time, the company premiered the ERC with a broader market in mind. thyssenkrupp initially targeted the underground hard rock minerals processing sector with the design of the ERC. It planned to develop a robust and compact machine that overcame long-standing disadvantages that traditional hard rock crushers faced, particularly their large height.

The company has, however, realised that surface mines and quarries with mobile equipment join underground operations as applications where the machine can add significant value.

Detlef Papajewski, head of

mineral processing at thyssenkrupp, says the potential for the ERC has expanded since the early focus on underground mining.

“Our customers wanted a hard rock crusher for underground mining that did not have the same height as the gyratory crusher,” Papajewski tells Australian Mining on the sidelines at Bauma.

“We started by developing a hard rock sizer. We soon realised that it was physically not possible to bring all of this energy into the small hold. A hard rock sizer was not an appropriate solution.”

The company researched ways to overcome this limitation and identified a new technology that could combine the advantages of crushers and screeners in one machine.

“We designed a crusher with a totally new operating principle and an integrated screen,” Papajewski continues. “If you look at a normal plant, screening and crushing both AUSTRALIANMINING

THEY WANTED A HARD ROCK CRUSHER FOR UNDERGROUND MINING THAT DID NOT HAVE THE SAME HEIGHT AS THE GYRATORY CRUSHER.” need a big height – not only for underground but also for open pit sites. The combination of an all-inone machine will lead to less capital investment for the customer.”

The ERC design includes a roll mounted eccentrically between the crushing and screening chambers.

The large, constant stroke of the crusher allows for a high degree of reduction.

An integrated screen increases the efficiency of the machine.

Fines are not guided through the crushing chamber, but instead discharged directly to reduce energy consumption and minimise wear to the crusher elements. thyssenkrupp has succeeded in its goal to develop a machine with a

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much lower height than conventional crushers while incorporating each of these elements.

The design of the ERC is 20 to 55 per cent lower in height than most primary crushers for hard rock. The reduced height greatly simplifies transportation, installation and maintenance (including underground), and saves costs.

Despite the low height, testing of the ERC has proven the machine also achieves significantly higher throughputs than conventional crushers. thyssenkrupp currently has four ERC models with throughput capacities of between 600 and 8000 tonnes per hour. The largest of these machines is the most ideally suited

BAUMA

to the massive mining operations of Australia.

Papajewski says there are plans to expand the range to up to six models. He believes collaboration with mining companies, which has included copper and iron ore miners in Australia, has and will continue to be critical as the range evolves.

“We wanted to cooperate with partners from the production side to move in the right direction and I think that was very healthy,” Papajewski says. “There was a lot of discussion about our general ideas and how to use the machine in an underground mine.

“It also turned out that thanks to its unique design the crusher is fully balanced. Thus, the ERC has great advantages also in mobile applications compared to incompletely balanced crusher types like gyratory or jaw crushers.

The next step was very quick to go into open pit mines with this machine as well.”

Falk Silbermann, head of research and development mineral processing, says the trials confirmed the benefits of having a crusher height that is significantly lower than conventional machines.

“The trials we’ve done have not only been for the performance of the machine itself, but also for the costs

DEWATERING

THE CRUSHER IN ACTION DURING THE TESTING PHASE.

of the machine,” Silbermann says.

“For that machine and that type of installation you could save a lot of capital investment on the underground cavity. You could decrease the cavity height by 20 to 30 per cent – that is really the big cost driver.”

With its unique kinematics and screening/crushing chamber design,

•

the ERC economically crushes hard rock and ore in underground operations, while also helping improve cost efficiency in open pit mines or quarries. thyssenkrupp found during trials that the symmetrical arrangement of the roll provides superior balance and lowers machine vibrations and the loads on surrounding structures

STANDPIPE DUTY

•

compared with other primary crushers. This factor makes the ERC useful as a mobile and semi-mobile crushing system.

The testing also provided a clearer view of how maintenance would be performed on the machines and what could be done to simplify this process, according to Silbermann.

“The beauty of having a collaboration for the development was to not just focus on the throughput and the performance of the machine itself, but to also discuss the maintenance issues,” Silbermann says.

“Our customers attach great importance to being able to maintain their machines quickly, safely and as easily as possible. We have found good ways that allow to quickly exchange crushing tools without safety issues.”

The ERC on display at Bauma was set to be commissioned at a German quarry during May. The company expects the first machine will provide guidance on how the ERC will be rolled out into other markets.

Australia is targeted as one of the major markets for the ERC, but Papajewski believes it could be until at least next year before mines in the country start to introduce the machine. AM

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BAUMA

THE R1700 LOADER HAS BEEN DESIGNED IN AUSTRALIA.

CATERPILLAR ELECTRIFIES THE UNDERGROUND WITH NEXT-GENERATION LOADER THE EQUIPMENT MANUFACTURER IS JUMPING ON THE TREND OF BATTERY-ELECTRIC MACHINERY FOR UNDERGROUND MINING WITH THE LAUNCH OF ITS R1700 XE LOADER CONCEPT AT BAUMA.

C

aterpillar has chosen the R1700 underground mining loader as the basis for its first battery electric load-hauldump (LHD) platform.

The original equipment manufacturer (OEM) put the company’s breakthrough product for the battery-electric sector on display at Bauma as part of an exhibition dominated by its construction equipment.

Caterpillar launched the R1700 loader in 2018 after it proved new levels of productivity and efficiency in extended field trials and in production studies.

The OEM’s field trials for the R1700 included underground sites in Australia. It has also worked with Newmont Mining at the Tanami mine in Northern Territory on automation trials with the machine over the past year.

The design of the 2018 release focuses on delivering productivity improvements for the R1700’s class size. This is primarily achieved by

an efficient electrohydraulic system that saves fuel and provides greater loader forces, providing improved digging performance in the pile.

Caterpillar has combined these features on the R1700 XE with a lithium-ion battery operating and charging system that has been developed in house.

The MEC 500 fast-charging system allows rapid, onboard charging with little or no impact to the mine’s existing electrical infrastructure.

It eliminates both the hazards of battery handling during recharging and the necessity to maintain change-out battery inventories, according to Caterpillar.

The R1700 XE may be the first battery electric LHD for Caterpillar, but the OEM has designed numerous electrified machines and power generation solutions, including the 794 AC and 795F AC mining trucks.

Caterpillar has reinforced the electrification system for underground mining with the development of a proof AUSTRALIANMINING

NOW WE SEE THE SAME REQUESTS COME FROM PERU, FROM AUSTRALIA – IT IS GETTING MORE TRACTION BUT THE ECONOMICS NEED TO MAKE SENSE.”

of concept machine.

The company converted a conventional diesel Cat LHD into a battery electric platform. At the same time, the MEC 500 charging system went through a series of trials. Caterpillar extensively tested both the loader and charging system at its Peoria Proving Ground in the United States, followed by weeks of operation and trials at a customer’s mine in Canada.

Compared with baseline numbers for a diesel-powered R1300 LHD, the battery-powered model delivered a 10-fold decrease in energy costs; nearly eight times less heat generated, significantly less noise at the operator’s ear, immediate torque availability from the electric motors, reduced dust levels attributed to not

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having a conventional diesel engine radiator fan, and reduced tyre wear.

Caterpillar underground general manager Robert Droogleever says the R1700 has been chosen as the company’s first underground electric machine mainly due to volumes.

However, demand from various mining jurisdictions also played a part in the decision.

“It is also (because) the battery requests come mostly out of Canada – they have deeper mines and there are more requests for ventilation,” Droogleever tells reporters at Bauma.

“But actually now we see the same requests come from Peru, from Australia – it is getting more traction but the economics need to make sense.”

BAUMA

Caterpillar is yet to announce a schedule for the battery electric machine’s release.

While Caterpillar revealed plans to introduce the battery electric innovation as the next generation of the R1700, it also used Bauma to promote the advances made on the diesel version launched late last year.

The R1700 features a 20 per cent increase in payload on its predecessor at 20 tonnes, but maintains the same dimensions of the R1700G. Caterpillar claims a head-to-head study and multiple field trials of the two machines showed the updated vehicle surpasses its payload advantage in faster truck loading and more productive load-and-carry operations, while delivering 21 per cent less fuel consumption per hour.

The R1700’s fuel consumption has been reduced during the trials through on-demand adjustment of the cooling fan and the hydraulic system, as well as the efficiency of the Cat C13 engine. The turbocharged, air-to-air aftercooled six-cylinder engine produces 269 kilowatt in standard configuration.

Caterpillar released the engine in three different configurations – Cat Ventilation Reduction, US EPA Tier/ EU Stage IIIA, and EU Stage V – to allow tailoring of the R1700 to the

mine’s ventilation needs.

The OEM focused on developing R1700 as a scalable machine in terms of technology, equipping it with subsystems for rapid implementation, if required.

It has made Autodig optional to help new operators and to reduce fatigue in more experience teams.

Caterpillar MineStar Command for underground manager Randy Schoepke says the OEM has integrated the best of its technologies in the R1700.

“From a technology perspective there are many things that are embedded in the base machine,” Schoepke explains at Bauma.

“From a scalability perspective under the MineStar suite we have got a lot of connectivity offerings for the customer.

“We have everything from automaton, machine health monitoring, personnel detection, collision avoidance, tracking of the machine, fleet management, task management – so basically we are offering the breadth of product from end to end.”

Caterpillar has completed the R1700 automation trial with Newmont at the Tanami mine without yet releasing its findings (at the time of writing). The company has also extensively trialled the

AUSTRALIANMINING

THE R1700 BATTERY ELECTRIC LOADER ON SHOW AT BAULMA.

machine’s autonomous capabilities at its testing grounds in Tasmania.

Schoepke says Caterpillar will release the outcomes of the testing at the Tanami mine to the marketplace this year. The R1700 is also designed to bring new levels of operator comfort and control to underground operations.

During the load or dump cycle, the harder the operator pushes the controls, the faster the machine responds, according to

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Caterpillar. The steering system is pilot controlled to provide more precise feel for the operator during manoeuvres in tight places.

For maintenance purposes, the R1700 features several components that have modular designs which can be removed and replaced. In addition to modular components, all filter and key service points have been grouped into a centralised section on the cold side of the engine. AM

BAUMA

REMA TIP TOP BUILDS A BRIDGE BETWEEN BAUMA AND AUSTRALIA AUSTRALIA HAS BEEN A FOCUS OF REMA TIP TOP’S GROWTH ASPIRATIONS IN RECENT YEARS, A STRATEGY THE COMPANY PLANS TO MAINTAIN WITH ITS LATEST SOLUTION FOR CONVEYOR SYSTEMS. BEN CREAGH WRITES.

B

auma may be staged a long way from Australia but the message Rema Tip Top conveyed at the 2019 event directly supported its strategy in the country’s mining industry.

Rema Tip Top presented its system for digital, proactive monitoring and maintenance of conveyor systems at the trade fair, a modern sensor technology known as Rema MCube.

The system focuses on the cycle of ‘monitor, maintain and manage’ to help mining companies and other operators prolong the lifetime of conveyor belts.

Rema Tip Top supported MCube with the associated CCube software, which delivers reporting based on the ‘command, control and communicate’ phases.

Karsten Bartnicki, Rema Tip Top Australia chief executive officer, says the solutions exhibited at Bauma reflect the direction the company is taking in Australian mining with some of the country’s leading companies in iron ore and coal.

“Our smart solutions across the conveyor provide valuable performance data so we can strategically plan maintenance activities and schedules with our clients to get the most out of their equipment,” Bartnicki tells Australian Mining on the sidelines at Bauma.

“When we bring this new product innovation to the table with our Australian clients the surprising response is that we are more than a service provider but also a solution provider.”

The digital and cloud-based monitoring enables operators to detect and eliminate critical loads at an early stage to prevent belt damage.

In addition to the service life of the material, Rema Tip Top believes productivity can also be increased through this process.

With Rema MCube, downtime caused by unexpected damages such as longitudinal rips can be significantly reduced.

Rema Tip Top aims to limit the

REMA TIP TOP IS MOVING MANAGEMENT OF CONVEYOR SYSTEMS INTO THE DIGITAL AGE.

length of the damage and perform repairs within a reasonable period through fast, automatic shutdowns.

The company views this approach as a decisive factor in securing availability and productivity of the entire conveyor system.

Bartnicki, who grew up in Germany, but has worked intimately with the Australian mining industry for many years, was appointed as Australian CEO last year.

He says Rema Tip Top will continue to provide Australian miners with initiatives like MCube under his watch, an approach focused on innovation that has progressed since the company’s acquisition of ConvaTech three years ago.

Bartnicki says data and analytics are an instrumental part of the solution Rema Tip Top offers in this way.

“This is our approach and the next business step for us,” Bartnicki says.

“Our clients have the same idea.

There is already an expectation to create smart plants.

AUSTRALIANMINING

“We provide smart solutions for conveyors and then help them optimise these systems to increase their productivity.”

Rema Tip Top is combining its technology initiatives with a focus on developing the company’s people to complement this direction.

The company has around 500 permanent employees in Australia, a number that ramps up significantly with contractors or casual workers during shutdown events.

To develop its next generation of workers, Rema Tip Top has introduced a training academy that is being rolled out across Australia.

The first crop of Rema Tip Top trainee belt splicers graduated from the program in October last year and were mobilised to a customer site in the Pilbara, Western Australia to work alongside experienced mentors.

A second group of trainees started the program in mid-January in Western Australia, followed by a third intake on the east coast, with further courses planned throughout

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2019 across the country.

Rema Tip Top Asia Pacific chief executive officer Benedikt Schneider believes the focus on technology and people will drive the company’s culture in the region.

“That’s what we are building at the moment, a culture. It is a Rema Tip Top culture, but also an Australian culture, and that combination is important,” Schneider tells Australian Mining.

“We are striving to be an employer of choice which is key in attracting people, especially the next generation workforce. That’s an exciting challenge for a modern business.”

Schneider says diversifying and attracting new talent will be essential for Rema Tip Top as it pursues growth opportunities in the Asia Pacific region.

“Mining is our core focus, but there is also a place for different and emerging industries to benefit from our products and innovations,” Schneider concludes. AM

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BAUMA PRODUCT SHOWCASE

HITACHI EX-7 RANGE EXCAVATORS

VOLVO R100E RIGID HAULER

Hitachi presented two EX-7 excavators – the EX1200-7 and EX2600-7 – at Bauma, coinciding with the global launch of this range in April. The Japanese manufacturer believes it has delivered its safest and most efficient excavator to date with the new models, building off the previous EX-6 range to develop the machines. Hitachi EX-7 models are supplied with Cummins engines, with users having the option to choose between MTU or Cummins engines for the EX2600-7 and above. According to the OEM, the excavators feature Hitachi technologies that will bring the Industrial Internet of Things to mining sites around the world. The machines will be able to connect to online servers that collect data that can be transformed by companies into actionable insights. Like the EX-6 range, the EX-7 series of excavators includes six models ranging from the 100-tonne class up to the 800-tonne class.

Volvo released its flagship R100E rigid hauler for the mining market in 2018 and made the machine a key attraction at Bauma in Munich. Part of a fourtruck rigid range, the R100E has a 95-tonne payload and is designed to offer a balance between productivity, fuel efficiency, comfort, ease of maintenance and safety. Volvo’s rigid range also includes 45-tonne, 60-tonne and 72-tonne machines. The Australian dealer for Volvo’s range of rigid trucks is CJD Equipment. Outside of the 100-tonne rigid truck, much of Volvo’s showcase at Bauma was on its construction-focused equipment, including its move to go electric on compact excavators and wheel loaders in 2020.

LIEBHERR R 9200 E EXCAVATOR

CDE COMBO ALL-IN-ONE WET TREATMENT PLANT

A popular attraction at Liebherr’s massive Bauma showcase was the R 9200 E excavator, an electric-driven 210-tonne machine with a rated output of 850 kilowatts. Liebherr promotes the R 9200 E for its balance of operational performance with environmental consciousness. While the electric-driven machine isn’t a good fit for the Australian market just yet, Leibherr is building a market for the product in Eastern Europe and other jurisdictions that offer the required infrastructure. The first R 9200 E was delivered to Bosnia-Herzegovina more than a year ago.

Using Liebherr’s Litronic Plus System for performance monitoring, the R 9200 E can achieve cycle times of under 20 seconds.

CDE officially launched its all-in-one wet processing line, known as the Combo, on the global market at Bauma. The company claims the Combo wet processing system provides the technological answer to the challenges facing material manufacturers. The Combo allows all important processes to take place on a single chassis, with the system acting as a linked and factory-ready unit that includes an integrated operator console with a single operating point. The system has been designed as an ultra-compact wash solution that requires minimal foundation and tubing. Users are able to easily move the facility within their location or transport it to another location.

AUSTRALIANMINING

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BAUMA PRODUCT SHOWCASE

CAT 777G OFF-ROAD TRUCK

KOMATSU PC4000-11 HYDRAULIC MINING SHOVEL

Another of Caterpillar’s mining products on show at Bauma was the Cat 777G truck, which has a Cat C32 engine rated at 704 kilowatt with Tier 2 equivalent emissions. With a payload just shy of 90 tonnes, the 777G was released by Caterpillar to replace the 777F and has continued a legacy in this class that has spanned 42 years for the company. The new 777G truck features a refined cab that positions the operator seat on the left side, along with a new console with an integrated hoist and shift lever. The updated machine provides customers with a choice of bodies. The 60.1 cubed metre dual-slope body is designed for maximum material retention on grades and has two side-board configurations available for light material, as well as a rubber liner.

Komatsu’s mining presence at Bauma 2019 was headlined by the PC4000-11 hydraulic mining shovel that was originally launched at the 2016 Minexpo in Las Vegas. The PC4000-11 at Bauma had the latest Tier 4 engine technology, as well as technological features such as KomVision and Komtrax Plus 2, integrated to elevate performance. The live displays of the machine in action proved a strong drawcard throughout the event. Locally, Komatsu Australia released the latest version of its 370-tonne-class mining excavator (PC40006 Series 3) earlier this year. Based on the PC4000-11, the Australian release incorporates a Tier 2 emissions standard engine rather than a Tier 4 Final.

THE WORLD’S LARGEST MINING TYRE

LEGO LIEBHERR R 9800 MINING EXCAVATOR

Bridgestone’s exhibit at Bauma 2019 was highlighted by the world’s largest tyre, a four-metre-tall tyre that is used on the biggest mining trucks across the globe. The company supported this headline act with a number of other tyres, including brand new products such as the VSDL loader. This product is the first wheeled-loader tyre to combine the benefits of the super-wide-base 65 series with the deep Bridgestone VSDL tread pattern.

Bridgestone also showcased the recently-launched VLTS articulated dump truck (ADT) tyre, which was specifically developed for Volvo Construction Equipment’s 60-tonne ADT.

For adults and kids alike, those that saw the Lego Technic R 9800 mining excavator in the offices at the Liebherr exhibition had to be impressed. From August, the 4000-piece excavator will be available from Lego shops around the world, giving enthusiasts an opportunity to recreate the 16.2-metre-high gigantic crawler. The R 9800 is, of course, a popular machine at mine sites in Australia. Therefore, this concept is sure to be a must-have with not only Lego fans, but also workers in the industry.

AUSTRALIANMINING

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COMMODITY SPOTLIGHT

DEMAND FOR PREMIUM IRON ORE OPENS THE DOOR FOR MID-TIER COMPANIES AN INCREASE IN GLOBAL DEMAND FOR HIGH QUALITY IRON ORE COUPLED WITH A SUPPLY SHORTAGE HAS SOME OF AUSTRALIA’S LESSER KNOWN MINING COMPANIES OPTIMISTIC. ALEX GLUYAS WRITES.

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hen you think about iron ore, the first companies that come to many minds are the giants of the industry like BHP, Rio Tinto and Fortescue Metals Group.

For years, the big guns have dominated the industry in Australia, churning out tonnes of iron ore to be shipped to steel mills across the globe.

That was until last year, when the demand for premium grade ore accelerated, giving opportunity to a raft of junior and mid-tier mining companies to capitalise on the vast market on offer.

This gap in the market occurred for a number of reasons, according to CRU global iron market analyst Andrew Gadd.

“Demand for high grade iron was exceptionally high in 2018, driven particularly by restrictions imposed on operations in the last two China winter heating seasons to control pollution, as well as strong steel demand,” he says.

The result of this combination of factors was that steel margins surged globally, as China reduced its steel exports.

One of the major benefits of premium ore is that it can be used to create pellets, which are typically used as raw material for blast furnaces.

In such an environment, mills were willing to pay higher premiums for high-grade ore to maximise blast furnace productivity – leading to pellet and lump premiums reaching record levels.

This demand outbalanced the global supply of high-grade ore and subsequently pellets due to interruptions stemming from Brazil.

“There were significant disruptions to seaborne high-grade supply last year, most notably Anglo’s Minas Rio in Brazil, while this year the pellet market is heavily impacted by the Vale Brumadinho tailings accident in Brazil,” Gadd says.

While the iron ore market remains volatile, high-grade ore producer Mount Gibson is emblematic of a mid-

tier mining company that has pounced on a gap in the market.

The restart of production and sales from its Koolan Island mine in April is already paying dividends, after the site was closed down in 2014 due to extensive flood damage.

Its Main Pit consistently returns a high-grade iron ore product of 65.5 per cent iron, capable of delivering significant profits for the company.

S&P Global Platts, which provides commodities benchmark price assessments, reported that iron of 62 per cent Fe sells for $US93 ($133) per tonne, 65 per cent Fe for $108 per tonne and 70 per cent Fe and above for in excess of $US120 per tonne (at the time of writing).

For Mount Gibson chief executive officer Peter Kerr, the reopening of Koolan Island symbolises an opportunity to capitalise on the new demand for premium ore.

“The unique high-grade nature and premium quality of ore from the Koolan Main Pit means it is significantly more valuable than the

DRILLING AT THE GRANTS BASIN IRON ORE DISCOVERY IN SOUTH AUSTRALIA. AUSTRALIANMINING

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material we have produced from the Mid West, which is why (Koolan Island) is such a compelling value creation opportunity,” he says.

“Its high iron grade and very low levels of alumina and phosphorous are very attractive for customers compared with hematite deposits in Australia and virtually anywhere else in the world.”

Kerr has also noticed increased interest from Chinese steel mills, which require the quality product to reduce environmental impact and meet tougher regulations.

“Higher grade ores enable steel mills to be both more productive and reduce their emissions intensity per tonne of steel produced, which has been a fundamental contributor to this trend,” he says.

It seems the reopening of Koolan Island couldn’t have come at a better time for Mount Gibson.

A similar visionary story applies to Havilah Resources, whose diverse portfolio of assets in Australia has become more focused on iron ore after it received a $100 million funding

COMMODITY SPOTLIGHT

MINING AT MOUNT GIBSON’S KOOLAN ISLAND MAIN PIT.

package from GFG Alliance in May. The deal was the culmination of years of patience, as Havilah slowly acquired land in the iron rich Grants Basin in South Australia despite the collapse of the commodity in 2015.

For Havilah’s technical director Dr Chris Giles the acquisition of Grants Basin and the GFG Alliance funding is due to some longer term strategic thinking and then “the stars aligning” at the right time.

“When the price of iron ore collapsed, many shareholders and brokers said ‘don’t even mention the word iron ore, but we had the view that there was a huge area of potential iron ore in Grants Basin that had gone unrecognised,” he says.

“We drilled at the very western end of the basin in 2012 and got encouraging results, but the problem was we didn’t initially hold the key

ground. Over the next four to five years from 2013-2018, while iron ore was in the doldrums, we acquired tenement holdings over the entire Grants Basin, but never had the funds to drill it.”

Luckily for Havilah, GFG Alliance believed its story and provided drill funding, which pointed to a 3.4 billion tonne plus exploration target.

Down the railway line from Grants Basin at Whyalla steelworks, the small town of 21,000 people was on the verge of collapse after the steelworks’ owner Arrium had gone into voluntary submission due to $4 billion of debt.

The move was set to affect up to 3000 employees, many of whom took a 10 per cent pay cut to entice new buyers.

This grabbed the attention of GFG Alliance chief executive officer Sanjeev Gupta, the saviour

of the small industrial town, who saw the potential of combining low transportation and production costs from the iron ore in Grants Basin as an unmissable opportunity.

“In the Whyalla Transformation plan, that includes the Next Gen Steel Plant, GFG Alliance is planning to make Whyalla a large-scale steel producing centre, with at least 10 times its present capacity and produced largely with renewable energy at a lower cost base than competitor steel mills,” Giles says.

“Havilah fits into this plan because Grants Basin is shaping as a very large iron ore deposit that could potentially supply the Whyalla steelworks for a very long period at the capacities they are requiring plus have ample surplus for export.”

Ultimately, the plan is that Whyalla is supplied iron ore from Havilah’s

prospective mines, produces the steel and then sends it to GFG Alliance’s global steelworks to manufacture into finished products for local markets.

Havilah hadn’t initially planned for iron ore to be the company’s priority, but the opportunity was too good to refuse.

Perhaps the biggest potential, however, lies with Carpentaria Resources, which has started to capitalise on the wealth of iron ore caches at its flagship Hawsons Iron project near Broken Hill in New South Wales.

At 70 per cent Fe, its Hawson’s supergrade is said to be the purest iron products in the world.

With access to established rail, road, port and power infrastructure, managing director Quentin Hill sees massive upside given the state of the market.

“Even before the Vale disaster there was still a supply gap in the pellet feed market and high quality pellet feed, but the incident exacerbated it,” he says. “(Vale) supplied half the world’s pellet feed which is our market and there’s always been a looming supply gap because of increased demand.”

The company expects the pellet feed usage in China to grow from its current 14 per cent use to 18 per cent with a market supply gap of up to 50 million tonnes per annum by 2022, according to CRU. The result has been spikes in share prices for the major miners in 2019, with BHP up 18 per cent, Rio Tinto 31 per cent and Fortescue 75 per cent (at the time of writing).

While these junior mining companies might not have the ability to compete with the major iron producers globally, the potential for growth still remains high. AM

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SANDFIRE LOOKS NEAR AND FAR TO STRIKE A GOAL SANDFIRE RESOURCES HAS PROVEN THERE IS PLENTY OF LIFE LEFT IN THE DEGRUSSA MINE AND BEYOND. CHIEF EXECUTIVE KARL SIMICH TELLS VANESSA ZHOU ABOUT THE COMPANY’S GROWTH STRATEGIES IN AUSTRALIA AND OVERSEAS.

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inning the Australian Mining Prospect Awards Hard Rock Mine of the Year and the Australian Mine of the Year in 2016 hasn’t stopped Sandfire Resources from gaining even more momentum.

The DeGrussa operation in Western Australia has delivered $4 billion worth of revenue at a 50 per cent margin for Sandfire in the 10 years since the volcanogenic massive sulphide (VMS) copper-gold deposit was discovered in 2009.

Sandfire made another discovery at around nine per cent copper at its Monty VMS project in 2016.

Collectively, the two sites have guided the company to a positive operating result in the years since.

During the 2019 financial year, Sandfire maintained its production guidance at 63,000–67,000 tonnes of copper and 37,000–40,000 ounces of gold, following a strong return in the December quarter and ramp up at the Monty copper-gold mine.

DeGrussa has produced more than 438,000 tonnes of copper and 254,000 ounces of gold, in excess of five per cent copper, since production commenced in 2012. But Sandfire chief executive Karl Simich believes the company is yet to hit its straps despite approaching the end of DeGrussa’s initial seven-year

mine life in mid-2019.

“We’ve been able to extend the mine from seven to about 11 years.

That’s very positive from that perspective. For us at the moment, it’s been a pre-dominantly copper business that has gone from strength to strength to strength,” Simich tells Australian Mining.

“We will see with the addition of multi high-grade complexes of over nine per cent copper to the DeGrussa complex over the next four years.

“We will have our best production profile in the next two to three years that we’ve ever had, even though we’ve already had good ones.

“And we’ll be generating it at stable copper prices – the most copper tonnes but at the lowest cost – and also the greatest revenue and the greatest margins. So it’s pretty exciting times for us at the moment.”

Simich’s confidence isn’t unfounded, as Sandfire is eager to make further discoveries in the 7000 square kilometres of tenements it has in the greater Doolgunna province, also home to the DeGrussa and Monty mines.

Sandfire is now speeding up its exploration endeavours in the region, which is considered extraordinarily prospective after the discovery of its two VMS high-grade copper deposits.

The opportunity to make further discoveries is, therefore, highly probable, according to Simich.

The company is also unfazed about AUSTRALIANMINING

SANDFIRE HAS BEEN ABLE TO EXTEND DEGRUSSA’S MINE LIFE TO 11 YEARS.

jumping on one of the world’s top 10 undeveloped copper projects by grade as far away as the United States.

Sandfire owns the Black Butte copper project in central Montana through its North American-listed subsidiary, Sandfire Resources America. The project’s copper concentration is 10 times higher than many existing mines.

The company has spent five years and an investment of $60 million to bring Black Butte to its final permitting stages, which has been a long and intensive journey for the company, the chief executive says.

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“Essentially, the Black Butte project has a very good grade of about 3.5 per cent copper – a quite lucrative grade relative to other potential mines around the world,” Simich says.

“The project contains about 600,000 tonnes of copper, with significant potential to have greater mineral resources.

“We will embark upon further exploration once we have that mine permitted.”

Sandfire aims to have Black Butte fully permitted in the September quarter this year to allow it to break ground and move into the

PROSPECT AWARDS

construction phase in 2019.

But this shouldn’t be too hard for Sandfire, which finds itself trading at an almost $1 billion market capitalisation (at time of writing) and sitting with access to $200 million in treasury.

Additional discoveries at DeGrussa, Monty or in the Doolgunna region, as well as approval for the Black Butte project, should have significant potential to add further value to the company.

Sandfire will have the ability to then advance its exploration endeavours in the central Montana region, which has never had any further exploration since the Black Butte discovery was made in the 1980s, Simich says.

The company’s growth ambitions don’t stop there. According to Simich, Sandfire has not only developed its capacity to continue with its exploration endeavours, but also in capturing business development opportunities.

“We are very active in the business development space at the moment, both in the inorganic and organic parts of the business,” Simich says.

“So we’re looking at other exploration projects further afield, as well as looking at business acquisition opportunities – projects, near-term mine development opportunities or

SANDFIRE’S MONTY MINE IS 10 KILOMETRES FROM DEGRUSSA.

operating assets … that we could acquire, bolster or add in to Sandfire.”

In April, Sandfire committed to a farm-in partnership with Alchemy Resources at its Bryah Basin project in the Gascoyne region of Western Australia, adjacent to the DeGrussa mine.

The copper-gold miner can earn up to 80 per cent in Alchemy’s interests by spending $3.1 million prior to October 28 this year.

Sandfire has also progressed its Morck Well joint venture with Auris Minerals in the same region, with the partners spending $9.4 million to complete a diamond drill and eight reverse circulation holes at the site in April.

“We are looking for where we can strategically create and add some value to another group in a lot of these situations,” Simich says.

“By joining forces with projects

or companies, that potentially opens up opportunity to create value for the greater sum rather than having individual situations.

“From a business development perspective, we see that we’re in a very strong position to be able to add value – that’s what we’re doing at the moment.” AM Nominations for the 2019 Prospect Awards are now open. Visit www.prospect awards.com.au for more information.

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PRODUCTIVITY AND EFFICIENCY

RAISING THE ROOF FOR PRODUCTIVITY AN EFFECTIVE AND SIMPLE SOLUTION TO A COAL MINE’S CRUSHER ISSUES PROVED EMBLEMATIC OF MCLANAHAN’S FLEXIBLE APPROACH TO DESIGN. EWEN HOSIE REPORTS. MCLANAHAN DEVELOPED A MECHANICAL CHUTE COVER FOR THE RECLAIM CHAIN FEEDER AT A COAL OPERATION IN QUEENSLAND, DRAMATICALLY IMPROVING PRODUCTIVITY.

B

ottleneck is a word no mining company likes to hear, but it isn’t a secret that equipment can become sluggish or even inoperable for a number of reasons.

One common cause of bottlenecking is production anomalies at brownfield sites where operators try to increase their tonnages but encounter issues arising from outmoded or worn equipment.

In addition, older equipment from the 1990s or early 2000s can lack the more open, maintenance-friendly design that operators have become used to in recent years, causing a bottleneck for workers trying to access and sort out the problem.

One type of machinery where this rings particularly true is crushing circuits, which can become clogged with oversize feed material, hard rock, or by feeding the crusher too quickly.

This leads to considerable downtime for operations as their staff work to disperse the build-up, a costly and high-risk endeavour.

Original equipment manufacturer (OEM) McLanahan was tasked with identifying a solution to this issue at an open-cut coal site in Queensland.

The site faced crusher blockage issues at its reclaim chain feeder, which was receiving raw run-of-mine (ROM) coal fragments of considerable sizes up to three metres in width.

This was a hindrance the company had traditionally solved through a lengthy process that involved cutting power to the feeder, disconnecting it from its chutes and rolling the crusher into a maintenance position to be serviced via use of an automated rock breaker.

This was excessively cutting into the company’s productivity and placed staff in high-risk situations during the removal process.

AUSTRALIANMINING

The company’s solution to its client’s concerns turned out to be fairly simple — they would literally lift a lid on the situation.

“What the client wanted to do was put a rock breaker on top of the machine and the only way we could do that efficiently and effectively was to have a flip top mechanically operated lid,” explains Brad Anstess, an application and product specialist who has worked at McLanahan Australia since 2003.

“That way we could open it up and then they could bring their rock breaker in and break that big lump of coal and rock blocking their process without having to disconnect and move the crusher out of its operational area.”

While the concept itself was relatively simplistic, the execution required considerable forethought.

While a hydraulic system was initially proposed, McLanahan designed the system so the lid could be lifted using

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two mechanical buddyboxes.

To ensure the technology worked efficiently, McLanahan collaborated with both the rock breaker manufacturer and the client’s control system engineers to integrate the mechanics of the lid as effectively as possible.

McLanahan’s design and engineering team designed and manufactured the machine locally in New South Wales to quickly supply the design to the mine and provide closer communication between the involved parties.

This helped ensure the end result could aid productivity and efficiency as much as possible.

McLanahan’s flexible approach to design is something the company has worked hard to cultivate over several years, combining the scale and resources of a larger OEM with the versatility and imagination of a smaller company.

PRODUCTIVITY AND EFFICIENCY

different, and having the ability to work in sync with them rather than against them is something that has really held us in good stead,” Anstess notes.

While the mechanical lid developed for the reclaim chain feeder project will probably not be as widely adopted as the DDC-Sizer due to the specificity of its application, it is still testament to McLanahan’s willingness to think outside the box in order to meet the needs of a client.

“We usually provide feeder breakers, and they don’t get to the point where the material gets stuck in

the throat of the sizer or transfer point because it gets crushed before it gets to those points,” Anstess says.

“Sometimes for cost-saving purposes, companies will purchase a crusher that is too small to crush lumps well, which is where the rock breaker comes in. With our feeder breakers, we haven’t had cause for rock breakers.”

Whether the job is large or small, McLanahan operates according to the proviso that its engineers be willing to customise its solutions to meet the demanding needs of the mining industry. AM

A COMPUTER-GENERATED RENDER OF MCLANAHAN’S RECLAIM CHAIN FEEDER LID.

This feel of a smaller company isn’t just philosophical in nature; it also extends to McLanahan’s output.

The company’s output in recent years has seen it respond to a growing industry trend towards miniaturisation of products, for example.

“The move towards smaller sizes wasn’t a big market move for us — it was just a case of listening to what the client requires. Flexibility is paramount,” Anstess explains.

“We’ve been gifted a number of jobs because of our oppositions’ inflexibility.”

The company launched a Mini

DDC sizer system last year in response to customer demand, being a miniaturised direct drive crusher designed as a cost-effective fine crushing solution for final product.

The wheel-mounted system, designed as a hybrid between traditional McLanahan double roll crushers and toothed sizers, was developed in response to a consumer request for a low-headroom, small-product sizer with minimal fines generation.

“With the engineering procurement companies and contractors we deal with, they put their reputation on the line to come up with something

MCLANAHAN’S IDENTIFICATION OF A MARKET NICHE FOR SMALLER MACHINES LED TO THE DEVELOPMENT OF ITS DDC MINI-SIZER.

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MATERIALS HANDLING

FENNER DUNLOP CELEBRATES A DECADE AT KWINANA FENNER DUNLOP AUSTRALIA MANAGING DIRECTOR GRAHAM LENZ REFLECTS ON A TRANSFORMATIVE DECADE FOR MINING AS THE COMPANY CELEBRATES THE 10TH ANNIVERSARY OF ITS FLAGSHIP KWINANA FACILITY. EWEN HOSIE REPORTS.

A

ustralia’s mining industry has gone through notable evolution over the past 10 years. From the wax and wane of the nation’s boom to the rise of the driverless truck, the sector has changed considerably.

Conveyor specialist Fenner Dunlop was in on the ground floor of this transition in 2009 when it developed its Kwinana manufacturing plant in Western Australia.

Designed as a manufacturing facility for conveyor belts, the plant was built to accommodate mining

FENNER DUNLOP’S KWINANA PLANT OPENED IN 2009 AND UNDERWENT A $16 MILLION EXPANSION IN 2013.

clients in the Pilbara region, saving them significant time by being able to order belts from a local supplier.

Fenner Dunlop’s choice of location, use of advanced technologies and an initial $70 million budget set the plant apart from its competition at the time.

Now celebrating its 10th anniversary, the Kwinana plant was not only innovative when it was commissioned, but was also built with an eye to the future.

To this day, the Kwinana plant is the most expensive investment made by a conveyor belting manufacturer in Australia. While it was arguably a risky investment at the time for AUSTRALIANMINING

Fenner Dunlop, it is one that has paid dividends in the years since.

The construction of the high-tech plant has accompanied the rise of the Pilbara as a premier mining region, particularly for commodities such as iron ore and gold.

“For us, Western Australia was where all the action was,” Fenner Dunlop Australia managing director Graham Lenz tells Australian Mining.

“It gave end users some key benefits in just naturally being that close to their facilities. We were — and still are — so much closer to them than anyone coming from Asia or anywhere else in the world so

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that was a natural fit.”

The end users of the Kwinana plant’s conveyor components have taken advantage of considerably shorter lead times than they were previously accustomed to when using overseas suppliers as it meant they weren’t reliant on shipping.

The shorter lead times in turn allowed mining operations to cut down on their working inventory due to a faster and more reliable supply chain.

Lenz says the logistical advantages, in addition to the sheer scale of the operation, allowed Fenner Dunlop to push its manufacturing to the limit

MATERIALS HANDLING

by delivering some of the biggest and heaviest conveyor belts ever built.

This culminated in the record delivery of a 580-metre roll of UsFlex ply belt in March 2019, a design accompanied by a 2.8 metre by six metre belt reel that was specially built by Kwinana-based Fenner Dunlop subsidiary JAF Engineering.

Following a $20 million expansion in 2013 that added a second press line, the plant boasted the capability to produce steel cord and rubber ply belting up to 3200 millimetres wide and 50 millimetres thick.

The plant was built with the space to accommodate another three expansions and according to Lenz, there’s room for much more growth.

“The plant was built with cuttingedge technology — that was what made it very special back then and still special today,” Lenz explains.

“We spent around $16 million then to put extra capacity into Kwinana in 2013 as a vote of confidence in the market, and since then we have invested heavily in innovative technology for greater efficiency and greater throughput.”

Fenner Dunlop’s expansion at Kwinana will continue beyond the site’s 10th anniversary. The company plans to leverage a deal of innovative upgrades over the next decade, with a host of upcoming developments in the pipeline (Lenz prospectively hints at the plant’s potential for solar investment, for example).

The company’s sizeable investment in the plant has not, however, been to the detriment of its older Australian facilities.

Fenner Dunlop’s Melbourne facility has recently gone through an extensive retrofit to implement Industry 4.0-driven smart technologies, for example.

THE SITE IS FORWARD THINKING IN ITS USE OF ADVANCED AUTOMATION SYSTEMS.

The company has built its service offering over the past decade through a series of engineeringfocused acquisitions, such as the aforementioned JAF; the Belle Banne group of companies, acquired in 2010; Statewide Belting, acquired in 2011; and Australian Conveyor Engineering (ACE), acquired in 2012.

In January 2019, Belle Banne Conveyor Services in turn purchased Victoria-based manufacturer Conveyor Pulleys Australia (CPA), further expanding Fenner Dunlop’s range.

Lenz believes the company’s philosophy supports the mining industry with the best engineering solutions and designs to support conveyors in total, not just the belts.

“CPA can handle pulley and structure — you’ve got to get that right. One thing that all our acquisitions have in common is that they can do engineering, refurbishment, overhaul and manufacturing of conveyor systems,

including the electrics,” Lenz says.

“We’ve invested heavily in engineering-focused businesses and products in the time since we built the Kwinana plant. All the things that support the conveyor — and everything that sits under it — is where we’ve concentrated our efforts over these last 10 years.”

This engineering focus runs parallel to Fenner Dunlop’s evolution as a trainer and service provider. As a registered training organisation (RTO), Fenner Dunlop expanded its remit last year to include mechanical services training, in addition to conveyor technician training.

The company’s RTO status has aided its launch of the Engineered Conveyor Solutions (ECS) arm of the business, envisioned to provide long-term, post-installation support for conveyor setups using in-house technicians.

This top-to-tail approach helps eliminate ‘the blame game’ that can arise during periods of equipment

breakdown when sites are reliant on multiple suppliers. The consequence of this back-and-forth interaction is that it exacerbates already costly downtime scenarios due to wasted time.

“Thanks to the ECS approach, we have embedded a lot of our in-house engineers on customer sites, which allows us to tailor these solutions right down to the individual conveyor,” Lenz says.

“If a customer has a particular mining conveyor where they can get energy savings from, say, low rolling resistance or high impact resistance, we can accommodate that.”

And what of the next decade?

According to Lenz, the evolution of Fenner Dunlop over the next 10 years could be even more radical than the previous one as concepts such as the Internet of Things (IoT) and the continued electrification of the mining workplace becomes more common.

Given the pace of change in the industry at present, perhaps it won’t be too long before we see ‘the improved Kwinana’.

“Electrification is a big part of it. We’re starting to see some changes now, but the big trucks and trains are largely diesel driven, whereas conveyors have always been electrified,” Lenz explains.

“So, because we’ve already got electrification and automation covered, we are always thinking about how we make conveyors smarter.

“In the future, we anticipate smart factories that have the ability to allocate construction slots based on knowing when something’s going to wear out so you can begin to build the solution before it becomes a problem.” AM

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CRUSHING & SCREENING

JAW CRUSHER BECOMES FIFTH POWERSCREEN MACHINE DELIVERED TO GROMAC LINCOM GROUP’S HIGH-PERFORMANCE POWERSCREEN PREMIERTRAK 600 CRUSHER HAS ATTRACTED FIVE ORDERS IN THE PAST 18 MONTHS. AUSTRALIAN MINING WRITES.

M

obile equipment is the best suited to service the market of Gromac Quarries, for example, when North Queensland faced unprecedented flooding in February.

The Queensland Government was redeveloping a rail line between Townsville and Mount Isa, a project that covered more

than 200 kilometres (according to Queensland Rail).

The railway project would ensure the state’s key freight routes efficiently connect mining regions to ports, airports and other transport hubs.

“Having a mobile plant gives them the versatility to move their plant to the busy locations in a short space of time, getting into high production and serving demand

from customers like Queensland Rail to help deal with situations like the North Queensland flood,” Lincom Group sales manager – North Queensland, North Territory and Papua New Guinea Erwin Koch tells Australian Mining.

The 600-tonne-an-hour jaw crusher was chosen for its capacity for processing ores and minerals, overburden, or aggregates for use in railway ballast. Its portability

also ticks off Gromac Quarries’ requirements for versatility.

The Powerscreen Premiertrak 600 has also demonstrated it can increase productivity by up to 30 per cent by removing bridged rock and breaking oversize material in the hopper without the need to stop a plant or reposition the equipment.

It runs on a direct drive Caterpillar C13 engine with 440 horsepower, which Lincom claims is the best

THE MOBILE POWERSCREEN PREMIERTRAK 600 PROVIDES FLEXIBILITY AND MOBILITY TO GROMAC QUARRIES. AUSTRALIANMINING

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CRUSHING & SCREENING

GROMAC MD RAY GROSS (L) AND LINCOM GROUP SALES MANAGER ERWIN KOCH.

transmission power available from an engine, while also being the most fuel efficient.

The Premiertrak 600 promotes aggressive crushing action with low noise emissions and a high swing jaw, which encourages material entry into the crushing chamber alongside a wide bypass chute.

One of Gromac Quarries’ purchasing decisions was driven by a working relationship between the company’s two brothers and Koch, who was personally involved in the commissioning of the machine.

Lincom flew its service technicians from the Brisbane head office for the commissioning and personal training of the equipment for the Gromac Quarries team.

Gromac Quarries has purchased machineries from other suppliers

over the life of its business, but found they received the best service from Lincom over the past couple of years, according to Koch.

“We provide all of the training, servicing support and machine spare parts from our head office in Brisbane, so it suits their requirements in North Queensland very well,” he says.

“In the event of any breakdown, they can either get our technical support over the phone or have people come to the site at any given day.”

Lincom Group also boasts a variety of genuine spare parts for its brands, including Powerscreen, as well as a rapid response parts service area to get mining machines up and running with the least downtime.

“We treat every parts order as

urgent and understand the potential costs associated with having a machine down,” Lincom Group chief executive Stephen Watterson says.

“Our national parts distribution centre located in Brisbane stocks an extensive range of parts to support the branches in Australia and New Zealand.”

Koch visited one of Gromac Quarries’ sites to discuss its requirements for high output, versatile equipment. He understands the different material processed in the company’s various locations and has tailored the machine’s optional features to Gromac’s specifications.

The remote-control rock hammer option, for example, aids with oversize material entering the chamber – an advanced, high performance 1200 millimetres by 820 millimetres Terex chamber with robust construction for tough applications.

Its users can also equip the crusher with a hydraulic unblock feature to help unclog any unexpected blockages in the crushing chamber.

“This option improves the safety of personnel as you no longer have to physically remove any of the rocks by hand from the machine,” Koch says.

“The unblock feature can deal with whatever blockages it encounters.”

Lincom Group has also released a pan feeder and live pre-screen option that removes some of the lesser quality and clay-bound material from the main product to produce either concrete aggregate or high-quality road base.

The compact Premiertrak 600 has an extensive range of options that include remote monitoring telemetry pulse system, electric cabinet positive pressurisation, extended discharge conveyor, to name a few, along with the standard things Lincom fits like conveyor guarding, lanyard safety pull, fire extinguisher and other possible site-specific options.

The success of Gromac Quarries post-North Queensland’s flooding demonstrates Lincom Group’s expertise in the provision of screening and crushing equipment, according to the company. AM THE JAW CRUSHER IS DRIVEN BY THE EFFICIENT CATERPILLAR C13 ENGINE.

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MINING INFRASTRUCTURE

CATERING TO FUTURE MINES WITH THE RIGHT SEWAGE PLANTS WASTEWATER TREATMENT EXPERT PAUL COBBIN EXPLORES THREE ISSUES MINING COMPANIES FACE – PLANT UPGRADABILITY, EXPANDABILITY AND WATER SCARCITY – AND HOW TO OVERCOME THEM. AUSTRALIAN MINING WRITES. MANY ROADTRAINS HAVE BEEN AROUND FOR UP TO 30 YEARS AND GRADUALLY UPGRADED TO MEET ENLARGED CAPACITY.

H

ydroflux Epco’s Paul Cobbin recalls building a water treatment plant in the Gulf Province of Papua New Guinea as a young foreman during a coup d’état in nearby Bougainville.

The plant was intended for a construction camp at a mine that had not yet been built, with only a runway already in the works.

A piece of this runway, unfortunately, knocked over the site’s only crane. The crane was key to building the water treatment plant and the only tool the foreman had to offload the fully welded tank from the truck it came in on.

“It was 1997. The camp foreman and I scratched our heads for a little while before coming up with the idea of using a Chinook two-blade helicopter to put the entire project together,” Cobbin says.

“Working in a remote site with two blades for eight hours a day in the 1990s was a little bit of hard

work. But that’s the sort of things you will encounter in mines. These mine sites are very remote and our sewage treatment technology is exactly designed for that.”

Cobbin was installing the technology known as Hydroflux Epco RoadTrain, which had been used in Australia since the 1960s.

The RoadTrain package plant first sprang to life in a Bowen Basin coal mine in central Queensland. This original plant was designed for a capacity of 400 people in 1970s, but after a couple of relocations and renovation, it could accommodate up to 800 people by 2012.

This 150-cubic-metre-a-day RoadTrain was also augmented, to increase treatment quality to allow for 100 per cent effluent reuse to flush the toilets, water the gardens and wash the laundry, from the original discharge criteria of being released to the creek.

It highlights the importance of having a scalable water treatment AUSTRALIANMINING

plant that meets current and future treatment capacity, while being adjustable to the changing environmental criteria of modern times.

“The compliance requirements of the 1970s are totally different to the compliance required in 2019 – there was no way you could picture back in the 1970s what the requirements of 2019 were going to be. Who knows what will be required in 2050?” Cobbin says.

“It’s quite possible that we won’t be allowed to discharge at all – the water might need to be fully reused or even be drinkable. Whereas a camp services designer in the 1970s would likely have lost his job if he suggested reusing sewage effluent.

“So when you buy equipment now, it should not only be bought for the requirements now, but also to allow for possibilities for change. That’s what we do with the plants we put around mine sites.”

BHP Mitsubishi Alliance (BMA) has experienced repeatable success

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with RoadTrain since 1978 at Blackwater, according to Hydroflux.

Six welded RoadTrains are spread across BMA’s 40 kilometres of the lease, requiring only operator skills, maintenance and testing regimes for one style of process system.

Hydroflux has added equipment and technologies to the plant to complement the base structure and bring it into a new level of compliance.

As mining operations have migrated along the coal seam, so have the facilities. The toughness and ease of relocating the RoadTrain have provided economic advantages through reusing instead of replacing the asset over time.

“A classic case in point at the moment is (an open-pit copper and gold mine) in Papua New Guinea, which is putting a treatment plant for a township in the Western Province,” Cobbin says.

“Right now, in their case, we’re putting in a capacity for 1000 people.

As they get their future budget, they will expand their capacity by 1000 each time. So we’re starting with the smaller component now and we’ll work on a larger component later.”

From a budget perspective, simpler technologies such as the RoadTrain are more robust but often dearer to buy upfront.

However, they have a longer life and are able to withstand the harshest environments. They can be refurbished and added to while retaining their robust design, according to Cobbin.

Exotic equipment such as a membrane bio reactor (MBR), meanwhile, is cheaper to buy but is more expensive to maintain. The mass-produced technology has a shorter lifespan of about 10 to 15 years, with suitability for mines with highly-skilled operators, greater operational budget and tighter capital expenditure.

“But nobody has a glass ball to see what is going to happen in the future,” Cobbin says. “It’s constantly moving – it’s always moving – and we’re helping mine sites bring through their expansion plans.” AM

DRILL AND BLAST

DYNO NOBEL HITS THE TARGET WITH EZSHOT DYNO NOBEL’S ELECTRONIC INITIATION SYSTEM EZSHOT COMBINES ‘THE BEST OF BOTH WORLDS’ FOR UNDERGROUND PERIMETER BLASTING. AUSTRALIAN MINING REPORTS.

D

EZSHOT’S USE OF FAMILIAR NONEL SHOCK TUBE ELIMINATES TRAINING TIME FOR MINERS.

rill and blast specialist Dyno Nobel’s EZshot technology — driven

by Nonel — combines the precision timing of electronic initiation systems with the straightforward setup of non-electric shock tube detonators to provide an accurate blasting system that is deployed quickly and easily.

The system couples Dyno Nobel’s world-class Nonel brand of shock tube — known for its robust application in non-electric blasting applications — with a smart detonator that features factory-programmed delay times starting at 1000 milliseconds.

Shotfirer familiarity with Nonel, which has existed since the 1970s, means the switch to EZshot does not require additional training.

“Nonel is very robust in its application,” Dyno Nobel vice

president, product and applications technology David Gribble says.

“It’s abrasion resistant, it has excellent elongation properties and the general feedback we get from our customers is that there are no issues with it as it does what it’s designed to do — day in, day out.”

EZshot’s hardy construction and ease of use combined with its electronic initiation technology is designed to deliver “the best of both worlds” for underground perimeter blasting, according to Paul Klaric, technical manager at Dyno Nobel’s specialist consulting division, DynoConsult.

“Historically, one of the key issues with electronic initiation systems in development is that they are wirebased and tend to take additional time to set up over conventional non-electric (pyrotechnic) initiation methods, where

AUSTRALIANMINING

accuracy is related to the length of the delay,” he explains.

“As our electronic initiation systems are deployed in an underground development environment where it’s high pressure and high intensity, this makes ease of use paramount.

Feedback from customers has been that the product was easy to use and no additional training was required.

“With EZshot we’re offering something that is robust, simple to use, and doesn’t add any more time to what you’re doing while providing the results of an accurate electronic delay.”

Dyno Nobel is progressing value propositions for wider use of EZshot, but the company’s initial focus is on underground perimeter mining.

The company believes the system will provide the biggest benefit to miners in the underground due to the associated reduction of overbreak that comes with the implementation of an electronic detonator.

Overbreak, where the volume of rock removed during the blasting process is in excess of design, is a condition caused by unfavourable geological conditions and inefficient or excessive drilling and blasting.

The volume of overbreak can be significantly reduced through electronic initiation, as it gives miners the ability to allow precision timing in perimeter holes. This leads to safer and more stable drive profiles, and less mucking and hauling after the blast, saving time, as well as money.

The inherent scatter of standard

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pyrotechnic delay blasting can result in scenarios where these perimeter holes (half barrels) are not visible after the blast. Electronically initiated blasting allows miners to see where drilling has occurred as half barrels are a good indicator of controlled blasting — and then the drilling profile is adjusted as required.

“In underground blasts, the blast duration is longer, and the longer the delay used, the more scatter you get with non-electric detonators,” says Gribble. “With accurate and precise timing, the breakage at the perimeter can be much cleaner, and miners can deliver profiles to design.

“EZshot is effectively giving underground miners an improved technology advantage, without extra training or any changes to what they are currently doing.

The demand for EZshot, launched in the United States in January and in Australia in February, is outstripping supply, according to Dyno Nobel. The company has rolled out the product in the Mt Isa region of Queensland and is building case studies to further elaborate on its benefits.

“The work we’ve done underground with electronics in development mining shows a reduction in overbreak through timing accuracy, improved profiles – thus improving safety —and conformance to design. Combining that precision timing with the ease of use and simple deployment of Nonel, really drives the value of EZshot home,” concludes Klaric. AM

MINING EQUIPMENT

MEASURING SAFETY GAINS – A SAFER WORKPLACE IS A MORE EFFICIENT WORKPLACE MANY FITTERS NO LONGER NEED TO WRESTLE WITH AND BE UNDER HEAVY MACHINERY WITH THE TRACKED ELEVATING DEVICE (TED) AT THEIR SERVICE ONSITE. AUSTRALIAN MINING REPORTS.

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ivek Industries has disrupted the way earthmoving maintenance operations are conducted across Australian mine sites. Its breakthrough equipment, tracked elevating device (TED), is designed by a fitter for fitters – Kevin Cant, Nivek founder.

TED is a battery operated, selfpropelled, all terrain belly plate jack that removes mining fitters from the line of fire. Australian Mining speaks to Nivek operations manager and former maintenance fitter Jeff Merchant and general manager Derrick Cant about opportunities to improve onsite maintenance applications.

Reflecting on your years working on mine sites, are there any prevailing problems with maintenance practices at mine sites?

JM: Pinch points are everywhere and often can’t be engineered out, so they are a very big consideration when working on mining machinery.

the sheer weight of components and tooling, and the awkward work environment being under machinery.

TED’S POWERFUL HYDRAULIC LIFTING ABILITY OF UP TO 800 KILOGRAMS IMPROVES FITTERS’ WORK ENVIRONMENT.

How does TED offer a solution?

JM: TED takes the weight of belly guards and many other components, removing a large amount of physical strain. The fact that TED is remote control-operated takes the danger out of the possibility of unplanned movements, as the fitter is out of the line of fire when lowering things like belly plates. The fact that TED is on tracks means that it can handle tough terrains, eliminating the need for fitters to be pushing and pulling whilst crawling on their hands and knees under machinery.

How does technology play a part in making innovation such as TED possible? Are there any breakthrough capabilities introduced by TED?

JM: Prior to TED, the ways of removing belly plates were dangerous and taxing on the body and outdated at best. With remote control technology, however, TED can be operated with fitters being a safe distance away from the danger zone. Although TED began as purely a safe way to remove belly plates, an array of attachments now allow TED to help with countless maintenance jobs. It offers the ongoing safety benefits of increased control and

TED’S REMOTE CONTROLLED OPERATION ENSURES FITTERS’ SAFETY BY KEEPING THEM OUT OF THE LINE OF FIRE WHILE LIFTING AND LOWERING.

What are the greatest hazards employees need to be mindful of when it comes to conducting maintenance operations?

JM: Some of the most dangerous things fitters must be aware of and plan prevention for on a daily basis are unplanned movements, hydraulic injections, crush injuries and unexpected release of stored energy. Unplanned movements can be caused by unseen hazards, unexpected weight distribution and the removal and replacement of components.

What are the common cases of injury and/or risks associated with these duties?

JM: Muscle strain and back injuries are all-too-common issues due to

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lowered manual handling.

DC: Although there were no groundbreaking technologies developed for TED, technology has still played an important part in the design and final capabilities of the machine.

The wireless radio system allows users to stay at a safe distance, the skid steer track system allows the deployment of TED into the field, and the combination and layout of the scissor lift hydraulic system allows for an extremely low profile – essential for belly plate removal.

MINING EQUIPMENT

AS FAR AS WE KNOW THERE HAS NOT BEEN A SINGLE FATALITY OR LOSS OF A LIMB WITH THE USE OF TED.”

TED HAS PROVEN TO BE THE SAFEST WAY TO REMOVE AND REPLACE BELLY PLATES IN THE FIELD

field, TED can save hours of vehicle downtime and float costs.

How has the sector’s attitude towards worker safety shifted in recent years? What has changed since?

JM: Mine site attitudes appear to have shifted over the past 20 years.

Rather than just trying to prevent critical and life-threatening injuries, they seem to be looking to workers’ future health, and often times attempting to prevent repetitive

DC: TED’s success can easily be measured by the amount of positive feedback we receive on our social media platforms. The constant requests for additional attachments is a clear indication that maintenance staff are using TED and can see benefits the system provides, as they would like to use it for more applications.

Although TED’s biggest benefit is gained through increased safety, its efficiency gains and cost-savings are also enormous. TED reduces the maintenance time of operations, required man-hours and workplace fatigue. By being deployable in the

How do you measure TED’s success in mine sites?

JM: As far as we know, there has not been a single fatality or loss of a limb with the use of TED so far as we are aware. In our opinion, one serious injury or life lost in a work environment is one too many. It keeps my mates working in the pits safe. The availability of all TED’s attachments mean that TED can make a myriad of jobs quicker and easier. The reduction in downtime experienced by most workshops with TEDs is definitely impressive and supports smoother running of the mining operation overall.

strain injury (RSI), back injuries and long-term injuries – all so that workers can enjoy their lives and families outside of work.

DC: Workplace safety has been a major part of mining culture for quite some time now. However, there are still some tasks that can be better mitigated against – belly plate and suspended load removal/installation being a prime example – especially in the field where maintenance staff had to use alternative methods. AM

NIVEK PAYS ATTENTION DOWN TO THE SMALLEST DETAILS, DESIGNING ATTACHMENTS THAT INCREASE THE VERSATILITY OF TED AT MINE SITES.

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MINING EQUIPMENT

ACS HAS PARTNERED WITH IFM FOR A DECADE.

FROM DAWN TO DUSK – EQUIPMENT THAT LASTS IN ENVIRONMENTS WHERE PRODUCTS CAN BE AFFECTED BY EXTREME WEATHER CONDITIONS WHILE THEY ARE IN NEAR-CONSTANT USE, RELIABILITY IS KEY IN KEEPING THE WHEELS ROLLING. MIRI SCHROETER WRITES.

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ust as employees can be struck by the consequences of long, hot days doing physical labour, machinery can also feel the strain of a full working day. Rest and recovery for employees is not only desired but also necessary in ensuring the day can begin over in a mine for weeks and months to come. While machines don’t necessarily have the luxury of shutting off for an evening, they need the support of quality parts to keep running efficiently and consistently.

Auto Control Systems (ACS) general manager John Watts works with mines across Western Australia to ensure companies get the best out of their machinery. He says in order to do this, he too needs access

to the best equipment or it could be detrimental to his customers and ultimately to ACS’ reputation.

“When a machine shuts down you get upset customers. Sometimes it’s not the cost of the machine. It can cost millions-of-dollars per day if that machine is not producing what it should be,” Watts says.

“Some of our machines load the explosives in the blast hole. The old saying in the mining industry is, if you don’t drill you don’t blast, you don’t dig you don’t mine you don’t make money. If you don’t blast for a day or two that means every machine in the mine site starts shutting down. If you’re not blasting you’ve got nothing to dig up, nothing to process, nothing to put on the train to send out to the boats.

“A mine site shutting down can AUSTRALIANMINING

cost a million to two million dollars a day. It’s the cost of the downtime for the whole mine site that is the issue.”

With this in mind, ACS chooses to partner with companies that supply reliable products that are easily accessible to the Perth-based company. ifm is able to offer this reliability in its range of condition monitoring systems, connection technology, sensors and industrial imaging products.

“I’ve had it before where machinery up north in the Pilbara hits the summer and we’ve had products getting too hot and they just shut down. We’ve had older machines that did that, where we’ve replaced it with ifm products and it just powers through. We didn’t get that problem again,” says Watts.

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He explains that ACS uses ifm equipment in its projects as it is robust enough to withstand Pilbara temperatures, which can soar to 55° Celcius, and temperatures in other sites that ACS delivers projects in such as the mountains in Siberia, which can drop to -40° Celcius.

“It’s fit for purpose. They know we’ve got quality and it guarantees our machinery does work.”

He says sometimes companies don’t even know their machinery has ifm products in it as they’ve never had to replace it.

“The reason they don’t know the ifm gear is in there is because it hasn’t broken down. If you’ve got a bad system or component that’s always breaking down, they really get to know the component and get to not like it sometimes. But if it’s in

MINING EQUIPMENT

the machine dormant underneath, and there’s no problem for 10 years, they are not going to know it,” Watts says.

Systems that work

ACS has been working with ifm for a decade and it’s a partnership that keeps on working – so much so that ACS stocks spare parts on behalf of ifm.

“We can get it out the door on the same day. That keeps the ifm customers happier now that they’ve got someone on the West Coast to help them out. Whether its parts, support or trade we can help,” Watts says.

One of the benefits of working with ifm is its range of systems for mobile machines, which ACS encourages many of its customers to use.

“Some of the equipment we used with the trucks before wasn’t mobile ready. For the mobile side, ifm’s products are one of the most robust systems around. It’s high temperature rated, high vibration proof and keeps on repeatedly working out there,” he says. ifm’s smart observer allows ACS to connect its customers’ machinery without re-configuring the entire fleet with ifm equipment. Watts says customers will often already be using ifm products without knowing it anyway.

“If you try to sell the smart observer and their response is, ‘there is no equipment to connect to,’ well they actually have six or so machines that already have ifm on it.”

The smart observer is a condition monitoring system that can identify possible damage or production stoppages, help reduce

AUTO CONTROL SYSTEMS GENERAL MANAGER JOHN WATTS.

energy consumption, and help with the maintenance and repair of machinery.

“Getting the data helps us with servicing and improvements. If we can see that we can make something more efficient by even three per cent, we will,” says Watts.

He explains that customers are able to budget better and keep an eye on machinery and workload to determine whether machines need servicing or whether they need another machine to keep up

THE REASON THEY DON’T KNOW THE IFM GEAR IS IN THERE IS BECAUSE IT HASN’T BROKEN DOWN... IF IT’S IN THE MACHINE DORMANT UNDERNEATH, AND THERE’S NO PROBLEM FOR 10 YEARS, THEY ARE NOT GOING TO KNOW IT.” with demand. It also helps monitor employees and work out whether they are working efficiently.

“Sometimes it highlights that if the person isn’t running it efficiently or correctly they need training. The person might be too frightened to put their hand up,” says Watts.

Safety at forefront

In an industry that needs stringent safety measures in place 24/7, ACS aims to offer the best solutions, with the help of ifm products. “For example, in the drilling industry as a whole, there is a big push to improve safety. The drilling companies and their customers see a need for this,” says Watts.

ACS is running pilot programs with drilling companies to implement better safety standards. ifm products such as cameras and sensors are helping in this program.

“If someone goes in a danger zone, you can stop the machine or make it go slower using safety controllers. When you’ve got sensors and outputs you want to make sure

IFM OFFERS RELIABILITY IN CONDITION MONITORING SYSTEMS, CONNECTION TECHNOLOGY, SENSORS AND MORE.

AUSTRALIANMINING

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that if the controller is running well, it is running 100 per cent fine,” Watts explains.

“We’ve got current engineers that are TÜV safety certified.

They can go and analyse a machine or a problem and give their recommendation on what needs to be done.

“If you have an ifm safety controller installed with redundant controllers, there is less chance of an unsafe condition occurring,” he says.

Upgrading machines is important for data and safety, and Watts says in remote locations it is having autonomous systems can minimise the risk to people.

“In some cases there will be a few staff in the remote area that aren’t easy to access if something goes wrong. The more you can automate a machine, the less people will be on site,” says Watts.

He explains that by having equipment that lasts, is reliable and promotes safety, such as ifm’s range, customers are more likely to come back to ACS. AM

THE MINING INDUSTRY HAS MOVED TO A NEW PHASE FOLLOWING THE MINING BOOM, ONE WHERE PRODUCTIVITY, INNOVATION AND SAFETY HAVE EMERGED AS ITS KEY PRIORITIES MINING SERVICES IRON ORE SPOTLIGHT VOLUME 111/5 | JUNE 2019

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MAINTENANCE

THE BENEFITS OF FACTORY DIRECT SERVICE TENNANT ADDRESSES SOME OF THE COMMON QUESTIONS AROUND EQUIPMENT MAINTENANCE AND HOW TO SCHEDULE SERVICES TO GET THE MOST OUT OF ITS MACHINES.

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ennant’s Factory Direct Service offers three plans: essential (ideal for organisations with just one machine); capped (ideal for organisations with several machines onsite and includes regular and preventative maintenance); and comprehensive (ideal for intensive users).

Each plan includes priority breakdown response from Tennant’s fleet of trained service technicians equipped with TennantTrue parts.

The best plan for every equipment and company will depend on what the machine needs and the type of site being operated on.

A Tennant representative will advise operators on the most suitable plan for their organisation, according to Tennant service manager, Australia and New Zealand, Chris Collier.

“Our team consists of 40-plus trained technicians and authorised dealers across Australia and New Zealand to service your machines every day. Our average response time to enquiries is 24 hours and we usually have a tech on site within two days,” Collier says.

Although Tennant’s Factory Direct Service is still relatively new to the

FACTORY DIRECT SERVICE HAS THREE PLANS.

example, IRIS Asset Manager, ech2O NanoClean and ReadySpace).

So even if the operator is not able to access Factory Direct Service, Tennant believes it is still worth choosing one of its machine for longevity and smarter technology.

Is Factory Direct Service worth paying for?

market, the company already has 6300 planned maintenance contracts, with this number increasing weekly.

What are the benefits?

Just like buying a new car from a dealership, when a new cleaning machine is purchased, the buyer will usually also get offered a planned maintenance package.

If a machine is brand new, the buyer might be tempted to skip the maintenance schedule, but before they do, it’s a good idea they look at the benefits and what they will get, according to Tennant.

The benefits include: direct support from specialists trained in equipment; priority support for repairs; discounted

TENNANT’S FACTORY DIRECT SERVICE TEAM CONSISTS OF OVER 40 TRAINED TECHNICIANS.

AUSTRALIANMINING

parts and labour when needed; fewer unexpected (expensive) breakdowns; longer lasting machines; greater reliability; assurance that all parts are fully functioning; access to the best quality parts (like TennantTrue Parts); access to lifetime training to help operators use the machines properly; and predictable, regular maintenance fees that can be budgeted for.

What are the alternatives for maintenance and repairs?

Machines will need to go on an equipment maintenance schedule to keep them running properly, maintain the warranty, and catch any problems before they become big (and expensive).

Operators don’t have to sign up for a Factory Direct Service plan, according to Tennant. In fact, if they are located outside of the service area, they will need to go with a different approach, like: find a Tennant-authorised service dealer that operates within their region; use a local equipment maintenance company; find an independent technician, and do inhouse servicing (if there is a capable team member trained in the machine).

Tennant does not, however, provide these options with the same benefits as Factory Direct Service.

The operator may find their machine needs more frequent or more significant services/repairs when they don’t go factory-direct.

Fortunately, many of the equipment purchased through Tennant already comes with builtin technology that decreases costs and increases productivity (for

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Usually, yes, according to Tennant.

“If you rely on your machine and it’s critical to your maintenance schedule, it’s a good idea to do everything you can to ensure it functions properly and doesn’t go offline,” Collier says.

“You’ll start getting value from your Factory Direct Service because it protects the initial investment you made in your cleaning equipment.”

Regular servicing reduces the likelihood of unplanned downtime, identifies potential problems before they become major, and helps a machine perform optimally. All of these benefits can help reduce the ongoing cost of a machine.

What happens during planned maintenance?

Equipment maintenance schedules vary depending on your machine and how it’s used onsite.

But in general, maintenance is scheduled every quarter (as a minimum) with options to plan more regular maintenance depending on an operator’s needs.

A maintenance service will include: checking parts like squeegees and brushes (and replacing if needed); ensuring batteries are charged and maintained; checking the filters to ensure they’re clean and replacing if needed; testing and troubleshooting; advice and recommendations; operator training; status reports; and scheduled parts replacements.

Tennant technicians will also provide feedback and guidance around what machine operators do between services to keep the machine well maintained.

For example, Tennant’s colour-coded machine service guidelines – if it’s yellow, it’s a touchpoint that operators can provide minor servicing between scheduled maintenance. AM

INDUSTRY COMMENT

THIRTY YEARS OF METS SECTOR TRANSFORMATION: EXPLORATION AUSTMINE CONTINUES A FOCUS ON THE EVOLUTION OF THE METS SECTOR OVER THE PAST 30 YEARS WITH AN IN-DEPTH LOOK AT EXPLORATION IN AUSTRALIA.

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ustmine is proud to be celebrating 30 years of support and advocacy for the Australian mining equipment, technology and services (METS) sector.

As we lead up to our anniversary date in November, we will be examining the significant transformations and key innovations driven by Australian METS and their effect on the global mining industry.

At a time where prospective mining districts are maturing and discovering the next major project is a cost-intensive and challenging exercise, mining is in a race against time to ensure the sustainability of the industry and many others that rely on natural resources.

While the industry is looking towards innovation to solve this

challenge, it is essential to consider how Australian METS have transformed exploration over time.

Exploration – 30 years ago

According to manager of exploration, Marcus Willson at CSA Global, leading exploration and mining consultants in the field, a lot has changed in 30 years.

“The larger global exploration field was just starting to open up, with the beginnings of more modern exploration techniques being developed. At the time, traditional exploration techniques were dominant and still very successful due to limited coherent exploration,” Willson says.

Further analysis of traditional techniques creates a stark contrast to what we know as common today.

“Minimal use of computers occurred. Early spreadsheet and primitive database systems

were starting to appear, but no centralisation occurred. The majority of exploration continued to be based on a combination of regional mapping/ prospecting, while a lack of computer power and appropriate software prevented the ability carry out true 3D modelling,” Willson says.

However, the industry has seen this scenario shift over time with the adoption and invention of digital technology, much of which has responded to the needs of the exploration industry.

What has changed in exploration?

Michelle Carey, general manager – product development, IMDEX, the leading provider of real-time subsurface intelligence solutions to the global minerals industry, describes this process of digital

change in exploration.

“In my mind, the most gamechanging innovation has been the digitisation of the exploration cycle, which has dramatically improved the availability, accuracy and timeliness of data for critical decision making,” Carey says.

“An example of this digitisation is the development of portable XRF on-site assays and how that has been incorporated into work flows that allow geologists to look at chemistry data they can trust in real-time.

“Similarly, the availably of analytical software to allow any geologist to interpret large amounts of data using sophisticated methodology, from classification diagrams and cluster analysis to self-organising maps.

“Finally, the trend of sensors and software all joining up into systems has enabled geologists to monitor progress

EXPLORATION HAS SEEN ITS SHARE OF CHANGES IN THE PAST 30 YEARS.

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INDUSTRY COMMENT

DRONES HAVE BEEN A REVOLUTIONARY NEW EXPLORATION TECHNOLOGY

of their programs in 3D, and no doubt will soon go from data to 3D modelling in a semi-autonomous way.”

What were the drivers of change?

Commenting on how these changes have occurred, Willson describes a promising trend for the future of greater industry collaboration.

“From a technological aspect, the most significant changes have been in increasing collaboration between stakeholders, which, when coupled with more openness amongst mining companies to embrace new technologies, has resulted in increased availability of, and uptake in new technologies,” Willson says.

Reinforcing this key point, Carey reflects on her own experiences with IMDEX. “Our own recent examples include collaboration with MICROMINE, Seequent and acQuire Technology Solutions, which mean that data from the field is seamlessly put where a geoscientist needs it,” Carey says.

“The Seequent partnership integrates IMDEXHUB-IQ with Seequent’s Central software, which provides 3D visualisation of geological data in real-time and our partnership with acQuire also integrates IMDEXHUB-IQ with its GIM Suite.

“The result for clients is an integrated and automated workflow, which means less manual handling of data, improved data governance and data quality, and streamlined access to trusted results.”

THE MOST GAME-CHANGING INNOVATION HAS BEEN THE DIGITISATION OF THE EXPLORATION CYCLE, WHICH HAS DRAMATICALLY IMPROVED THE AVAILABILITY, ACCURACY AND TIMELINESS OF DATA FOR CRITICAL DECISION MAKING.” What are the next great challenges for exploration?

As Expedio, a geological data science consultancy, stresses, people are vital to the future of exploration.

“As near surface finds become rarer, technologies will need to be found to further exploit opportunities. Finding the right people to make this happen will be a challenge, with many of the best and brightest future employees looking elsewhere from mining,” the company states.

CSA Global reinforces this challenge of finding people but also incorporating the current skills sets that will always be needed.

“As remote sensing/remote analysis tools become more effective, increased desktop prospecting will occur.

Ultimately, key primary datasets, such as structure, geochemistry and basic geological mapping cannot be done in this environment,” CSA Global adds.

“We can postulate all we like from afar, but you must get up close and personal (on the ground) to gain true understanding. We are in danger of losing our field skills. You might find some interesting features via AUSTRALIANMINING

your computer screen, but you won’t know much at all until you get out in the field.”

In combating the primary exploration challenge of finding new orebodies, CSA Global emphasises that much of the technology is here, it just needs to be utilised.

“The exploration business is endeavouring to explore in areas of known prospectivity but at greater depth and with more difficult cover. While tools and techniques increasingly exist to help mitigate the explicit additional risk, there remains very poor uptake within the industry. There will be no easy solutions, so the industry MUST get more sophisticated across the board,” the company adds.

What next for exploration innovation?

“Machine learning and artificial intelligence is a blanket buzz word for expertise in using computers to exploit data better, but it will no doubt play a big part across the industry,” Expedio believes.

“Cheaper sensors will contribute

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to more widespread data and information available, which will be exploited through advanced processing techniques for greater understanding of the orebody.”

CSA Global notes the overall nature of exploration has the potential to change. “Mineral deposits are created by processes, of variable nature depending on the type and style. At present, the industry remains reliant on a high degree of interpretive analysis to assess the presence/absence of those processes, identifying where it has occurred and where it may result in the future,” CSA Global states.

“Progressive developments in remote sensing and analytical tools and techniques will see the industry define and measure proxies for these processes, but progressively measure them more directly and understand the variations that help define where an ore body will be located. This will revolutionise the entire process.”

Conclusion

With such vast change occurring in exploration across the past 30 years, the possibilities and technologies 30 years from now are almost unimaginable and unquantifiable at this point.

No matter what this holds, it is certain that Australian METS will continue to lead the way to a more sustainable future, driven by further smart innovations, industry collaboration and problem-solving techniques for our toughest challenges. AM

2019

AUSTRALIAN MINING PROSPECT AWARDS

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INDUSTRY COMMENT

A MATTER OF SCALE METS IGNITED IS PARTNERING WITH KPMG AND STATE GOVERNMENTS TO GIVE MINING INNOVATORS A LEG-UP TO THE NEXT PHASE OF THEIR BUSINESSES. AUSTRALIAN MINING REPORTS.

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itching can be both exciting and nervewracking. Indeed, popular films and TV series such as The Pursuit of Happyness and Shark Tank have traded on the inherent drama of the process. But it’s something that is also important in the real world, and mining businesses are no exception.

Programs focused on startup developments are plentiful, but the development of ‘scale-up’ companies is something that is less established in industry in Australia.

Scale-up companies are defined as being more developed than startups, but not as established as large organisations. They fill an important role in the mining equipment, technology and services (METS) sector in Australia.

With this in mind, industry growth centre METS Ignited and accounting firm KPMG have collaborated on a scale-up focused accelerator over the past two years that allows METS companies to build their business case for the best possible audience.

Launched in 2017, in association with the Queensland Government as a pilot program called Igniting METS, the initiative has expanded in 2019.

The 2017 program involved seven Queensland-based companies and one Victoria-based company that sold into Queensland mining operations, working through a 12-week intensive course that used industry mentors.

It culminated in the companies having the opportunity to pitch to a variety of potential clients and investors at the International Mining and Resources Conference (IMARC) in Melbourne.

Now, with further support from the Western Australian Government and National Energy Resources Australia (NERA), the program has a new name to complement its broader focus: the Resources Innovators, Scale-ups and Entrepreneurs (RISE) Accelerator.

“If the participants need access to specific advice in specific areas, we can bring people in from our advisory teams to support that,” METS Ignited acting chief executive officer Ian Dover tells Australian Mining.

“The collaboration, sharing and constructive criticism from other METS companies in the cohort is invaluable.”

METS IGNITED CEO IAN DOVER AT THE RISE LAUNCH.

The program extended to 17 scale ups across both the METS and (for the first time) oil and gas sectors this year. The Austmine and Australian Petroleum Production and Exploration Association (APPEA) conferences in Brisbane will serve as the respective locales for the conclusion of the cohorts’ journey.

“The two events have a slightly different format but the broad objectives are split into decision makers and representatives from major operators and major equipment manufacturers in the industry that they normally would not be afforded the opportunity to engage with,” KPMG Australia’s RISE program director Ashley Brown says.

“The RISE Accelerator allows participants the opportunity to not only build relationships and networks with potential collaborators and clients, but also to work through a program that can result in a considerable improvement to their pitching skills and their confidence in addressing new markets – a small number of the organisations have elected to be at both of AUSTRALIANMINING

those conferences as well.”

From the initial Igniting METS pilot two years ago, RISE has extended into a wider scope to provide a national accelerator pathway for established businesses that require capability development around new products and services.

This extends to the development of regional accelerators for businesses on the rung below the required level for RISE participation.

“In late 2018, we rolled out regional ‘mini-accelerators’ in association with the Queensland Government for METS start-ups and small-tomedium businesses that focused on businesses looking to expand their markets,” explains Dover.

“These accelerators are developed with a smaller format than RISE and are cheaper to run, encouraging regional facilitation.”

The Western Australia-based finalists taking part in the 2019 Accelerator include OrwayIQ; Innovative Blasting Technologies; Gecko Telemetry; A6oN; Global Tenements; Tan Ninety; Beruseal/ Carbontech Composite Systems;

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Digatex; and Chironix.

The Queensland cohort includes Compella Compression; Team Airconstruct/AirConnect; Team Group; Kelly’s Australia; Gen 7 & iRoller Team; Modulr Tech; Magman; and Connec Industrial Power.

The participants run the gamut from automation and Industry 4.0-focused software providers to robotics specialists and machine engineering companies.

Since the participants are scaleups, not startups, they don’t necessarily need to prove the validity of their products, but require access to an appropriate audience often in a new market or an injection of capital to push their designs and technologies forward.

“It gives the participants a structured curriculum and the time to work on their business. They can learn about capital, unique selling positions and staffing and recruitment and growth. It teaches them how to grow and scale up sustainably, which is vital for success internationally,” Dover concludes. AM

INDUSTRY COMMENT

PROFESSIONAL DEVELOPMENT SETS THE FOUNDATION OUT WEST THE AUSTRALASIAN INSTITUTE OF MINING AND METALLURGY (AUSIMM) PUTS FORWARD PROFESSIONAL DEVELOPMENT OPPORTUNITIES TO SUSTAIN THE GROWTH OF THE LITHIUM AND IRON ORE SECTORS IN AUSTRALIA.

LITHIUM AND SPODUMENE EXTRACTION AND PROCESSING PLANT AT RAVENSTHORPE.

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s the world’s largest lithium refinery begins construction in Perth and with a powerful resurgence of iron ore demand since last November, Western Australia is continuing to set itself apart as the mining capital of Australia.

Iron ore continues to be Australia’s largest export, contributing to 39 per cent of the world’s global supply in 2018.

Lithium is described as the metal of the future as governments, society and corporations explore a battery powered world.

The challenge around professional development in a changing sector of growing commodities and opportunities will remain relevant into the future, according to the Australasian Institute of Mining and Metallurgy (AusIMM) chief executive Stephen Durkin.

“Professional development is at the heart of industry growth

and stability,” Durkin says.

“This is why we have an unprecedented amount of AusIMM conferences to be hosted in Western Australia in 2019, including our International Lithium and Battery Metals Conference and our Iron Ore Conference.”

AusIMM is bringing its highly successful Lithium Conference to Perth on July 3-4, focusing on the key theme of ‘metal of the decade’.

Lithium has become an indispensable metal used globally across a range of industries over the past decade, highlighted by the creation and continual improvement of lightweight, efficient batteries.

Durkin says part of the success with the battery metals industry in Western Australia so far has been the collaboration between state government, federal government, industry, academia and professionals to support development, growth and opportunities for lithium in Western Australia.

In the spirit of this collaboration, AUSTRALIANMINING

AusIMM is partnering with Murdoch University to deliver the conference, which will see hundreds of delegates from across Australia and the world gather in Perth to discuss the future direction of lithium on a global scale.

Experts from industry, government and academia will share their knowledge on a variety of lithium-centred topics, including mineral processing, mineralogy, next-generation battery materials, lithium applications and much more.

This two-day conference will cover the entire life-cycle of lithium, focusing on the successes and challenges, the technical evolution, the end usage and the future of lithium and associated metals and commodities, highlighting the synergy of minerals and energy industries and challenges ahead.

The International Lithium Conference will be followed by AusIMM’s Iron Ore Conference from July 22-24, drawing on the strong history of iron ore in Western Australia and the opportunities it

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has provided the state.

The nature of uncertain price trends in the iron ore market has informed this year’s conference theme of ‘optimising value’, and the conference will look at a wide range of topics ranging from operating strategies aimed at reducing costs to social licence from the perspective of the iron ore sector.

“In 2017, nearly half of those employed in the Western Australian mining sector were employed in iron ore,” Durkin notes.

“Conferences such as Iron Ore 2019 provide presentations, workshops and modern discussions that offer ongoing, relevant support that professionals in this space require.

“This conference offers delegates unparalleled opportunities to network with iron ore producers and consumers from around the world and share their experiences.” AM More information on AusIMM conferences can be found on ausimm.com/print/conferences/

TICKETS

AVAILABLE NOW WOMENININDUSTRY.COM.AU P R O U D LY P R E S E N T E D B Y

SPONSORED BY

PRODUCTS

MEA LAUNCHES 50 HERTZ, 500 AMPERE WELDING PACKAGE

ENERPAC AUTOMATES HEAVY LIFTING WITH JS500 JACK-UP SYSTEM

Mobile Energy Australia (MEA) has developed a three-in-one versatile welding package. It comprises a 500 Amp welder, 65 cubic feet per minute (cfm) rotary screw compressor and 38 KVa 50 Hertz generator. The Smartweld package is designed to mine specifications, for use as a standalone multifunction flexible work station that is suitable for all Australian conditions.

The standard Smartweld package uses an Essab Warrior welder and provides plenty of compressed air for arc air gouging with 10 millimetre rods. It features plasma cutting, wire feeder, and MIG and TIG functions to give users work flexibility from one machine.

MEA’s attention to detail is evident in the inclusion of an option for a breathing air package with carbon monoxide monitor to connect to a welding hood. The Smartweld package has also been designed for ease of servicing and saving ongoing maintenance costs.

The fully computer-controlled JS500 Series multi-point incremental jack-up system is engineered to provide optimum safety and precision control for demanding high-tonnage lifting and lowering applications.

It features simple-to-use software with automatic synchronisation of multiple networked lift points. The typical setup involves four jack-up units that are positioned under each corner of a load. A four-unit setup has the ability to lift 2000 tonnes.

Safety is further enhanced by step-by-step operator interaction, while the JS system operates in auto-mode. It is also pre-programmed with emergency alarms that automatically stop lift-based parameters, such as load and stroke per tower and the entire system.

The Enerpac JS500 jack-up system is suitable for lifting heavy machinery and electrical plant, steelwork, road and rail bridges, ports structures and even entire buildings throughout Australia, New Zealand and Papua New Guinea.

• enerpac.com

• mobileenergyaustralia.com.au

ESS ENGINEERING AIR CANNON SYSTEMS SEND REAL BLAST ESS engineers Mick Hutton and James Stievenard have designed a tank and valve that can be retrofitted onto any previously installed valve arrangement – an industry first.

The newly-designed ESS air cannons are available in both internal and external valve arrangements with four- (i4) and six-inch (i6) valves. The direct blast design of the i4 and i6 valves allow stored air in 40, 70, 150 or 250-litre receivers to escape directly through the valve and into a discharge pipe without bends or obstructions.

ESS’s air cannon system is highly effective and safer than those previously available, with features such as fill-on demand, reduced hazard level rating and statutory inspection requirements for larger pressure vessels. The newly designed valve also includes only one moving part with no metal-onmetal contact.

• esseng.com.au

SMALLER FOOTPRINT, GREATER TRANSPORTABILITY WITH BIG BLUE 400X PRO Welding Industries Australia (WIA) has introduced a new engine-driven industrial welder to the Australian market – the Big Blue 400x Pro. Ideal for mining construction sites, the Big Blue 400x Pro includes ArcReach, a feature that gives welding operators control over their settings at the joint site through a wirefeeder or Stick TIG control, rather than having to travel back to the power source to make adjustments. This not only saves time but ensures weld quality and compliance.

WIA product and sales manager for end markets Fuhai Liu says: “Like all Miller products, the 400x is reliable and being a smaller machine, it has a smaller footprint, which provides a real benefit on mining sites where transportability is vital.”

• welding.com.au

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PRODUCTS

EPIROC ROLLS OUT NEX-GEN RIG CONTROL SYSTEM Epiroc’s fifth generation of rig control system (RCS 5) is designed as an evolutionary step towards fully autonomous mining. The RCS 5 for pit viper blasthole drilling features machine-to-machine communication, real time drill plan updates sharing, auto tower angle and integrated camera view advanced awareness.

The RCS 5’s intuitive main menu creates a user-friendly experience that increases productivity, whether operating from a remote location or onboard the drill. This new design enables the operator to focus on the task-athand and switch seamlessly between screens in a well-organised and dynamic environment.

RCS 5, with the new drill plan generator (DPG), allows for quick and easy creation and editing of drill plans on-board the rig or from a remote location.

Its new drilling data screen also features real time depth and penetration rate feedback with histogram for easy in-hole monitoring.

• epiroc.com

KOMATSU SELECTS ABB FOR 100TH AC MULTIDRIVE ORDER ABB will provide Komatsu with the ACS880 multidrive line-up with backto-back installation for its open-pit shovels.

The multidrive features direct torque control (DTC) that delivers fast dynamic performance at low motor speeds and prevents premature ageing of power components.

It comprises one insulated-gate bipolar transistor (IGBT) supply unit, modified with a non-standard direct unit (DC) charging circuit and up to eight motor inverter drivers, which work together to operate the shovel at low voltage AC. The use of individual motor inverters for all drives increases production uptime, while the AC technology provides better overall driver train efficiency than conventional DC applications, according to ABB product manager shovel and dragline Boris Rathmann.

This request comes since Komatsu’s first order for ABB drive technology to support P&H shovels 15 years ago, making it the 100th milestone order.

• abb.com/au

AQUILA OFFERS IMPACT PROTECTION GLOVES HIGH IN COMFORT

HILLIARD CORP SHOWCASES BRAKE MODEL M900SH

Aquila has considered many materials and types to develop high performance impact gloves before arriving at impact pads – primarily made of thermalplastic elastomer (TPE), otherwise known as thermalplastic rubber (TPR), to aid wearability and enhance dexterity.

This helps ensure users keep their gloves on, providing glove comfort when both worn and during put-on/take-off without compromising the operator’s ability to properly handle the equipment.

The TPE/TPR is excellent for impact protection even though more costly compared to PVC, which rapidly ages and hardens, leading to hard, brittle protection and increased hand fatigue over time.

The Aquila TOG4B/G is a TPR impact resistant glove with cut four level (ISO 13997 level E) protection developed for high performance hand protection.

Suitable for the mining industry, the glove delivers cut protection throughout the glove.

For protection against blunt force impacts, Aquila’s TOG6W range offers cushioned silicone protection shielding with an unusually high degree of comfort.

This system includes a “floating” spring-applied, hydraulically released brake designed for both static and dynamic operations in grinding mill installations.

In static operation, the braking system is used to hold the mill during liner replacement and mill maintenance.

In dynamic operation, the system has been designed to operate in two modes: firstly, a controlled application of the brakes to stop the mill rotating at full speed, such as an emergency stop. The second mode is a quick application of the brakes to accurately stop the mill during inching and creeping operations.

The latter is required during incidents of mill bearing lubrication system or power failure.

• hilliardcorp.com

• aquilaglove.com

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EVENTS

CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@AUSTRALIANMINING.COM.AU Copper to the World Conference, Adelaide, June 17-18

Iron Ore Conference 2019, Perth, July 22-24

The 2019 Copper to the World forum will bring together delegates to make business connections, share technical insights, learn new technologies and, most importantly, discuss the latest ideas on the future for copper. Delegates will hear about global trends and market demand for copper; the latest innovations that will drive productivity; emerging opportunities to develop the copper sector; data analytics to unlock mineral assets; and the benefits of diversification for a business. Speakers this year include Dan van Host Pellekaan, South Australian Minister for Energy and Mining; Paul Heithersay, South Australian Department for Energy and Mining chief executive; and industry figures from leading mining companies like Newcrest Mining, BHP and OZ Minerals.

• energymining.sa.gov.au/c2tw

The optimisation of iron ore value is not only the major focus of the resources industry in recent years, but also the key theme for AusIMM’s Iron Ore Conference in 2019. The program will feature 11 keynote speakers who will discuss the importance for iron ore producers to remain flexible and be able to respond to major industry disruptions in a more competitive environment. This conference will cover a range of topics from innovative ironmaking technologies to applications for sustainable mining, and new iron ore deposits to ore characterisation. Delegates will be offered unparalleled opportunities to network with iron ore producers and consumers from around the world and access an exhibition showcasing the latest technology for exploration. An extended program of workshops and tours will be available to delegates preand post-conference, providing further professional development opportunities to conference delegates.

• ironore.ausimm.com

Mine Rehab 2019, Newcastle, June 19-21 The ninth annual Best Practice Ecological Rehabilitation of Mined Lands Conference (Mine Rehab 2019) promotes innovative approaches to best-practice rehabilitation of mined lands. The conference will feature professional development workshops; presentations from the research, industry and government sectors; and mine site tours. Mine Rehab 2019 is organised by the Cooperative Research Centre for Contamination Assessment and Remediation of the Environment (CRC CARE) with the School of Environmental and Life Sciences at the University of Newcastle.

• minedlandrehab.com.au

Diggers & Dealers Mining Forum, Kalgoorlie, August 5-7 Diggers & Dealers Mining Forum is back with its unique combination of mining presentations and large exhibition area, with a delegation made up of mining and exploration companies, mining services companies, investors, bankers and financiers, among others. Highly respected experts will be in attendance to provide insightful commentary to delegates. A world-class entertainment program also ensures that delegates

AUSTRALIANMINING

experience the best of the style and hospitality of Kalgoorlie.

• diggersndealers.com.au PNG Investment Conference 2019, Sydney, August 19-20 The annual Business Advantage Papua New Guinea Investment Conference is dedicated to the promotion of business and investment opportunities in PNG to a global audience. Featuring an unrivalled line-up of influential speakers, the conference will provide a forum where delegates will have the opportunity to hear from investors, innovators and facilitators across key industry sectors – including mining and petroleum – focusing on trends and opportunities in PNG’s growing economy. Attracting some of the most dynamic companies in the Asia Pacific, as well as government backed and global investors, delegates will rub shoulders with thought-leaders, company heads, senior executives, investors and board members.

• pnginvestmentconference.com

and suppliers, government regulators, consultants and research and technology personnel to explore achievements and build a better industry.

• minevent.ausimm.com AIMEX 2019, Sydney, August 27-29 AIMEX will host a free-to-attend conference series which aims to discuss ground breaking topics within the mining industry. The program will deliver operational improvements for all mining techniques and bring together industry leaders and mining experts, allowing visitors the opportunity to create a personalised program that addresses specific areas related to their job function or site. The program will address themes such as economic and political outlook; automation and digital advancements to improve operational efficiency and maintenance; advancements in drilling and blasting, processing and bulk materials handling; fleet performance and tyre management; health and safety.

• aimex.com.au

Mine Ventilation Conference 2019, Perth, August 26-28

Australian Mining Prospect Awards 2019, Brisbane, October 10

Ventilation controls are one of the core risk activities in mines. There have been significant developments in practice and research in recent years to ensure an improvement in safety levels in underground mines. Coupled with this is the re-emergence of pneumoconiosis in mine workers. Mine Vent 2019 calls on expertise from industry and academia to present these developments. The fifth in a series of ventilation conferences will bring together operators, planning personnel, equipment manufacturers

Australian mining’s biggest awards celebration is heading to the Sunshine State for the first time this year. With coal becoming the nation’s biggest mining export this year, the timing couldn’t be better to celebrate the industry’s contribution in Queensland. The 2019 Australian Mining Prospect Awards will take place at Moda Events in Brisbane on October 10, honouring the best and brightest of an industry that prides itself as a cultural and economic cornerstone.

• prospectawards.com.au

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“Taking the Mining Industry into an era of digitalisation and smart mining.

Ensuring Intelligent Blasting processes for optimal blast outcomes.�

Nigel Convey AEL Executive: Asia Pacific

AEL Intelligent Blasting Tel: +61 7 322 101 68 www.aelworld.com