Australian Mining - December 2016

AUSTRALIAN MINING ON SITE A LOOK BACK AT MINING 2016 VOLUME 108/11 | DECEMBER 2016

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COMMENT

IS OPTIMISM IN THE AIR? WHILE THE MAJOR PLAYERS IN THE INDUSTRY MIGHT NOT ADMIT IT, THERE IS A HINT OF OPTIMISM CREEPING INTO AUSTRALIA’S MINING INDUSTRY.

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t has been a while since optimism was a common theme in Australia’s mining BEN CREAGH industry.

Ben.Creagh@primecreative.com.au However, it is hard to ignore the recent buoyancy for the industry that is being documented by commentators and analysts as 2016 nears its conclusion.

In what is a good sign, the key reasons for this boost in positivity are varied.

For PricewaterhouseCoopers (PwC) it is the growing market value of Australia’s mid-tier mining companies that has provided the impetus for the firm to comment that a mining comeback is around the corner.

Ernst & Young (EY) also reported that confidence in Australia’s mining industry is building, with a significant rise in mergers and acquisitions (M&A) activity in the country demonstrating this is the case.

Then there is the Reserve Bank of Australia (RBA), which has forecast much-needed economic improvement in key mining states – Western Australia and Queensland – next year as the downturn softens.

A common link of these uplifting views is the recent rise in commodity prices, which has been led by an iron ore price that was around 40 per cent higher at the end of November than it was at the start of the year.

Copper, nickel, zinc and lead join iron ore as commodities that are showing gains not seen for some time.

Whether these factors are setting the foundation for a better performing industry in 2017 is anybody’s guess.

Just don’t expect to see Australia’s producers, explorers and service providers develop a sudden case of hubris and openly jump on the optimism bandwagon anytime

MANAGING DIRECTOR JOHN MURPHY EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALIST SHARON MASIGE Tel: (02) 8484 0854 Email: sharon.masige@primecreative.com.au CLIENT SUCCESS MANAGER JUSTINE NARDONE Tel: (03) 9690 8766 Email: justine.nardone@primecreative.com.au

soon – considering the ups and downs they have faced in recent years.

While these industry players will be watching the latest industry developments and commentary with interest, their public focus continues to be on innovation, productivity and cost cutting measures that will maintain their competitiveness.

It has been these areas that have been the dominant themes and trends of the mining industry in 2016, and that doesn’t look like changing as mining organisations continue to communicate this focus to the marketplace.

But who knows, if optimism does continue to grow, and then flows through to operational performance, then perhaps we will start to more visibly see how these initiatives are going to benefit organisations and the industry in the coming years.

Only time will tell if, or when, this will happen.

In the meantime, I would like to wish you all a Merry Christmas from Australian Mining and we look forward to your readership again in 2017.

On the front cover of this edition of Australian Mining is a snapshot from Cudeco’s new Rocklands copper mine facility in Queensland. In this issue we explore the new mine and its policy on minimising the use of FIFO workers. We take a look back at mining in 2016 and provide an insight into next year’s metal outlook. We also continue to explore the issues surrounding black lung and expand on a new dust management technology being developed.

Ben Creagh Editor, Australian Mining *Australian Mining would like to apologise for misspelling the name of Micromine founder and director, Graeme Tuder, in the October edition.

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FRONT COVER

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DECEMBER 2016

PRIME CREATIVE MEDIA Suite 303, 1-9 Chandos Street Saint Leonards NSW 2065, Australia www.primecreative.com.au © Copyright Prime Creative Media, 2016 All rights reserved. No part of the publication may be reproduced or copied in any form or by any means without the written permission of the p ­ ublisher.

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CONTENTS

WEAR RESISTANCE ENSURING THE FUTURE DOES NOT WEAR OUT Laserbond’s 2016 highlights

MINING OUTLOOK 2016

10-11

28-29

DRILLING, BLAST & GEOMECHANICS

AUTOMATION & REMOTE CONTROL

30

12

AUTOMATION DRIVES MINING SAFETY How automation increases safety on site

BLUETOOTH MINING SENSORS IN DIAMOND DRILLING A new drilling technology to increase efficiency

MOBILE TECHNOLOGY

AUSTRALIAN MINING ONSITE A NEW MINE BRINGS A ROCKING END TO THE YEAR Cudeco’s official opening of the Rocklands copper mine

A LOOK BACK AT MINING IN 2016 An overview of the highs and lows in precious metals this year

14-15

33

SAFETY

ANDROID TABLET NOW RUGGEDISED FOR THE MINING INDUSTRY Panasonic launches a new rugged laptop

METALS OUTLOOK 2017

UNDERGROUND MINERS AND THEIR OCCUPATIONAL HEALTH & SAFETY ISSUES The final in a two-part series examining the issues around black lung

16-19

34-35

DUST MANAGEMENT MAKING BLACK LUNG BITE THE DUST A new technology to manage dust onsite

INDUSTRY 4.0

20-21

36-37

WINNERS PROFILE

THE FOURTH INDUSTRIAL REVOLUTION IS HERE. BUT ARE YOU READY? How to tackle the shift into the fourth industrial revolution

INDUSTRY OPINION

22

MORE THAN A CONTRIBUTION TO MINING An insight into 2016 Prospect Awards winner Graeme Tuder

38-39

BUSINESS DEVELOPMENT NEW PREMISES, NEW STAFF AND NEW MARKET OPPORTUNITIES WOMA (Australia) opens its head office in Perth

METALS, MARKETS, AND 2017 A glimpse into the future of metals in 2017

ROOM TO GROW AT ATLAS COPCO Atlas Copco discusses the company’s future outlook

CORROSION

24-25

CORROSION - THE PROBLEM GRATING AWAY THE AUSTRALIAN INDUSTRY Exploring the costly effects of corrosion

40 SENSORS UNLOCKING YOUR TRAPPED DATA WITH IO-LINK Monitoring made easier with sensors

MAINTENANCE AND MONITORING

26

42

ADG ENGINEERS INTEGRATED SOLUTION FOR MACLEAN MANUALS Using software to streamline maintenance

REGULARS

INDUSTRIAL COMMENT

NEWS 8

PRODUCT SHOWCASE 44

AUSTRALIANMINING

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DECEMBER 2016

EVENTS 46

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INDUSTRIAL COMMENT

AUSTRALIA CAN’T BANK ON AN IRON ORE TRUMP BUMP IN THE LONG TERM DONALD TRUMP’S FISCAL POLICIES COULD MEAN COMMODITIES RALLY IN THE SHORT TERM, BOOSTING THE AUSTRALIAN GOVERNMENT’S BUDGET, BUT THIS COULD BE UNDONE IN THE LONG TERM. LEE SMALES, ASSOCIATE PROFESSOR, FINANCE, AT CURTIN UNIVERSITY WRITES.

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lobal growth and movements in commodity prices have important implications for the Australian economy.

A significant component of economic growth and tax receipts derives from the sale of commodities, and so generally rising commodity prices are a positive for Australia.

The recent 2016-17 Federal Budget assumed an iron ore price of US$55 per tonne (currently US$79) and a thermal coal price of US$52 per tonne (currently US$105). Treasury also forecast that a US$10 per tonne increase in the iron ore price would raise nominal GDP by

US$6.1 billion, and provide an additional US$1.4 billion in tax receipts over the next year. As a result, the government will receive a significant budget boost in the near term.

As a Donald Trump victory became increasingly likely, investors were initially cautious. Risky assets, such as stocks, were sold and funds flowed into safe havens such as government bonds and gold. Within hours this reaction was reversed as investors considered the broader repercussions of the result.

Gold has proven to be one of the more volatile assets; the Trump victory initially pushing prices almost five per cent higher, but falling nine per cent from a peak a week before. The price of

AUSTRALIANMINING

commodities that are typically related to economic output, such as base metals and energy, have surged as markets hope that Trump will enact a fiscal expansion to boost growth.

Copper has increased in price by more than seven per cent. More impressively, iron ore has risen nearly 19 per cent.

However these gains could be short lived as volatility sets in, in the long term.

Trump policies and commodities

Much of the volatility in commodity prices relates to uncertainty surrounding what economic polices Trump will actually seek to implement once he is inaugurated in January 2017. This task is made all the more difficult by the lack of honesty during the campaign and backtracking on policies in the days since. Until there is some resolution regarding Trump’s specific plans this market uncertainty will last – likely benefiting the gold “safe haven”.

Trump has already signalled that he will bring an end to fiscal restraint. He has vowed to drastically reduce taxes, increasing the federal debt by US$7.2 trillion in the process, and pledged to invest US$550 billion in infrastructure.

Both measures are meant to boost growth, and both would be positive for base metal prices.

Trump is also not a believer in climate change and is intent on using more fossil fuels. This could be a positive for commodities such as coal (the price of which has more than doubled since the start of the year) and crude oil. However,

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the outcome is not clear as the promised removal of environmental regulations may also serve to increase oil & gas drilling in the US and produce a price depressing glut.

Greater demand for coal would clearly be beneficial for Australian coal miners (if not the environment). Although the prospect of lower oil prices would not be good news for operators of major LNG projects still struggling to break even, at least households would gain from lower fuel prices.

The more important factor for long term commodity prices is the risk that a Trump Presidency provides for global trade should his policy of protectionism be enacted. If this happens, then global growth will be adversely affected which would be bad news for commodities.

In Australia, this could push the Federal budget further into deficit, reduce economic growth, and increase unemployment (or at least ensure that wages continue to stagnate). Clearly, this would not support the Turnbull mantra of jobs and growth.

A “trade war” also could mean geopolitical tensions will increase, particularly between the US and China, and this would be positive for precious metals such as gold.

At the very least, the coming period will provide greater geopolitical uncertainty that may delay corporate investment, hamper economic growth and put pressure on commodity prices. AM This article was originally published on The Conversation.

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NEWS

THE LATEST MINING NEWS AND SAFETY AUSTRALIAN MINING PRESENTS THE LATEST NEWS AND SAFETY AFFECTING YOU FROM THE BOARDROOM TO THE MINE AND EVERYWHERE IN BETWEEN. VISIT WWW.AUSTRALIANMINING.COM.AU TO KEEP UP TO DATE WITH WHAT IS HAPPENING. PROPOSED WA IRON ORE TAX COULD COST THOUSANDS OF JOBS The Minerals Council of Australia (MCA) has savaged the Western Australian Nationals’ proposed iron ore tax, saying it commissioned a report by Deloitte Access Economics that found the new tax would cost 7,200 jobs, according to the ABC. However, Nationals leader Brendon Grylls, who is pushing for a lift in production taxes for BHP Billiton and Rio Tinto from 25 cents to $5 a tonne, claims it will raise an additional $7.2 billion over four years.

Grylls has dismissed the research by Deloitte Access Economics claiming it was “paying for misleading analysis of the policy”.

The Deloitte report, WA Iron Ore Royalty Analysis, found the proposed tax would see the Australian economy shrink by $2.9

billion per year as a result of a tax that is supposed to raise $2.3 billion.

At the same time, the research also found the WA economy would be the biggest loser and there would be a 4.3 per cent reduction in employment across the Pilbara, the ABC reports.

According to the news report, MCA chief executive Brendan Pearson said, “In raising all that extra revenue, it will harm one of Western Australia’s most important industries, that iron ore sector, and cost jobs in WA itself, so it’s really a no-brainer in terms of bad ideas.”

For his part, Grylls said that he “absolutely refutes” the job loss figures quoted in the report.

Australian Mining reported last month that

ADANI AIMS FOR CARMICHAEL MINE CONSTRUCTION NEXT YEAR Adani expects the Carmichael project to begin construction next year, following the Queensland Government’s decision to exempt it from new water legislation.

An Adani spokesperson said the company hoped to commence the project in the September quarter, according to The Gladstone Observer.

This comes after the government passed new laws – an amendment to the Environmental Protection (Underground Water Management) and Other Legislation Amendment Bill – ordering all mines currently under development to obtain a groundwater licence.

The Carmichael mine, however, was exempt, through a new amendment outlining that companies that have already undertaken an environmental impact statement and the Land Court still need a licence but would not be subjected to the public objection process.

Adani said the amendment recognises efforts to manage the impact on water, avoids duplication, and cuts down on delays.

“We are very encouraged the government did recognise the balance between its commitment on water licensing and acknowledging that this work has already been done in our case, and that the new provisions as originally drafted risked unintended duplication and activist appeals,” Adani Australia CEO Jeyakumar Janakaraj said.

An Adani spokesperson said, “The water legislation was a significant road block for us, and now that it’s been resolved, we can focus on working through more machinery.”

However, the Association of Mining and Exploration Companies (AMEC) expressed concern over the effects of the bill and its negative impact on investor confidence.

AMEC regional manager Les Cox said it would increase environmental requirements on both large and small projects.

“The additional and ‘strengthened’ assessments to be undertaken as part of the environmental authority application are still largely undefined and would seem to largely duplicate the already extensive reporting requirements at the expense, literally, of the smaller explorers and operators,” Cox said.

“The possibility of additional and more lengthy delays in the processing and granting of approvals will only serve to increase the risk profile of the resources industry in Queensland to explorers, operators, investors and financiers.”

job losses were just one issue bedevilling the proposed tax. According to that story, under Section 90 of the Australian constitution, states are not allowed to introduce taxes on the production, manufacture, sale or distribution of goods.

Moreover, Murdoch University law lecturer Lorraine Finlay told the ABC that the production rental levy [i.e. tax] “is really an excise duty dressed up as a levy and if the High Court held that that was the case, then the levy would be constitutionally invalid.” So even if the tax was not unconstitutional, which by all accounts it seems to be, then it could also be uneconomical.

In other words, a lose-lose situation for all involved.

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

QLD GOVT PUSHES BAN ON 100 PER CENT FIFO WORKERS Queensland natural resources and mines minister Anthony Lynham has introduced to state parliament proposed laws banning 100 per cent FIFO workers on new large resource projects.

The requirements will apply to all large resource projects 100km or less from the regional centre and are designed to give locals the choice to work in nearby projects, ensure local businesses have the opportunity to win contracts and be part of the supply chain, and help protect the health and wellbeing of workers.

The proposed laws will also make it an offence to advertise jobs in a way that prevents residents from regional communities from applying.

Lynham told parliament, “It is only right that local workers get an opportunity to be considered for these jobs and are not discriminated against because they are local residents.”

The laws come off the back of a Parliamentary Committee inquiry into FIFO work practices in the resource sector which took into consideration a range of factors including the the health impacts of workers and their families, and the commuting practices of FIFO workforces.

However, the Queensland Resources Council is opposed to them.

“There is no justification for this sledgehammer approach when, of the nearly 50 operating coal mines in

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Queensland, there are just two FIFO mines, and those were approved by the Bligh Labor government,” QRC chief executive Michael Roche said.

“It is simply ludicrous to ban 100 per cent FIFO operations if a proposed new mine is within 100km of a community as tiny as 200 people.

“QRC accepts that all parties in the Queensland parliament do not support future 100 per cent mining operations where there are nearby towns that have a capable workforce, however we do not support any retrospective regulatory action against existing mines.”

Roche went on to say that in the midst of recovering commodity prices, more red tape would add extra costs to companies.

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WEAR RESISTANCE

ENSURING THE FUTURE DOES NOT WEAR OUT LASERBOND RECENTLY HELD THEIR AGM, DISCUSSING THE COMPANY’S HIGHLIGHTS OF THE YEAR. SHARON MASIGE SPOKE TO CHAIRMAN ALLAN MORTON ABOUT THEIR RECENT PARTNERSHIPS WITH THE UNIVERSITY OF SOUTH AUSTRALIA AND THEIR VISION FOR THE FUTURE.

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fter 25 years and still going strong, Laserbond has continued in its effort to become a globally recognised leader in innovative advanced surface engineers, products, services, and technologies. Rounding out 2016, they have experienced even more success, including a 10.2 per cent growth in export sales invested in the development of new products and customers both domestically and internationally.

Collaboration is king

One of their biggest achievements so far this year, however, has been their work in South Australia. They recently received what Laserbond chairman Allan Morton described as “small but highly appreciated” grants

from the state government to enhance their manufacturing capabilities.

Morton spoke highly of the southern state, particularly in terms of its manufacturing knowledge and the close proximity of its hard rock mines to the company’s new facility.

“A lot of our advanced materials and advanced additive manufacturing suits that so we have a very high fit with what South Australia was looking for - in fact what all of the country should be looking for,” he said.

One of the major highlights of the year however was the company’s collaboration with UniSA’s Future Industries institute develop - amongst several other innovations - wear life technologies.

“We’ve already recognised there is an opportunity to extend wear life, if we extend wear life we reduce the cost of mining. The unit cost or the

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total cost of ownership - we can drop that - and if you drop the total cost of ownership, everything becomes more productive,” he said.

This comes on the back of the release of the national Ten Year Sector Competitiveness Plan for the METS industry. Released at this year’s International Mining and Resources Conference (IMARC), it provides a roadmap for the sector to help increase global competitiveness, including a focus on collaboration between METS companies and researchers and the development of a stronger brand identity for Australia’s METS sector.

On a recent trade mission to Canada with Austmine, Morton realised the importance of developing a strong Australian brand to spearhead the country’s innovation capabilities.

Attending with a team of six, he said

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each company was very innovative and had to do seven-minute presentations to potential customers.

He acknowledged that the team did not have a strong brand around being ‘smart Aussie METS’.

“What really got me is once people thought ‘Australia, you guys are really innovative, you guys are really good.

But we didn’t have a strong brand around that,” he said.

He then pondered what opportunities could arise if Australia did enhance their brand in this space.“Now to me it was a ‘what if’, which is my favourite question. What if we had a strong brand? That we were packaged like that?”

The Living Lab

While on the trade mission Morton also got to experience working in a living minesite or ‘living lab’ where

WEAR RESISTANCE

technologies can be tested without risk of affecting operations or injuring workers. He mentioned the Northern Centre for Advanced Technology (NORCAT) in northern Ontario which enables researchers to test particular technologies.

“Norcat is an operating mine but it provides all of these locations for innovative companies to work in,” he said.

“For example when we get out initial trials on our down the hole hammer, we prove we can get a 300 per cent extension in life, but the thing is we couldn’t run them to destruction. When you’re in an operating mine you’ve got the production schedules that have to be met or you can’t leave a piece of steel in the ground because it can damage downstream processes. But if you’ve actually got a living lab, you can actually go do this. Now you can literally break something, then go down, fish it out, and have a look at it in your own time.”

In collaboration with Canadian company Boart Longyear South Australia and UniSA, the company also has plans to build a living lab.

He also identified the benefits of a living lab when identifying increasingly difficult to find ore reserves.

“The quality of our ore reserves are declining and they’re harder to get at,” he said. “To get more mines you have to drill more holes, so you’ve got to find better places to drill more holes and you’ve got to drill the holes cheaper. So the ‘what if’ question is what if we could actually make the stuff that drills the holes last longer.

So that takes you to the living lab.”

‘Three things we know’

Morton emphasised the three key aspects of wear the company knows very well to position themselves as a strong leader in technology development.

“We know a lot about tribology; we know a lot about how surfaces wear and the wear mechanisms that make it wear,” he said. He identified the financial burden of the different types of wear mechanisms, particularly of corrosion, which he said represented approximately 3.7 per cent of the global GDP. He went on to say that between 18 and 32 per cent of global corrosion can be prevented with known technology.

“The second thing we know - we know a lot about advanced metallurgy.

We’re very good at figuring out [and] tailoring an alloy for a specific duty so if we know the wear characteristic that’s occurring in a pump or in a drill

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or inside a continuous mine, we can start to identify what’s causing the wear and what happens if we tailor an alloy specifically for that.”

“The third thing is we’re very good at understanding how to apply it [the alloy]. So you know what’s causing the wear, you know what metals survived the wear, now you gotta figure out how to attach it to it. So depending on the load conditions, you can design materials to be metallurgically bonded, mechanically bonded, vacuum fused or whatever we choose to do.”

Beyond the valley of death

Laserbond has found collaboration to be one of their greatest weapons to help them across the proverbial ‘valley of death’ - the period of time between when startups begin receiving funds and when they start gaining revenue. Morton said it was also something the SA Government and UniSA had figured out, which was proving beneficial for all parties involved, particularly when it came to innovation.

“Innovation used to be about R&D, and pure R&D and all the IT stuff and lots of great ideas were locked in a cupboard because the ideas were only able to get to the edge of the valley of death. They

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didn’t know how to get across,” he said.

“So when you add industry collaboration or strategic partnering together with that, you’re shifting the relationship - you’re not a vendor and you’re no longer perhaps a key supplier - you’re actually pioneering things together, you’re partnering, you’re having an alliance. It opens a huge opportunity.”

“And that’s why I think DSD (the South Australian department of state development) has done a really great job and I think that the department of innovation and science has done well.”

What the future holds

Morton said the company was on track for a forecasted 30 per cent growth this year. They are also planning to invest in a new laser manufacturing technology cell which could open doors for them in the resources sector - allowing them to give greater coating coverage on larger products. Although Morton did not want to give too much away of what the company has in store for next year, he remained rather optimistic over the future.

“There’s no absolute on the future, you just position yourself as best you can until you get there.” AM

AUTOMATION AND REMOTE CONTROL

AUTOMATION DRIVES MINING SAFETY DR. NEIL SLATCHER, RESEARCH AND DEVELOPMENT MANAGER AT 3D LASER MAPPING, SPEAKS TO AUSTRALIAN MINING ON AUTOMATION IN THE MINING INDUSTRY.

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rom autonomous vehicles to robotic drilling, automation technology is beginning to revolutionise the mining industry. Both equipment automation and automation software programmes are allowing mine operators to improve efficiencies at the same time as improving safety in high-risk environments.

Many see automation simply as a threat to job security, but high levels of advancement in automation technology comes at a time where sector downturns and market volatility have dictated the need for optimising existing operations, rather than exploring expansion and new opportunities. To some extent, this has meant reducing labour burdens, though often this same technology not only increases efficiencies, but also makes conditions safer for previously at-risk workers. By embracing automation technologies, many mining operations have never been closer to becoming a ‘zeroharm’ environment.

Light Detection and Ranging (LiDAR) is one such technology allowing operators to reduce the human risk factor in dangerous situations. Commonly used for surveying and the creation of highresolution maps, LiDAR systems are increasingly being integrated into self-driving vehicles for both commercial and consumer use, allowing vehicles to navigate through difficult terrain and detect obstacles.

For example, Japanese construction equipment supplier Komatsu, is currently using its Autonomous Haulage System in Rio Tinto’s Mine of the Future, which has had a direct impact on increasing efficiency and productivity at the site, as well as removing workers from hazardous parts of the mine.

Mobile and terrestrial LiDAR scanners are also playing their part in the journey towards full automation.

Scanners enable business and other critical data to be collected for the rapid evaluation of geological hazards and stockpile control. For monitoring applications, LiDAR is able to capture high res data to determine displacement on a scale of metres down to millimetres. This gives a broader understanding of slope dynamics prior to large scale failures,

as well as help determine measures for future mitigation of risk.

As with most technological advances, LiDAR systems have now become small enough and light enough to be portable. Mobile mapping of geological features and stockpiles can be carried out via wearable systems such as ROBIN, which allows for faster data capture where results are needed within critical timeframes. ROBIN can also be mounted to a vehicle, helicopter or UAV, minimising the safety risks for personnel further by capturing accurate data remotely, even in the most extreme conditions.

The benefits of remote capture are clear in a mining context – the ability to gather safety critical data without exposing workers to hazardous conditions. Yet it is only when combined with autonomous software programmes that this data becomes invaluable to the future of mining operations. Solutions such as SiteMonitor allow for the advanced analysis of critical infrastructure via repeat, time-series laser measurements.

Inaccessible or hazardous areas can be safely and continuously monitored, allowing decisions to be made quickly and without putting human lives at further risk.

Most automated monitoring systems allow for customisation of alarm criteria depending on the application, and the resulting data can be used to monitor any acceleration in movements and 3D changes over time which can often be precursory behaviour of slope failure. The integrated geospatial analysis tools enable planning teams to track displacement and changes in rock mass more accurately. In 2013, we embarked on an innovative research project with Durham University to explore the benefits of using rockfall analysis as an indicator of total failure. Using a terrestrial scanner and SiteMonitor software, data is continually collected at a resolution of 0.01 metres, and all rockfall is quantified by volume, with the smallest detectable rockfall registering at 0.00001 cubic metre.

The project revealed that mean monthly rockfall activity showed a correlation to the size of the final failure. By monitoring the number and magnitude of events, it is possible to identify potential failures and allow AUSTRALIANMINING

for preventative measures to be put in place or at least warn of a critical situation before it has life-affecting consequences and a severe impact on operations.

Automated solutions such as SiteMonitor are not only powerful tools to assist in creating a zeroharm environment, they also help to provide vital business intelligence to streamline processes and increase efficiency. By creating 3D volumetric models of stockpiles, mining operations can then measure and distribute its resources more effectively. Automated remote stockpile management cuts down the time spent manually monitoring levels, reducing the labour burden and physical exposure to risk.

The mining sector has faced some complex challenges in recent years and as with all industrial

businesses, the adoption of new technology can be a slow and complex to implement. The introduction of automated technologies, including sensor systems and software, does not have to be disruptive, and often they can be integrated into existing infrastructure. Mining operations are on an automation curve, so whilst businesses are considering how technology can improve efficiency, it seems logical to also consider how automated systems can be exploited to get closer to the elusive ‘zeroharm’ environment and improve intelligence about changes in the physical environment.

Mining may never be a fully automated industry, yet lessons in both safety and sustainability can be learnt by applying autonomous technology to measure and monitor critical assets. AM SITE MONITOR ASSISTS IN CREATING A ZERO HARM ENVIRONMENT

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, D E E N U .

O T Y E R R E ER N. V E F O T N A O H IS H W D IT RC A N I E F ES TH

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MINESITE VISIT

A NEW MINE BRINGS A ROCKING END TO THE YEAR AS 2016 HEADS TO A CLOSE, AUSTRALIA’S RESOURCES SECTOR IS BEGINNING TO SEE GREENSHOOTS ONCE AGAIN, WITH SEVERAL ANNOUNCEMENTS OF MINE OPENINGS AND RE-OPENINGS. ONE OF THESE NEW MINES IS THE ROCKLANDS COPPER MINE WHICH RECENTLY CELEBRATED ITS OFFICIAL OPENING. AUSTRALIAN MINING JOURNALIST SHARON MASIGE ATTENDED THE CEREMONY.

W

ith turbulent market conditions often striking hard at Australia’s resources industry, the recent jump in coal price presented a ray of hope for companies and potential workers alike. It has seen the revival of shuttered mines both in Australia and overseas, such as Glencore’s Integra underground coal mine in NSW and its Collinsville mine in Queensland. But it’s not just coal miners that are reaping the rewards, as the announcement of new mines such as Rocklands shows more far reaching benefits.

Located around 15km west of Cloncurry in north-west Queensland, Rocklands - part owned by majority shareholder China Oceanwide International - is expected to create more than 200 jobs for the region, as well as hundreds more from the economic flow on effects.

Amid the near-stifling heat was an air of undeniable excitement from both Australian and Chinese shareholders alike, who were present to witness the event.

Speaking at the event opening, Cudeo managing director Dr. Dianmen Chen said it was a historic occasion for the company, with the opening of their first mine.

“This marks our company’s successful transition from explorer to developer,” he said.

High grade copper

The overall project contains 11 ore bodies - one of the most significant being Las Minerales - which contain high grades of native copper. It also features a three million tonnes per annum processing plant with a crushing circuit, high pressure grinding rollers (HPGR), scrubber, gravity circuit, ball mill, floatation circuit, a filter plant, and a tailing storage facility.

Peter Hutchison, a member of Cudeco’s board of directors, said one of the major challenges during development was determining the grade of the mine.

“The large nuggets of native copper that are present that makes it very hard to estimate the amount that’s in the ground,” he told Australian Mining.

Even more difficult, he said, was finding a way to process the amount of native copper they had.

“The other challenge [was] being able to process that material and recover it efficiently. Most copper mines have some native copper, it’s only a small amount. A bit more and it’s difficult to deal with.

“But in our case, it’s such a large proportion of the ore body that we

AUSTRALIANMINING

had to establish a process to be able to move it in a saleable from.”

Cudeco general manager of operations, Mark Roberts, further emphasised the challenges of processing native copper, adding that several mines do not have the money to invest in smelting it.

“The native copper is quite impressive but it is quite difficult to process,” he said.

“I’ve never seen native copper like this in my life.”

The site’s processing facility is also home to a cobalt/pyrite and a magnetite circuit, however these are yet to be commissioned particularly due to the low cobalt price.

“Cobalt product is not generating a lot of revenue so we’re not commissioning those plants in this point in time,” Roberts said.

This was echoed by Hutchison who said when they first settled on cobalt, it was $150 a pound but now it was around $10.

“Cobalt prices are quite depressed at the moment,” Hutchison said.

Prior to the opening, the mine already achieved significant milestones this year. On October 17, it sent its first shipment of native copper via the Port of Townsville to China, followed a few weeks later by the first shipment of sulphide copper concentrate.

Now the company is on track to head into full scale production.

“We have now reached an important, more so critical, stage of ramping up our production in capacity,” Chen said during the opening.

But look back a bit further and the journey to development was marred by a few hiccups, namely by founding member and former CEO Wayne McRae whose colourful comments about the potential of Rocklands made more than a few headlines.

His time at the helm of the company ended last year after he was ousted by Chinese investors who claimed they were no longer confident in his ability to successfully manage the company.

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A commitment to the local community

One of the most notable features of the mine is the company’s commitment to having a no fly in fly out policy in an attempt to increase local employment.

“Due to our policy of not encouraging fIy in fly out workers, the vast majority of our workforce are based here in Cloncurry. This means more economic benefit for Cloncurry,” Chen said.

This mirrors the Queensland government’s recent push to ban 100 per cent FIFO workers on large resource projects. Tabled by the state’s natural resources and mines minister Anthony Lynham, the proposed law will apply to projects 100km or less from the regional centres. It is designed to protect worker health and wellbeing and give locals the opportunity to seek employment closer to home.

Member for Mt Isa, Rob Katter, was

MINESITE VISIT

pleased with the decision to minimise FIFO workers at Rocklands as it would benefit nearby communities.

“We love having development out here as long as there’s payback into the local communities and payback is jobs that we want and desperately need,” he said.

With a new mine comes not only jobs, but a potential boost to the state and national economy as well. China’s investment in Rocklands is another peg in a string of resources agreements with Australia, reinforcing its place as the country’s biggest trading partner.

Counsul Jian, director of the economic and commercial office of the Chinese consulate, said China’s investment in Australia almost breached $76 billion, with more than 60 Chinese companies investing in Queensland.

Speaking at the opening, she said, “I’m glad to see my Chinese colleagues working very closely with the Australian partners and I really hope that we can work even closer in the future for the prosperous development of this copper [mine].”

China’s investment in the mine LAS MINERALES

AUSTRALIANMINING

also comes as part of their country’s ‘One Belt One Road’ (OBOR) policy which aims to develop stronger economic ties with Australia as well as Eurasia and Africa. Its goals include strengthening investment and trade relations and developing infrastructure and facilities. The ‘Belt’ refers to linking countries in Central Asia to China, as well as a long term mission of creating railways to connect China to Europe. The other part refers to a maritime ‘Road’ through the development of key ports to provide more access through the Indian Ocean.

While the initiative may pave the way for greater cooperation with China, it has also been criticised for its use as a means to potentially dominate smaller economies.

Nonetheless, the Australian government is welcoming the investment, as minister acting for the premier on north Queensland, Coralee O’Rourke, told Australian Mining it provides confidence for other investment opportunities in the state.

“This is going to provide the opportunity for people to start thinking ‘Okay this is where we want to invest’,” she said.

However, there are still some issues yet to be resolved now that the mine has opened.

Katter pointed to the monopoly of power supply in the area as it is not connected to the national electricity grid. While the site recently installed a powerline, supply is still one of the issues to be assessed. Katter further mentioned the possibility of installing a rail line at the site as well.

To assist with these, and the wider resources industry issues, the state government recently established the Northwest Minerals Task Force - a combination of mining companies and explorers, industry peak bodies, government, and traditional owners

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that sets out recommendations and identifies key opportunities to increase mining in the state.

“We know that the new wave of exploration activity and innovative approaches will be needed to unlock this new generation of mines which is why we have established the north west minerals province task force and are currently considering a series of recommendations from the taskforce to help overcome barriers and challenges to exploration and production in the region,” O’Rourke said.

Resilience now and into 2017

The company’s long term plan is to expand into Phase Two of Rocklands project, extending into a 30 year mine life. This further signals a renewed confidence in the sector.

The opening of Rocklands reflected the resilience of people in the north west, with Katter comparing Cudeco to Mt Isa mines and its 95-year life. He commented on the rewards that can happen if companies remained with developments throughout its difficulties.

“That’s what can happen if you push ahead and you’re aggressive with these developments and you stick with it,” he said.

“It embodies the spirit of the people in the northwest and how we’ve come to be out here in the first place; anything from the single miners themselves to the big developers, that’s what you gotta do if you wanna make something out here. I think Cudeco is a pretty good example of that.”

Katter went on to say, “This is not a finish line here at all, this is a starting point for development in the North West.”

With the year coming to a close, perhaps 2017 will see even more mines in the region. AM

SAFETY

UNDERGROUND MINERS AND THEIR OCCUPATIONAL HEALTH & SAFETY ISSUES THE SECOND AND FINAL OF A TWO-PART SERIES EXAMINING THE ISSUES SURROUNDING THE RESURGENCE OF COAL WORKERS PNEUMOCONIOSIS, OR BLACK LUNG, IN AUSTRALIA. EMERITUS PROFESSOR ODWYN JONES AO, FELLOW OF THE AUSTRALASIAN INSTITUTE OF MINING AND METALLURGY (FAUSIMM), WRITES.

The recent outbreak of CWP amongst Queensland’s coal miners is indicative of a very serious and growing challenge to those responsible for the “Duty of Care” of coal industry’s underground miners. The existing regulatory standards prevailing in Queensland and New South Wales of 3.0 mg/m3 and 2.5 mg/m3 of respirable coal mine dust respectively are well above the standards recently enacted in the USA. The Queensland Government’s recent review of its coal mine workers’ health scheme revealed many systemic failures and deficiencies including lack of appropriately trained medical advisors; too few highly qualified B-readers for interpreting X-rays resulting in large numbers of worker medicals waiting assessment; poor conduct of spirometry with poorly calibrated equipment and use of untrained staff; and questionable decisions regarding precautionary measures for those at high risk of excessive dust exposure As stated by Dr Anthony Lynham, Queensland’s minister for natural resources and mines, “every worker has a right to go to work and return home safe and healthy”, whilst emphasising the three key action areas of prevention, early detection and a safety net for CWP sufferers.

Prevention requires more rigorous attention to the suppression of respirable dust on power loading longwall faces and, if having done so, the situation is still unsatisfactory, exposed workers need to be supplied with personal protective equipment.

Early detection requires prompt attention to the results of spirometry testing and interpretation of X-rays by suitably qualified persons. The need to diagnose early signs of disease is paramount and those workers affected must be removed from tasks exposing them to high dust concentrations and if necessary from underground mining.

medical journals. As an example here are a couple of extracts from one such article: • Primary Care Physicians should be aware of the acute and chronic deleterious health effects from diesel exhaust and its potential to exacerbate other chronic disease states.

• The majority of patients who present to urban primary care clinics and emergency departments will have had significant chronic exposure to diesel exhaust because most use and/or live near busy streets and highways.

Finally, the safety net for CWP sufferers requires appropriate employment opportunities for those able to continue working and appropriate care facilities and services for those unable to do so.

The health hazard of diesel engine exhaust exposure in underground mines

If anyone doubts the seriousness of health risks to those living and/or working in environments polluted by diesel exhaust products, they should read one of many articles published on the topic in one of the many

Bearing in mind such serious community concerns one wonders how much more serious are the health challenges facing those working in underground mines where dieselpowered equipment predominate.

The extent of the challenge to the global mining industry was emphasised in 2012 following the publication of the National Institute for Occupational Safety and Health (NIOSH) and the National Cancer Institute’s (NCI) 20-year “Diesel Exhaust in Miners Study” which involved over 12,000 miners in eight US non-metal underground mines.

0.25 Normallized Concentration (1/Ctotal)dC/dlogDp

Urgency of dealing with the Coal Workers Pneumoconiosis (CWP) challenge in Australia

Nuclei Mode - Usually forms from volatile precursors as exhaust dilutes and cools

0.2

Fine Particles Dp < 2.5 µm

Nanoparticles Dp < 50 mm Ultrafine Particles Dp < 100 mm

0.15

In some cases this mode may consist of very small particles below the range of conventional instruments.

Dp < 10 mm

0.1

PM10 Dp < 10 µm

Accumulation Mode - Usually consists of carbonaceous agglomerates and absorbed material Coarse Mode - Usually consists of reentrained accumulation mode particles

0.05

0 1

100

10

1,000

Diameter (nm) Number

Surface

Mass

FIG. 1. TYPICAL DIESEL ENGINE PARTICLE SIZE DISTRIBUTION BY MASS, NUMBER AND SURFACE AREA. Dp = PARTICLE DIAMETER, CTOTAL = TOTAL CONCENTRATION

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10,000

SAFETY

It reported that the underground miners most heavily exposed to diesel engine exhaust fumes were three to five times more likely to develop lung cancer than those exposed to the lowest levels.

However, these were non-metal miners, whereas our concern is for underground miners who in addition to being exposed over extended periods to diesel exhaust fumes, could also be variously exposed to radon daughters, asbestos fibres, crystalline silica, arsenic and/or nickel compounds, all of whom are listed by the IARC as “Carcinogenic to humans”.

Soon thereafter the World Health Organisation’s (WHO) International Agency for Research on Cancer (IARC) changed its categorisation of diesel exhaust from Group 2A to “Carcinogenic to Humans, Group1”, based on the results of numerous epidemiological and toxicological studies over the previous decade.

In a detailed analysis of this challenge as it affects underground miners in Western Australia the author highlighted the fact that in the older, less efficient engines more soot particles are produced. These soot particles whilst unwanted, serve a useful purpose by providing free surfaces for the condensed gases which formulate in the dilution zone beyond the tailpipe as well as adsorbing unwanted gaseous products. Researchers investigating such conditions in the dilution zone have clearly identified a tri-modal distribution of particulates as shown in Fig 1.

In analysing this challenge as it affects underground miners in Western Australia, reference was made to a number of major contributing factors including: • One of the many complexities associated with assessing the hazard to humans of working in close proximity to diesel engines is the manner conditions vary with different engine types. As pointed out in a recent research paper, diesel engines have progressed from traditional technology (< 1986) for which particulate matter was uncontrolled through transitional systems with progressively advanced technology resulting in lower particulates, NOx and hydrocarbon emissions to “new

diesel” technology characterised by integration of wall-flow diesel particulate filter and diesel oxidation catalysts.

• The complex physical and chemical dynamics occurring in the dilution plume as the exhaust products cool in the ambient air beyond the tailpipe. With the newer more efficient engines which produce significantly less, highly adsorbent, soot particles - the discharged toxic gases cool and condense on available surfaces, or if supersaturated, nucleate to form a new range of ultrafine nano-scale volatile organic compounds (VOCs). These, due to their number, surface area and toxicity, also present a serious health hazard.

• The predominance of cascading, or series ventilation systems at Western Australian’s underground metal mines compound the problem of achieving satisfactory air-quality control at work sites.

Series ventilation systems involve the transport of ore and waste rock in main intake airways, using diesel powered trucks (up to 600 kW), thus continuously polluting the fresh air being drawn into the mine with diesel engine exhaust emissions. That apart, each mine has numerous other dieselpowered items of equipment such as personnel carriers, boggers and jumbo drill-rigs; all adding to the in-mine pollution. It is within this environment that underground miners spend up to 12 hours each working day.

• The inadequacy of existing exposure metrics, which currently only involves adhering to the guideline of maintaining the mass of elemental carbon below 0.1 mg/m3 for an eight hour shift. That apart, particulate/aerosol size and surface area defined as “lung deposited surface area” (LDSA) is a much better measure of the health impact of nanoparticles and ultra-fine aerosols. But whereas the LDSA is a better measure of conditions within which miners work, increasing efforts are also being directed to identify biomarkers which personalise the assessment, thus indicating the influence of exposure on the health of each individual.

• Diesel engine exhaust emissions AUSTRALIANMINING

include both carbonaceous particulates and a range of gases of which two are particularly difficult to control and manage; nitric oxide (NO) and nitrogen dioxide (NO2).

Both can cause short-term (acute|) and long-term (chronic) pulmonary and cardiac health problems Of these, NO2 is extremely toxic, as evidenced by its recently reduced eight-hour TWA by the American Conference of Government Hygienists (ACGIH) from 3 ppm to 0.2 ppm.

• Whilst there is no universally accepted metric for assessing the health effect of exposure to diesel engine exhaust emissions, the challenge of finding one is complicated by the wide range of possible health effects. The currently available biomarkers include Urinary 1 –hydroxypyrene as the most comprehensive biomarker for PAH exposure and the measurement of induced DNA damage by the analysis of blood samples using the alkaline Comet assay, • There is also very recent evidence of diesel engine exhaust exposure having long-term effects on blood-brain barrier function and integrity, which could lead to the onset or progression of neurological disorders.

Needless to say, research is continuing with various epidemiological and clinical studies in an attempt to better define internal measures of absorbed dose rather than the use of external exposure metrics.

An interesting consequence of the introduction of new technology engines is that elemental carbon will be greatly reduced whilst the genotoxic compounds may still be present - although at much lower levels - and many of the low volatile compounds will no longer be adsorbed to carbon cores. Many of these compounds will not remain in the gaseous phase and will either become part of an organic condensate in the nucleation mode or adsorb to other solids in the engine exhaust such as metal oxides or sulphate particles. Either way they will appear in the workplace atmospheres as ultrafine particles, which may alter their lung uptake and bioavailability.

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Risk reduction and control measures

Suffice it to say that long-term exposure to diesel engine exhaust has a deleterious effect on human health and is an issue of continuing and growing concern to regional health authorities worldwide.

All the more reason for being concerned about the health and wellbeing of our underground miners working in close proximity to dieselpowered equipment in confined spaces in series ventilated mines.

However, the challenges are so varied and complex that no mining operation can be considered to typify the industry norm. There are, for example, a plethora of diesel engines in current use from U.S. EPA Tier 1- 4 with a variety of after-treatment devices installed in tailpipes. Couple that with the fact that each mine will have its own Diesel Emissions Management Plan defining its maintenance strategies, fuel and lubricants to be used etc., and not forgetting that each mine ventilation system will have its own characteristics, one soon realises that those responsible for each mining operation must exercise their own “Duty of Care” for their employees.

This requires management and mine workers to be kept informed of the health hazards and what is and/or can be done to minimise their effect.

They should, for example, realise that fine carbonaceous particulates below 2.5 microns and ultrafine particles with diameters below 100 nm are particularly hazardous since they are small enough to travel deep into the lungs and for a given mass their surface areas increase with decreasing size.

That apart, toxic and carcinogenic organic compounds readily adsorb onto the surfaces of these fine particles and are thus carried with them into the alveolar sacs where they can be absorbed through the lung tissue and adversely affecting the cardiovascular system and/or other organs and possibly contributing to the development of Parkinson’s disease and brain inflammation.

Bearing in mind there is currently no agreement on the most appropriate and relevant metric for assessing the health hazard of diesel engine emission exposure, the best we can do is to use one of many newly developed

SAFETY

battery-operated “multi-metric” real-time monitors that record size distribution, number concentration and lung-deposited surface area of particulates which correlate well with inflammatory lung response.

Hopefully the industry will also support and participate in applied research exploring the use of other metrics with particular reference to biomarkers.

In the final analysis, however, it is important to acknowledge that the problem of air quality control in most underground metal mines where diesel-powered mobile equipment predominate is exacerbated by a flawed ventilation system. Having the excavated ore and rock transported out of the mine in the intake airway ramp continually pollutes the fresh air supply. This fundamental flaw in mine ventilation practice needs urgent attention with consideration being given to developing hybrid/ parallel ventilation circuits at existing mines, or alternatively, reversing the ventilation so that fresh air is delivered to the deepest production unit, which otherwise would suffer the worst level of particulate, gaseous and heat pollution.

Whilst accepting these proposed

actions have cost implications and some technical challenges, let’s not forget that our first-priority issue should always be the health, safety and wellbeing of our mineworkers.

In mines yet to be developed, as stated in the Department of Mines and Petroleum “Guideline for the Management of Diesel Emissions in Western Australian Mining Operations”, endorsed by its Mining Industry Advisory Committee, only parallel ventilation circuits should be employed.

Conclusions

The seriousness of these respiratory health issues in Australian underground mines cannot be over-emphasised as evidenced by the re-emergence of coal miners’ pneumoconiosis (black lung) in Queensland and the increasing global concern regarding the impact of diesel engine exhaust exposure on human beings.

As stated in the Department of Mines and Petroleum’s “Accident and Incident Investigation Manual”, the Duty of Care involves taking all reasonable care to minimise foreseeable risk of injury to an employee. In this context injury

must of necessity include injurious or adverse health effects. This manual also states that such a duty covers the provision of safe systems of work, safe premises or work places, safe plant and equipment, and mandatory reporting to a central authority.

Bearing in mind the current level of knowledge on the respiratory health issues relating to the long-term exposure of underground miners to excessive concentrations of coal dust and/or diesel engine exhaust products, one cannot but be critical of the industry’s shortcomings in discharging its duty of care for its employees.

Rectifying the situation will need: For underground metal mines with diesel-powered mobile equipment.

• Improved mine ventilation design for underground metal mines where diesel-powered mobile equipment predominate, in order to eliminate or minimise polluting the fresh air intake, by using parallel ventilation circuits in new mines and taking steps to minimise the problem in existing mines as mentioned earlier.

• Ensuring better qualified and experienced Ventilation Officers are available and appointed to assist management in the design of bestpractice ventilation systems and

developing “Risk-based Hygiene Management Plans” as suggested in the newly proposed “Code of Practice for Ventilation in Western Australian mining operations.

• Review current standards and guidelines relating to underground miners’ exposure to diesel engine exhaust pollutants with a view to adopting more stringent standards and monitoring regimes and continuing research into the development of appropriate biomarkers for personalising risk assessment.

• Establish better resourced and upgraded regulatory regimes with more emphasis being placed on the supervision of mining operator compliance with legislative requirements.

For underground coal mines: • Review current standards and guidelines relating to underground miners’ exposure to respirable coal dust with the intention of bringing them into line with more appropriate and recently developed standards and legislative requirements in the USA. • Efficient dust suppression systems installed and maintained on all power-loading equipment with special attention being paid to longwall faces equipped with Single or Double-drum Shearers.

• The introduction of more stringent monitoring and recording regimes and screening programs, including storage of data at a central repository accessible to workers, government agencies and employers as recently recommended by Australian clinicians.

• Digital radiography to ILO standards should be performed on miners exposed to coal or coal and silica dust at the commencement of employment, and at least every three years thereafter. These images should be assessed by Royal Australian and New Zealand College of Radiologists who can assess to ILO standards.

• Establish mandatory reporting of those diagnosed with pneumoconiosis to a centralised occupational lung disease register and the development of training materials for General Practitioners to assist with the care of at-risk current or retired mine workers.

In general, mining companies should encourage and assist with funding applied research into all

AUSTRALIANMINING

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SAFETY

aspects of respirable-related health of mine workers; provide mine workers with personal protective equipment if and when the air quality is questionable or known to be sub-standard; and must ensure the highest level of communication with employees in an attempt to inform and educate them of the risks associated with their work and actions necessary to minimise them.

Finally, it is important to recognise that black lung disease is not limited to underground workers as evidenced by the recent confirmation of the first case of the disease amongst open-cut coal mine workers in Queensland.

As mentioned earlier, the recently enacted Final Rule legislation in the USA, which lowers the standard for respirable coal mine dust to 1.5 mg/m3, is equally applicable to underground and surface coal mines. AM References Holtz, J C, Safety with Mobile DieselPowered Equipment Underground, U S Bureau of Mines, RI 5616, 1960 Brezlin J, Strazirar, A, and Stein, R, Size Distribution and Mass Content of Particulates from Diesel Engine Exhaust, U S Bureau of Mines, IC 8141, 1976 French, I W, and Associates, Health Implications of Exposure of Underground Workers to Diesel Exhaust Emissions, Contract Report OSQ77-OOOO5, CANMET, Canada, 1978 Aziz, N, Cram, K, Hewitt, A, Mine Dust and Dust Suppression, Australasian Coal Mining Practice, Monograph 12, Third Edition, 2009 Balusu, S R, Longwall Dust Control, PhD

Thesis, University of Wollongong, 1993 Zosky G R, Hoy R F, Silverstone E J, Miles S, Johnson A R, Gibson, P G AND Yates D H; Coal workers’ pneumoconiosis: an Australian perspective. The Medical Journal of Australia, Vol 204 No 11, June 2016 Krishovto I N, Toxicity of Diesel Exhaust: Implications for Primary Care, Journal of American Board of Family Medicine, Vol 21, 2008 Attfield, MD, Schleiff P L, Lubin, J H, Blair, A, Stewart P A, Vermeulen R, Coble J B and Silverman DT, The diesel exhaust in miners study: a cohort mortality study with emphasis on lung cancer. J Natl Cancer Inst. 2012 Jones I O. Diesel Exhaust and theUnderground Miner in Western Australia, Proceedings of the Australian Mine Ventilation Conference, September 2015.

Uhrner U, Zallinger M, von Lowis S, Vehkamaki H, Wehner B, Stratman F, and Wiedensohler A, Volatile nanoparticle formation and growth within a diluting diesel car exhaust, Journal of the Air and Waste Management Association, 2011 Scheepers P T J and Vermeulen R C H. Diesel engine exhaust classified as a human lung carcinogen. How will this affect occupational exposure? Occup Environ Med 2012 Kittelson D and Watts W, Disel Aerosol Sampling Methodology, University of Minnesota, CRC E-43, 2002 Kittelson D and Kraft M, Particle Formation and Models in Internal Combustion Engines (Cambridge Centre for Computational Chemical Engineering, University of Cambridge, 2014 Bugarski, A D and Timko, R J. Characterisation of nanometer and ultrafine diesel aerosols in the underground mining environment, Proceedings CIM Mining

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Conference and Exhibition, 2007 Caudia, E G, Bugarski, A D and Patts, L, Diesel after-treatment control technologies in underground mines: the NO2 issue, National Institute for Occupational Safety and Health, Office of Mine Safety and Health Research, 2005 Huawei Duan, Xiaowel Jia, Qing feng Zhai, Lu Ma, Shan Wang, Chuanfeng Huang, Haisheng Wang, Yong Niu, Xue Li, Yufei Dai, Shanfa Yu, Weimin Gao, Wen Chen and Yuxin Zheng, Long-term exposure to diesel engine exhaust induces primary DNA damage: a population-based study, Occupational and Environmental Medicine, 2015

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Nejad, S H, Takechi R, Mullins B J, Giles C, Larcombe AS N, Bertolatti D, Rumchev K, Dhaliwal S and Mamo J, The effect of diesel exhaust on blood-brain barrier integrity and function in a murine model, Journal of Applied Toxicology, 2014 Wierzbicka, A, Nillson P, Rissler J, Sallston G, Xu Y, Pagels J H, Albin M, Osterberg K, Standberg B, Eriksson A, Bohgard M, Bergmalm-Rynell K and Gudmundsson A, Detailed diesel exhaust characteristics including particle surface area and lung deposited dose for better understanding of health effects in human chamber exposure studies, Atmospheric Environment, 86, 2014

DUST MANAGEMENT

MAKING BLACK LUNG BITE THE DUST A NEW DUST SUPPRESSION TECHNOLOGY HAS BEEN DEVELOPED TO HELP TACKLE THE INCIDENCE OF BLACK LUNG. SHARON MASIGE WRITES.

T

he resurfacing of black lung in Australia has undoubtedly shaken the mining sector. Thought to have been eradicated 30 years ago, the government and industry have been scrambling to determine why it came back, and find ways to enforce stricter preventative measures to safeguard workers.

David Brims, co-founder of VTEX Industries developed a dust suppression technology – the VTEX Venturi – to minimise the chances of black lung.

Brims said the technology works in a similar way to bladeless air fans and is much simpler than other systems as it has no moving parts. This also means it does not require constant servicing, and instead just needs to be monitored.

The technology is built from carbon fibre, making it lightweight and durable.

“It’s constructed from carbon fibre, so bonuses with that is the weight,” Brims told Australian Mining.

“So [for] anyone that’s handling it, it’s not a two-man lift, it’s a single person lift and the weight’s kept right down.”

The technology simplifies

underground processes and minimises manual handling as it cuts down on the number of vent tubes required for ventilation. It can be used with air or water - where roads and underground surfaces can be ‘watered down’ to ease dust problems – and is also capable of injecting stone dust as well as water.

Coal dust, black lung, and finding a solution

There are currently 16 confirmed cases of black lung in Australia, with one of the most recent cases affecting a worker from an open cut mine. This further sent shock waves across the industry, as it was believed to only affect underground workers.

Constant exposure to coal dust is the main cause of the disease and yet acceptable dust levels vary between states. NSW has a maximum level of 2.5mg/m3 of air while Queensland’s is higher, at 3mg/m3 of air. Earlier this year the Select Committee on Health’s black lung report recommended all coal companies adopt the lowest Australian level of 2.5mg/m3 until a national standard is implemented.

Following the growing number of AUSTRALIANMINING

THE VTEX VENTURI WILL HELP WITH DUST SUPPRESSION ON SITE

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DUST MANAGEMENT

GOOD DUST MANAGEMENT IS PARAMOUNT AT THE MOMENT, ESPECIALLY WITH ALL THE TALK AND NOISE AROUND BLACK LUNG.” workers diagnosed in Queensland, the state government launched a Coal Worker’s Pneumoconiosis select committee to conduct an inquiry into the resurgence of black lung.

Hearings have been held in Brisbane, as well as regional areas including Ipswich, Collinsville, and Mackay throughout November and December, with victims, community members, and experts providing evidence to highlight the impacts of the disease on workers and the community. The committee will give a final report to the Legislative Assembly in April next year.

In terms of more practical efforts to reduce the likelihood of black lung, the Queensland Government is tightening safety across all mines. As of January 1 2017, current measures to protect coal mine workers from the disease will become regulations required by law.

“Government, employers, and unions are tackling the re-emergence of this disease on three fronts – through prevention, early detection, and a safety net for workers,” natural resources and mines minister Anthony Lynham said.

Stricter rules will be enforced around dust management, reporting, and medical assessments for workers.

There will also be a tougher stance on medical assessments, whereby current employees who have worked in underground mines are to have respiratory function and chest x-ray tests once every five years and above ground workers must be tested once every 10 years. Tests are also to be given to retiring coal mine workers at their request.

The construction, forestry, mining and energy union (CFMEU) has also been on the bandwagon for tougher action against black lung since it resurfaced, calling for a 10c a tonne compensation levy on all coal produced to support victims of the disease.

“Black Lung sufferers are victims of a deadly disease inflicted on them by employers who failed to ensure a safe workplace for them and by successive state governments that failed them,” CFMEU mining and energy district

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president Stephen Smyth said.

“Many of them are now being further punished financially because the existing Workers Compensation and Common Law systems don’t adequately cover them.”

The importance of dust management

When initially developing the technology, Brims said they had always focused on dust suppression but found more motivation to hasten the project due to news of black lung.

“In the last 12 months with black lung being highlighted and getting so much attention, it probably motivated [the technology] a bit more,” he said.

“We thought well this might be a great opportunity to actually help and do something.”

The technology can be used across all mines that have ventilation requirements as well as in tunnelling.

Currently, it is in its manufacturing stages, with sizes ranging from 250mm up to 280mm.

“It could be used anywhere where there is a dust problem in a confined space,” Brims said.

While the product has not been released commercially as yet, Brims said they have received a lot of interest from prospective buyers and even delivered prototypes for testing.

“We’re looking to involve a mining company or someone like that to help get it out there and advance the product further.”

Brims emphasised the importance of adequate dust management levels and how their technology can be a part of preventing black lung.

“Good dust management is paramount at the moment especially with all the talk and noise around black lung.”

“It’d be interesting to see what sort of impact we can have with this product when they start testing it.

“It’s not probably the be all and end all for black lung but it’ll definitely be an improvement to help keep the dust down in underground mines and tunneling.” AM

WINNERS PROFILE

MORE THAN A CONTRIBUTION TO MINING MICROMINE FOUNDER AND DIRECTOR, GRAEME TUDER WON THE CONTRIBUTION TO MINING AWARD AT THE AUSTRALIAN MINING PROSPECT AWARDS CEREMONY THIS YEAR - THE ICING ON THE CAKE AS THE COMPANY CELEBRATES ITS 30TH ANNIVERSARY. CLAIRE TUDER ACCEPTING THE CONTRIBUTION TO MINING AWARD ON BEHALF OF GRAEME TUDER AT THE 2016 PROSPECT AWARDS

I

n 1986, Graeme Tuder created Micromine as a business unit of Geometra after seeing an opportunity to develop software by applying offshore oilfield technology ideas to mineral exploration techniques. By 1989, he resigned from Geometra and became the sole owner of Micromine, seeing it grow in both domestic and international sales.

Since then, the company acquired new product concepts in geological data management (now Geobank) and mine production and control (now Pitram). It became the first western mining software company to enter the former Soviet Union – opening offices in Russia, Ukraine, and Kazakhstan in 2001 – as well as China – opening a representative office there in 2002.

In addition, its software has been the first and only to be accredited by the Chinese Ministry of Lands and Resources as acceptable for calculating mineral reserves and resources. By government instruction, all mineral exploration data and reserves in Mongolia must be reported in Micromine format.

In 2011, the company was awarded Microsoft Gold Partner Certification as an independent software vendor and Windows 8 Compatible, and has maintained this certification every year since.

The company now exports to more than 90 countries and has 22 offices

located in all mining capitals of the world.

With Micromine celebrating its 30th anniversary this year, the company found it fitting to nominate Tuder for Contribution to Mining.

He later won the award, with his daughter, Micromine CEO and director Claire Tuder, accepting it on his behalf.

“Since its beginning in 1986, Graeme’s vision for the company has been to provide high quality products and services that create value for exploration and mining companies,” Ms Tuder said.

“This is a fantastic recognition of Graeme’s contribution to the industry.”

Graeme Tuder has made a positive impression on all those he has worked with, managing to inspire them in the process. His humour and generosity of spirit is also renowned amongst his staff.

“Without pomp or ceremony, he inspires people,” one of his colleagues said.

“He is down to earth, a surveyor from the Victorian bush who still wears R.M. Williams to board meetings. People can relate to him and he has the ability to put people at ease, which is a very useful skill particularly at important international meetings or social receptions.”

These characteristics have led Tuder to develop influential yet

AUSTRALIANMINING

genuine and enduring relationships.

He has made friends in all of Micromine’s export regions and has introduced them to each other for their, not his own, benefit.

When overseas, Tuder adopts each region’s culture with enthusiasm; absorbing social nuances and developing an innate understanding of the people, how they do business, and the market opportunities. This cultural awareness has led to the development of products solely in response to the needs of the export market.

Another key attribute is Tuder’s ability to accurately predict global trends, which has driven the company to the forefront of mining software innovation.

Tuder calls his staff the ‘Micromine

MICROMINE FOUNDER AND DIRECTOR GRAEME TUDER

22

DECEMBER 2016

family’ and it is this personal approach to global business that, above all other skills, experience and traits, make people want to work for, and with, him. The company culture, along with Tuder’s leadership, has led to a high staff retention rate, with many workers having been with the company for more than 20 years. The very first Micromine employee, hired over 27 years ago, is still working for the company and the number of returning, or ‘boomerang’, staff is also high – a testament to Tuder’s enduring commitment to ensuring the best for his staff and his business. AM Australian Mining congratulates all winners and finalists at this year’s Prospect Awards. Entries are now open for 2017.

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BUSINESS DEVELOPMENT

NEW PREMISES, NEW STAFF AND NEW MARKET OPPORTUNITIES WOMA (AUSTRALIA) HAVE OPENED A NEW HEAD OFFICE IN WESTERN AUSTRALIA, WITH THE COMPANY NOW FOCUSED ON GROWTH AND DEVELOPING THEIR STAFF AS THEY HEAD INTO 2017.

I

ndustrial high pressure jetting company WOMA (Australia) have opened their new head office and manufacturing, service and support centre in the Australian Marine Complex, Henderson, WA. The company has spread its wings logistically and operationally with new staff, premises, products, and markets; providing services to the mining, oil & gas, marine, shipping, construction, and municipal industries across Australia, New Zealand, Papua New Guinea and the Pacific Islands.

“Our staff are making the transition into their new purpose-built facility and are enjoying its many features,” Ian Blevin, managing director of WOMA (Australia) told Australian Mining.

“It is rewarding to see them making the most of the new space with the ability to better serve our customers.”

Established in Australia in 1950, WOMA has grown to become a key distributor of industrial and waste services technologies, particularly high and ultra-high pressure water jetting, vacuum extraction and recovery, remotely operated manipulators and robotics, and other related services and accessories. They currently have 30 staff across five Australasian countries.

Having worked at WOMA from 1996 to 2003, and after a brief sabbatical out of the engineering world, Blevin came on board as managing director in 2007. An alumni of the Royal Military Academy Sandhurst, Manchester (UK) and Murdoch (Australia) Universities, Blevin draws upon his experience in the military and in business, and his time with ‘start-up’ and global companies such as Veolia to complement his current position within the company.

“Some of the organisations that I have previously worked at were excellent at leadership development, none better than the Royal Military Academy. In light of this, a number of concepts and best practices gleaned over the many years are gradually being deployed at WOMA.” Blevin emphasised the importance of staff development, and explained how there is a general lack of competence based training in the industry.

“We need to develop our staff to be the best that they can be, and that’s a mantra that we work at here at WOMA.” “It is our experience that industry in general lacks quality, competence-based training. This has led us to establish our own iCert (Industrial Centre for Environmental and Resource Training) business with programmes designed to further develop both our own staff and those of our customers.

“In time, we intend to become a Registered Training Organisation (RTO) offering training to specific industrial sectors in addition to developing our own people”.

“Over the past two years we have put over 1500

AUSTRALIANMINING

24

DECEMBER 2016

BUSINESS DEVELOPMENT

people through training programmes.

As such, our trainees end up with industry relevant qualifications and a technical competence which raises the safety and productivity benchmarks for industry personnel.”

When it comes to employing staff, the main attributes Blevin looks for are those who are customer focused, courageous, communicative, and honest.

“Being courageous is one of the most important attributes for leadership. It takes steadfast resolve to make the tough decisions, particularly when you have people who make judgements before they have all the information,” he said.

“It’s crucial that a WOMA team member remains grounded, and is both willing and capable of talking to people at all levels within an organisation, from a ‘blue chip’ company director to an apprentice or trade assistant in production and operations.”

In terms of the sector’s volatile market, Blevin said the company was not immune to its effects.

“The Australian resource sector has gone through a super-cycle over the past seven or eight years. During that period, within the company, WOMA created 60 per cent job growth. In the past 18 months the resource spike has well and truly come to a stop, and if you analyse industry sectors across the nation, you can see there have been huge job losses.”

“We’re not immune to the slowing down of the resource sector - our business too, has at times contracted – but in spite of some extremely trying circumstances, we have managed to sustain a positive thrust.”

One of the principle foundations underpinning the business is taking care of both their staff and their customers.

“Care is another very important value for us. We don’t make a song and a dance about it, but we will quietly

AUSTRALIANMINING

help our people and their families in times of personal need,” Blevin said.

“We don’t broadcast these practices very much - even internally - but we do it because we think it’s the right thing to do. This culture has been with us for many years, and it makes a lot of what we do feel like a true ‘family’ business rather than just an enterprise. It’s the same with our customers: there’s no point in treating your customer like a number, every single one of our customers is an individual with whom we work hard to develop and maintain a personal relationship.”

This same attitude goes for their relationships with their suppliers as well, including WOMA Germany, Dietmar Kaiser, Stoneage, and TST Sweden.

Blevin is confident that WOMA is heading towards a bright and successful future.

“The future brings with it new technologies, new information,

25

DECEMBER 2016

faster communication channels and therefore new opportunities for service refinement to our customers,” he said.

“Technology is an exciting space at WOMA. It continues to allow us to broaden our value proposition beyond products and in to the provision of safety, productivity and operational improvement strategies for our customers. It has enhanced our service offering and has helped our customers to improve their business performance.”

To celebrate the launch of this new facility, WOMA will also hold a number of display ‘open’ days next year, to coincide with the unveiling of new technologies.

As they transition from 2016 through to 2017, WOMA will see further market expansion in to Central and East Africa, with the potential to positively impact not only their production and profits, but the people as well. AM

SENSORS

UNLOCKING YOUR TRAPPED DATA WITH IO-LINK DESIGNED FOR SIMPLICITY AND UNIVERSALITY, THE COMMUNICATIONS PROTOCOL IO-LINK ISN’T THE LATEST THING, BUT THERE ARE PLENTY OF FACTORIES THAT ARE MISSING OUT ON WHAT IT OFFERS.

T

here is sometimes a little confusion about IO-Link - the first global standard for communicating with sensors and actuators.

To begin with, it is not a proprietary solution, which is the first thing that needs clearing up, believes Freddie Coertze, Field Technical Support Engineer, Networks and Controls at ifm efector Australia.

“It’s a nice thing to actually buy into from a customer point of view; the main reason is you’re not locked into one supplier,” Coertze told Australian Mining.

“So you can use different manufacturers’ IO modules, sensors, whatever, as long as they’ve got IOLink in it.”

Secondly, though the buzzword Industry 4.0 might call up something futuristic in your imagination, IO-Link - one of the essential connectivity solutions required for this - is very much here and now. In fact the Company Coertze works, ifm efector, for has been making IO-Linkenabled sensors for almost a decade.

IO-Link can help users get much more data out of their sensors and unlock some of the “trapped data” currently held prisoner in the sensor.

“We can basically link a sensor up to your SAP [a major ERP software provider] interface. To be able to do that is a benefit, because let’s say your sensor is starting to fail,” explained Coertze.

“As an example, let’s use an IOLink-enabled pressure sensor. It’s working all good, giving my pressure values, everything is fine, but if that pressure valve becomes invalid I can get a message from my sensor saying I am no longer healthy.” This is achievable via the sensor’s error messages monitored by the IO-Link master and passed up to the PLC or Controller.

In such a case, a diagnosis can be made via information sent through the sensor - which may have failed due to overheating - via the PLC to the enterprise system. A job ticket is produced and a floor worker can change the failed device.

Further to this, a network using IOLink does not have to be shut down

YOU CAN BASICALLY SEE ALL OF YOUR SENSOR PARAMETERS IN THERE. YOU CAN SEE - EVEN WITH A SIMPLE PRESSURE SWITCH - FOR INSTANCE - NOT JUST AN ON/OFF SIGNAL.” in its entirety and a production line or machine can keep running, provided it is safe to do so.

Right from installation, in fact, an IO-Link-enabled sensor can begin displaying its usefulness. It can display three types of data, the first of these being service data: data about the device itself, including part number and manufacturer details.

The other two types of data are event data (such as notifications and flags, for example in the failed pressure sensor example) and process data (whatever the sensor is supposed to be reading).

Crucial data can be accessed remotely - very much essential in any Industry 4.0 cyber-physical representation of a factory and its workings.

“You can basically see all of your sensor parameters in there. You can see - even with a simple pressure switch - for instance - not just an on/ off signal,” said Coertze.

“And that means if I connect it to an IO-Link input I enable more out of my sensors. I can basically get a floating value and my resolution is much higher because if I wanted to create an analog, I’ve got to scale it between 4 and 20 milliamps. Where now I can have the real value.”

The simplicity of IO-Link was being enthusiastically embraced by younger engineers, he added.

“New engineers moving into the field, you can see they are more adapted to technology and can really see the benefit of this,” he said, continuing “if you can basically screw

AN IO-LINK-ENABLED SENSOR

AUSTRALIANMINING

26

DECEMBER 2016

an M12 connector on a sensor, you can basically do IO-Link - it’s really not that difficult.”

The benefits of the newer types of data made available can save money, and apply to even the most traditional of manufacturers.

One example is in energy monitoring, a purpose which Coertze’s company covers (along with condition monitoring) through its partnership with SAP and its cloud platform.

“For example, in most manufacturing environments you need to have compressed air. So let’s say I’ve got leaks in my compressed air lines which I never knew about, that means my compressors will be running inefficiently 24/7,” he said.

“So we want to use that sort of SAP environment to colleczt data… Our sensors can collect data for us and that means I can measure the input of all my airlines and I can see on the end that I’m losing all my air.

“And that means I can collect all of my data into a Historian, I can transfer the data into SAP, and draw a report.” AM

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LOOK BACK AT MINING 2016

LOOK BACK AT MINING 2016 AN INSIGHT INTO HOW PRECIOUS METALS HAVE PERFORMED IN 2016, WITH FOCUS ON THE FINAL QUARTER OF THE YEAR. PALLION GROUP AND ABC BULLION GENERAL MANAGER NICHOLAS FRAPPELL WRITES.

S

eptember’s negative gold price action and stagnation continued into October with the precious metal opening on a high at US$1318 ($1721) before dropping to a low at US$1241.50 ($1636). Gold did however recover in the latter part of the month.

The precious metal faced headwinds from a substantial move higher in the US dollar index (DXY), which opened at basically a monthly low of 95.495, traded as high as 99.119, and then closed at 98.445. And though US treasury yields remained at historically low levels, the movement was unmistakably higher, with yields opening at 1.598 per cent, before trading to a high of 1.877 per cent.

The US dollar was boosted by the second month of significantly higher Treasury International Capital (TIC) long-term purchases. Foreign purchases outweighed domestic purchases of long-term securities, with the reported number more than US$26 billion higher than the US$48 billion forecast.

The US dollar and yields were also helped by a decent Philly Fed Manufacturing Index and the Fed vice-chair, Stanley Fischer, reaffirming that the US economy at full employment was also providing benefits. American real wages showed signs of firming at the beginning of the month. The market grew comfortably certain that a December rate rise was on the cards, although the anticipated

pace of tightening remained well behind the ambitious dot plots of Federal Reserve voting members.

The US election effect

Prior to the US election, the prospect of a Trump presidency did not appear to intrude too heavily, with most polls showing Hilary Clinton comfortably ahead during October. Post-election, the US dollar index pushed through 2015 highs, targeting 105-107 in the medium term, while 10-year US treasury bonds weakened considerably, giving up over 50 basis points in little over a week after the election.

The loss was caused by there being one policy course open to the incoming president to go for a debtfinanced infrastructure spend, with a commensurate increase in the number of bonds issued.

Almost equally, as the Fed watched US unemployment hug five per cent, and real wages turn higher again, the scope for further monetary easing was called into question, which could coincide with a natural turn in the credit cycle amplified by the election result.

All that glitters

Technically, in the case of US dollar gold, the price touched the Monthly Turning line (the mid of the high and low of the previous nine months) before staging a rally. In the case of AUD gold, the price hit the top of the weekly cloud before recovering in wellbehaved technical action. Later, the price sank to hit the base of the cloud, AUSTRALIANMINING

and then rallied strongly once more, aided by the weakening AUD. Gold withdrawals on the Shanghai Gold Exchange (SGE) stood at 153.25 million tonnes during October, a yearon-year decline of 23 million tonnes.

The figures were broadly comparable with September’s 171 million tonnes as there were two fewer trading days due to Golden Week. The People’s Bank added a negligible four tonnes to official reserves during the month, reinforcing declining demand relative to the same period last year.

Given that the average price in October 2015 was US$1158.19, almost US$110 lower than last month’s average of US$1267.75, a relative decline in these data points was no surprise.

Positioning on the CME saw a substantial decrease in Managed Money gross length, which stood at 24.477 million fine troy ounces on Tuesday October 4, before falling to 20.367 million fine troy ounces by November 1, a monthly decline of 4.11 million fine troy ounces.

Gross short speculative positioning by the Managed Money sector declined by 0.725 million fine troy ounces over the same period. The gross Managed Money length declined again to 17.813 million troy ounces by November 15, almost half of the 2016 high.

Positioning changed hands on the CME at a volume weighted average price (VWAP) of around US$1269 during October. By the end of the month, net length was around 10 million fine troy ounces lower than the

28

DECEMBER 2016

July peak, with the difference almost entirely accounted for by a reduction in speculative length.

The ‘melancholy, long, withdrawing roar’ of the longs – to more sensible levels at least – has not been accompanied by an aggressive move by speculative shorts, with positioning still slightly elevated but nonetheless below the average of the year so far.

What to make of that? Well, gold might be below highs but its story so far has not ignited the imagination of the shorts, which have remained sidelined and unwilling to make a significant commitment.

Global exchange traded fund (ETF) holdings at the end of October were 63,902,496 fine troy ounces, an increase of 278,824 fine troy ounces.

This declined to 62,132,376 fine troy ounces by November 18.

Hi ho silver

Silver opened October almost on highs (US$19.21) and declined through the Monthly Turning and Standard Lines.

It would then approach the trend line that rises from the January 2016 lows.

The price dropped to a low of US$17.10 before closing at US$17.91. In doing so, the price retraced about half of the 2016 rally, and found a level that ‘ought’ to be supportive if the bullish psychology of the market remains in place.

The long and short of it

Positioning on the CME Managed Money sector showed that gross longs

LOOK BACK AT MINING 2016

declined by 108.26 million troy ounces, using the Commitment of Traders (COT) report period from October 4 to November 1. Shorts also declined, by about 24.06 million troy ounces, over the course of the month.

This disguised a build-up of speculative short positions in the first two weeks of October at VWAP of US$19.00 and US$17.76, before reducing sharply by 42 million troy ounces at US$17.87.

The pronounced exit by some of the Managed Money longs must be viewed in the context of the significant increase in the previous month, where 20 million troy ounces were added at a VWAP of US$19.36.

By contrast, the VWAP calculation in October was US$1.61 lower, at US$17.75. There was a significant legacy position from the mid-June to late-July period where gross longs had increased by around 135 million troy ounces.

The first half of November saw Managed Money longs add over 30 million troy ounces, followed by a substantial exit as prices fell, with 39.87 million troy ounces of long liquidation.

Price action in September created significant downside price targets, and the move towards those targets was a feature of October and November.

In terms of relative performance, the gold-silver ratio was expected to reach 74.40 and 74.80 levels after struggling at 67 at the end of September. October saw silver weaken to 73 before strengthening again – the 66-67 area remains resistive.

Global silver ETFs at the end of October were 673,565,652 troy ounces, a reduction of 424,731 troy ounces.

That declined to 670,722,036 troy ounces by November 18.

The long-term outlook in October implied support at US$17.10, then US$16.14 and US$15.83. Very ambitious upside targets remained in place, for example to US$24.88, as far as the price remains above the

distant December lows.

In the bigger picture, even a retreat to US$16.06 looks consistent with a long-term rally. Based on the very macro charts referenced in September, there is a target to US$16.00, where the price should be supported again.

Platinum

Platinum pushed lower, past support at US$995-999, and broke down below major technical supports – namely the Weekly Cloud – in October.

CME positioning showed that Managed Money gross length changed direction tremendously, with strong liquidation in the first fortnight of the month. This amounted to 152,500 troy ounces of selling at a VWAP of US$978 and US$945 for the weeks ending October 11 and 18, followed in the next fortnight by 167,500 troy ounces of buying.

The VWAP for the final two weeks of October was US$946 and US$973 respectively, so in fact, longs could re-establish much of their position at slightly advantageous levels. Gross speculative shorts grew substantially during October, rising by 452,600 troy ounces to 1,130,200 by November 1.

The bet against platinum may be driven by several factors, including weakness in Chinese jewellery offtake, lower expected auto sales next year, and a forecasted increase in recycling as older cars with decent catalyst loadings come up for scrapping.

Out of Africa

Additionally, the threat of labour disruption in South Africa seems to have been allayed as both workers and unions seek a more constructive tone – with workers mindful that the last significant stoppage caused longterm financial pain that was probably not offset by higher wages.

Finally, the mines

and the Association of Mineworkers and Construction Union (AMCU) signed agreements with Amplats and, by default, Sibanye.

In combination, the weaker South African rand, an apparent reduction in threat from organised labour and expectations of weaker demand in 2017 have helped make the case for speculative shorts to remain short, although some 387,500 troy ounces were bought in the second week of November.

In the end, prices are low in terms of producer cash costs again. The picture in November indicated that targets extended lower to US$875-885 and to US$845. The last time prices dropped below that area (and bottomed out either side of US$800) there was a sustained rally afterwards.

Global ETFs on October 31 were 2,339,268 troy ounces, an increase of 78,675 troy ounces since October 3.

Palladium

Palladium opened October at US$722.76, which was basically a high.

It then closed towards a low, stopping at the Monthly Turning Line support level at US$611.50 and then finishing at US$621.40, a decline of US$100 that contrasted with the previous month.

The whole process now looks like a retest of the huge downtrend resistance line that extends back to September 2014. And, if that test is successful, it could lead to a strong rebound higher. The price has cycled off the US$7818.50 target almost reached in August, and that

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remains a key area.

CME positioning witnessed a substantial reduction in Managed Money longs in October, with 675,000 troy ounces of liquidation. Managed Money shorts increased by 165,500 troy ounces. The VWAP for the month was US$650. The initial round of selling from longs took place in the early to middle part of the month at a VWAP of US$675 and US$646, whereas the major short selling took place in the final week, at a VWAP of US$624.48.

Global ETFs stood at 2,020,702 troy ounces, a decline of about 24,000 troy ounces, through the month.

By mid-November, the retest of the trend line was a success, and the market had rallied considerably, reaching the 61.8 per cent Fibonacci retracement. Overall, the amount of short-covering in November meant that buying from shorts covering back exceeded buying from longs by about 151,000 troy ounces.

This might imply that buying strength would weaken, however for the bulls there are encouraging signs that having run down the size of speculative length, Managed Money longs are now beginning to swing their interest back to buying again. Longerterm targets returned to the US$814842 levels, with US$746 the level to beat in the short-term.

There are assessments of palladium’s chances of moving into a deficit as demand for pd-loaded autocat increases, helping the metal’s bullish case. AM

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AUSTRALIANMINING

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DECEMBER 2016

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DRILL, BLAST & GEOMECHANICS

BLUETOOTH MINING SENSORS IN DIAMOND DRILLING BLUETOOTH TECHNOLOGY IS BEING USED TO INCREASE THE EFFICIENCY AND PRECISION OF DIAMOND DRILLING. CALEB RADFORD WRITES.

T

he Wireless Sub was developed by Deep Exploration Technologies Co-operative Research Centre (DET CRC) in South Australia and uses Bluetooth sensors to deliver precise drill rig data.

The sub couples the drill rig to the drill rods in the hole and enables drillers to replicate the highest performing parameters in any drilling program.

The steel component can be retrofitted to any drill rig and measures feed force, torque, water pressure, rotation speed, axial force, tangential acceleration as well as drill bit erosion.

The Wireless Sub was developed in collaboration with CSIRO, Globaltech Corporation, Epslog and will now be commercialised by mining technology group Boart Longyear after it recently signed an agreement with DET CRC. DET CRC chief executive officer

Richard Hillis said the sub not only optimises drill performance but also measures properties that have not been monitored in similar technologies.

“Existing measurements are made based on pressures in the hydraulic fluid rather than the actual stresses and strains on the drill string,” he said.

“One of its key features is it measures drill bit life, which can save the driller a lot of time because it allows them to avoid having to change the bit so often.”

Hillis said the sensor was designed for diamond drilling but had the potential to be used in other areas as well.

The sensors collect the drill rig data and send the information through to a nearby laptop.

A dashboard then illustrates rates and pressures, giving drillers the ability to change rotation speeds, insert additional fluid and

AUSTRALIANMINING

alter the weight on the bit as soon as necessary.

The real-time data from the remote drilling sites can also be reviewed by exploration teams around the world and can be used by drillers of any experience level.

The Wireless Sub was trialled and tested at the Gawler Craton in central South Australia, which covers about 440,000 square kilometres of mineral rich terrain.

It was set the task of drilling a piece of ground adjacent to a contemporary system with conventional gauges.

The results showed the hole dug by the rig with the Wireless Sub had a 10 per cent increase in rate of penetration. It also increased drill bit life by more than 100 per cent.

Boart Longyear director of geological data services Mike Ravella said he was pleased to add the Wireless Sub to the company’s range of innovative technology.

“The information obtained from

30

DECEMBER 2016

the detailed parameters recorded by the Wireless Sub is the next step in driving safe drilling productivity,” he said.

“In addition, there is much more that can be done with the data.”

The Wireless Sub is the third major technology licensed by DET CRC, following the AutoSonde for downhole determination of rock properties and the Lab-atRig for surface determination of geochemistry and mineralogy.

Together these technologies provide a suite of real-time or near real-time drilling, geophysical and geological data from the drill site. AM DET CRC was established in 2010 under the Australian Government’s Co-operative Research Centre Program to develop technologies to discover new mineral deposits at depth beneath barren rock cover.

This article originally appeared on The Lead South Australia.

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AUSTRALIANMINING

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DECEMBER 2016

MOBILE TECHNOLOGY

ANDROID TABLET NOW RUGGEDISED FOR THE MINING INDUSTRY PANASONIC HAS LAUNCHED WHAT IT CLAIMS IS THE WORLD’S LIGHTEST FULLY-RUGGED ANDROID 10.1” TOUGHPAD TABLET.

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ngineered to provide a more effective mobile solution across multiple work applications and challenging environments, the FZ-A2 Android tablet employs military-standard rugged capabilities and is designed to deliver fully-rugged protection against drops and shocks, heat and cold, vibration, contamination, dust, rain and more.

The Toughpad FZ-A2 combines Intel and Android productivity with full ruggedisation and is suited to a range of mobile users such as servicing, repair and technical support teams; utility and infrastructure providers; logistics and transport operators and on-site subcontractors in the mining sector.

Suitable for use by mobile outdoor workers in challenging conditions, it has a sunlight-

viewable 10-finger multi-touch IPS display, flexible configurable ports, expansion capability, plus enterprise class security.

The Panasonic Toughpad FZ-A2 is lightweight (880gm) and slim (16.4mm deep) with a fanless design and runs the latest Android 6.0 Marshmallow operating system with Enterprise Security from Android for Work.

It is equipped with an Intel Atom x5-Z8550 Quad Core processor (2 MB cache, 1.44GHz up to 2.4GHz) with 4GB RAM and a 32GB eMMC. The Toughpad FZ-A2 can withstand 1.2-metre drops, is sealed against dust and water spills with an IP65 ingress protection rating, and can operate in harsh temperature extremes ranging from -10 to +50°C. The 10.1-inch daylight-readable display (1920x1200), with high visibility (800cd/m2), has been designed for easy use and clarity of

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vision in all conditions both outside and indoors.

The 10- point capacitive touchscreen display can be used by hand, with gloves or with the capacitive stylus pen for accurate annotation or signature collection even in the rain.

The tablet also comes with a rich set of customisable business interfaces and wireless connectivity options to tailor the device to exact user requirements, alongside a full range of business features (1xUSB 3.0 Type A, 1xUSB 3.1 Type C OTG, 1xHDMI and 1xMicro SD, GPS), optional smartcard reader, 2D barcode reader and 4G (optional).

The USB 3.1 Type C OTG port for reversible connection comes with transmission speeds of up to 5Gbps, power charging (up to 5V 900mA - USB PD is not supported) and USB functionality for copying and transferring files from one

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Android device to another.

The FZ-A2 includes the latest WLAN 802.11ac Intel Dual Band Wireless-AC 8260 technology for the fastest data transfer and Bluetooth v4.2 class 1.

The Panasonic Toughpad FZ-A2 tablet also incorporates a userremovable battery with a nine hour working life to match the needs of shift workers, with an optional hot swappable battery capability for when around the clock usage is required.

For users needing live video conference capabilities or to capture photographic in the field, the FZ-A2 is equipped with Full HD front web and 8MP rear camera with flash.

It also comes with built-in directional array microphones and voice recognition software. AM For further information, please visit www.panasonic.com.au/toughbook

METALS OUTLOOK 2017

METALS, MARKETS AND 2017 HASSALLS’ GENERAL MANAGER STEVE WALL SHARES HIS INSIGHTS INTO THE YEAR THAT WAS, AND HOW SUPPLY CHAIN IMPACTS WILL AFFECT CIVIL, INDUSTRIAL, MINING AND CONSTRUCTION IN 2017.

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lthough 2016 was a year of volatility, the resources sector in parts has seen a rebirth, evident with definite market and business operation shifts moving into 2017. While lending, commodity prices and equipment values may not be to the level we’ve seen previously, recent spending trends show we’ve entered another interesting, but unfortunately volatile, period.

Commodities

If there’s one takeaway from 2016, it’s that the decline of coal is over and the commodity has bottomed out. Coal took its largest ever hit in 2015, due primarily to a drop in demand from China. However, twelve months on, mining giants are looking at many of

the sites that were mothballed when prices plummeted with optimism, and demand for the commodity is expected to remain stable. Iron ore prices have been boosted by rising coking coal prices, with record twelve-month highs for both commodities.

We are seeing lead times for new mining equipment lengthening to nine and 12 months in some classes and renewed pre-stripping activity in Queensland.

Looking broadly across the spectrum, silver, crude oil, and zinc are all up over 30 per cent; and gold, palladium, natural gas, and nickel are all up over 20 per cent. The only metal to see a fall is uranium, with predictions it could be years before the industry recovers from the Fukushima disaster.

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Looking to 2017, some Australian miners are predicting shortterm negative impacts as the United States transitions into its

Lending and spending

There’s the old saying that “it takes money to make money”, and when we’re dealing with large

SOME AUSTRALIAN MINERS ARE PREDICTING SHORT-TERM NEGATIVE IMPACTS AS THE UNITED STATES TRANSITIONS INTO ITS NEXT PRESIDENTIAL TENURE AND THE UNCERTAINTY REGARDING CHINA’S MINING RESTRICTIONS.” next presidential tenure and the uncertainty regarding China’s mining restrictions. The consensus view among commodities experts is still that demand will strengthen next year triggered by brighter prospects for prices of energy and base metal commodities.

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calibre earthmoving, mining, civil, infrastructure and drilling equipment across the resources sector, it takes substantial financial investment to grow a business. While the downturn affected many owners and operators, reducing their capacity to borrow, the amount of ‘bad debt’ carried

METALS OUTLOOK 2017

by the banks also impacted mining contractors and ‘services to mining’s’ ability to raise funds. No one could escape the impact of the downturn – so when The Reserve Bank of Australia declared the end of the mining bust in November, Christmas had come early and some confidence was restored. The bank observed that the recent rally in coal and iron ore prices had lifted Australia’s terms of trade for the first time in more than two years with further gains expected. In the past few weeks alone we’ve seen capital expenditure increasing, recruitment lifting and general sentiment rising.

With that said, one aspect we’re all watching closely is the impact of the Chinese Government’s restrictions on coal mining and slower production. Typically this could create challenges for our Australian exporters, but as we have some of the lowest production costs in the world, we’re still very much in demand, especially with the premium coking coal reserves we hold.

No one in the industry wants another big boom. The industry wants steady, consistent growth, but the fear of the unknown as we head into 2017 sees lenders maintaining a cautious approach with how much and where they put their dollars. There has, however, been some increased loan activity to mid-tier mining in

the last twelve months with the majority of funds directed towards refinancing existing loans rather than new projects or acquisitions. The challenge now is to move past the doom and gloom story that financiers have held onto and reveal the new opportunities within the market as more coal contracts come up.

Equipment

The previous 12 months saw tighter lending, a decrease in exploration and the end of the construction phase for many sites, pressuring some of the largest mining companies to sell assets to reduce debt and improve cash flow. Run to fail coupled with no capex created a very unusual landscape. Conversely, small to midtier asset owners were forced to hold gear for longer and run machines they would have rebuilt or replaced on site at the height of the boom.

For contractors, work will remain with some mid-scale contracts up for grabs in the hot spots like Bowen Basin and Hunter Valley that will continue to need equipment.

In terms of buyers, we are seeing smaller construction players and beef farmers looking to upgrade their stock will making up the majority of bidders at our auction yards across the country, particularly in Queensland. Assets including +200T haul trucks and +300T diggers are AUSTRALIANMINING

selling especially strong due to renewed interest in coal, with highhoured, old equipment struggling to attract buyer interest.

As the industry enters the next phase and mine sites finish up or look to offload excess stock, there has never been a better time to understand the value of your assets, especially those assets which are now back in demand.

Looking ahead

With uncertainty in the US, LNG demand increasing on the east coast of Australia and China likely to hold its mining restrictions until March, 2017 indeed has a question mark over it, albeit with some optimism.

an increase in lending capacity.

If China’s restrictions on mining relaxes, Australia’s role could be seen to either drive their mining production, or alternatively, no longer be needed as we are now.

However, the resources industry has grown accustomed to operating lean and reducing waste or excess spending. The challenge will be to maintain this mindset through an improving economy to yield the greatest profits.

Overall green shoots are appearing in the resources sector and there are positive stories to tell. But whether you’re buying or selling assets, lending or streamlining operations in 2017, a conservative approach

IF CHINA’S RESTRICTIONS ON MINING RELAXES, AUSTRALIA’S ROLE COULD BE SEEN TO EITHER DRIVE THEIR MINING PRODUCTION, OR ALTERNATIVELY, NO LONGER BE NEEDED AS WE ARE NOW.” If commodity prices continue to soar in 2017 as predicted, we could be in for a return to strong growth across the coal and gold mining sectors. This renewed confidence along with a growth in LNG production, should see more jobs and

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appears to be the norm throughout this volatile industry, which is likely to continue in 2017.

Steve Wall is the general manager at Hassalls, with more than 20 years’ experience in financial services and appraisal. AM

INDUSTRY 4.0

ARE YOU READY FOR THE FOURTH INDUSTRIAL REVOLUTION? FIRST THERE WAS STEAM POWER. THEN ELECTRICITY. THEN ELECTRONICS AND IT. NOW THE FOURTH INDUSTRIAL REVOLUTION HAS ARRIVED: A MIX OF CLOUD COMPUTING, GENERATIVE DESIGN AND ADDITIVE MANUFACTURING. ARE YOU READY TO RIDE THE WAVE FOR WHAT’S ARGUABLY MANKIND’S GREATEST STEP FORWARD? JIM WARD WRITES.

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HE above question was posed to more than 150 engineers and technicians at a workshop held in Perth in September

by Autodesk, a global leader in the creation of software for architecture, engineering, construction, manufacturing, mining and the entertainment industry. Richard Elving, Autodesk’s

manufacturing sales manager in Australia, said dominant technology trends - cloud computing, mobile technology, social connection, and collaboration - were driving businesses and consumers alike to explore profoundly different ways to design, make and use things.

ABOUT THE SPEAKERS Richard Elving (Autodesk) is an award winning sales manager with a 14-year sales career reflecting experience and outstanding performance in product design and manufacturing. He has an extensive network through the manufacturing community across Australia, Asia and Northern Europe, and a strong passion to enable innovation in manufacturing.

Manufacturers have always been seeking ways to make things quicker, easier, cheaper, but now the new and growing expectation for products customised to the needs of individuals is posing a fundamental challenge to the current approach to product design and manufacture.

Dubbed “The future of making things”, the path ahead for the manufacturing sector world-wide is rich in opportunities but also littered with traps for the unwary. It’s a future that will involve three transformations – how things are designed and made, what customers care about and want and the nature of the products we make.

For the first time, large-scale manufacturers face a serious challenge from smaller – even start-up – companies that are quick on their feet, take the massive computing power offered by cloud-based technologies as a given, and focus on imagination and innovation, creating new products and distribution methods for the future instead of simply looking for ways to tweak the present.

Key to the development of products in the future is the “Internet of Things” – the cloud-based linking of products worldwide to make a reality of concepts like the smart city and the driverless car.

“We moved on from the age of documentation to the era of optimisation. Now we have to prepare ourselves for the era of connection,” Elving said.

“It’s estimated that by 2020, 50 billion products will be interconnected.”

He cited the example of Tesla cars, which use interconnectivity to send updates to car owners, for example to increase power from the existing unit, or to solve problems that may arise.

Interconnectivity will facilitate the exchange of information between all the disciplines involved in the flow from concept, through design and engineering, to manufacture and distribution. This, said Autodesk, will replace the need to use multiple software programs that don’t talk to each other with a single product AUSTRALIANMINING

innovation platform that will extend from concept right through to customer feedback, to facilitate ongoing product improvement.

Autodesk is working towards the fulfilment of this need with Project Dreamcatcher, which it describes as the next generation of CAD. Dreamcatcher is a generative design system that enables designers to craft a definition of their design problem through goals and constraints. This information is used to synthesise alternative design solutions that meet the specified objectives.

Designers can then explore trade-offs between many alternative approaches and select design solutions for manufacture.

This marks a massive step forward in the evolution of CAD. Although the acronym stands for “Computer Aided Design” it is essentially a passive system that would more accurately be termed “Computer Aided Documentation”.

The emerging generation of design tools enables designers to go beyond simply telling the computer what to do. By feeding in objectives and restraints they can tell it what they want to achieve. This makes the computer not simply a tool for execution, but an active player in the process of creativity – a process that will produce literally hundreds of solutions, many of which would lie outside the scope of human imagination.

When generative design is combined with new forms of manufacturing like 3D printing, which lends itself to smaller manufacturing spaces, total flexibility in product output and commercially feasible short production runs, it sets the scene for a complete restructure of the manufacturing sector.

This raises the other key question in the future of making things, which is the translation of generative design to the manufacturing process – “taking it from art to part”, in the lingo of the industry.

The most frequently touted solution is additive manufacturing (AM), or 3D printing.

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Despite having many impressive runs on the board, AM is yet to win universal acceptance. Is it, as many still claim, just a fad?

No, says Autodesk. While Australia may be lagging behind industrial giants like the USA, China, Germany and Japan in the adoption of AM, its small and scattered population, coupled with the logistical problems associated with a preponderance of remotely located industries like mining and agriculture, makes it ideally suited to take up this flexible technology on a grand scale.

AM has clearly demonstrated its ability to go further than the economical manufacture of prototypes and short run products.

Despite common perceptions, it is also well suited to long run mass

ABOUT THE SPEAKERS Matthew McKnight (Autodesk) is a mechanical design/ project engineer with over 15 years’ experience. His particular strengths lie in project management, with a proven ability to research, design, prototype, develop and implement innovative solutions.

INDUSTRY 4.0

production. In Germany, a company servicing the medical industry last year produced ten million items using AM. And, importantly, variations to the original item did not involve expensive retooling – simply an amendment to the computer program.

Matthew McKnight, senior technical specialist, manufacturing, for Autodesk in Australia, illustrated to the potency of the marriage

between generative design and AM by outlining a case study of a joint project between Autodesk, Airbus and New York design consultancy, The Living, to produce the world’s largest metal 3D printed aircraft component.

He explained that the specifications for the existing partition, currently in use in every Airbus in the world, were fed into the

THE FUTURE OF MAKING THINGS HERALDS AN ENTIRELY NEW WAY OF APPROACHING THE MANUFACTURING PROCESS, FROM CONCEPT TO PRODUCTION, AND EVEN THE ONGOING DEVELOPMENT AND MAINTENANCE OF THE FINISHED ITEM. THE POTENTIAL BENEFITS ARE, QUITE LITERALLY, STAGGERING.”

ABOUT THE SPEAKERS David Budge, managing director of Aurora Laboratories, has a Bachelor of Science (Chemistry) degree from the University of Western Australia. He has extensive industry experience in robotics, robotic welding, surfacing engineering, product development and manufacturing processes. He is recognised for his experience in solving difficult fabrication and surface engineering problems. He is the primary inventor of the large majority of Aurora’s inventions.

computer together with a number of weight and strength constraints.

From the myriad of solutions produced by the generative design program, one was selected that met – and exceeded – the criteria. The organic design, although complex in detail, was totally capable of being produced by a 3D metal printer.

The finished product met all the prescribed aviation strength and safety criteria, and weighed in at 45 per cent less than the production item currently in use in the Airbus fleet.

Airbus estimates the new partition, which will be in operational service by 2018, will create a saving of up to 465,000 metric tons of C02 emissions per year, the equivalent of taking about 96,000 passenger cars off the road for one year. And, of course, the application of generative design and additive manufacturing won’t stop there for the aircraft manufacturer.

Autodesk describe this as a perfect example of technology making the quantum leap from passive to generative.

McKnight said it had involved taking new approaches at every stage of the manufacturing process, from the software used to conceive and design the new partition, through the manufacturing hardware to the materials used in the end product.

“This is the way manufacturing is heading, and it’s what we should all be doing,” said McKnight.

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“It’s not a question of if, but when these new technologies will be widely available.

“It’s a question of ‘be proactive, or be overtaken’,” he said.

One Western Australian company that has already emphatically opted for the proactive route is Perth-based Aurora Laboratories.

Established just two years ago, Aurora’s primary goal was to enable the mass adoption of 3D metal printing via new technologies that would significantly reduce the purchase price and make production faster and cheaper.

“Our first goal, which we recently achieved, was to build an industrial quality small format printer that could be marketed for around $50,000,” said Aurora’s managing director, David Budge.

Additive manufacturing costs are predicated on the weight, rather than the shape, of the item being produced – “the complexity comes free”, as Budge puts it. In practical terms, this means that producing a complex shape like a turbine would cost roughly the same as producing a simple square block of the same weight in the same material.

“Our next goal is to produce a highspeed, large format printer capable of producing a high-resolution one-tonne component in one day – which would take from three to six months using current technology,” said Budge.

“We’re currently building our first large format prototype, and we expect it to be commercially available within two years.

“It will have a massive impact on production costs and will seriously challenge the viability of traditional manufacturing methods, as well as the existing supply chain mentality,” he said.

Aurora’s vision for the large machine is that it will be able to produce a heavy and complex component, such as a 300kg pump or valve, for as little as $4,500, compared to a probable cost in the region of $80,000 using conventional manufacturing methods.

According to Budge, this will impact on the way people approach issues like spares inventory, for example on mines in remote areas, where currently the high cost of maintaining a large spares inventory has to be weighed against the loss

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of production caused by a long wait for parts.

Aurora is confident that as soon as AM costs match conventional methodologies like milling and casting, there will be a strong and sustained swing to the new technology.

With this will come major industrial changes, by no means limited to increased productivity and reduced costs.

Factories dedicated to a single product line – a car plant, for example – will give way to multipurpose production areas where AM machines can switch seamlessly from one product to another with a simple software change, and where modifications to individual products are just a matter of keystrokes.

The capacity to profitably produce in small quantities, and to tailor products to a client’s or consumer’s specific needs, will facilitate the localisation of businesses. This, in turn, will aid local development, at the same time greatly reducing the manufacturing sector’s transport footprint.

Elving summarised Autodesk’s view on future directions for industry by reiterating that when generative design is combined with new forms of manufacturing like 3D printing and applied to small-scale production facilities, it sets the scene for the development of a very different manufacturing landscape.

“The future of making things heralds an entirely new way of approaching the manufacturing process, from concept to production, and even the ongoing development and maintenance of the finished item.

The potential benefits are, quite literally, staggering,” he said.

Elving said Autodesk was facilitating accessibility to its total software range by moving the provision of its products to a subscription system.

“Although this has only been in place for a matter of months, this has already led to an increase in uptake from both large and small companies.

It replaces the upfront cost and maintenance fees with a regular subscription that includes updates. If the software is acquired for a specific project, the subscription can be cancelled when the job is complete,” said Elving. AM

INDUSTRY OPINION

ROOM TO GROW AT ATLAS COPCO AS WE OFTEN SPEAK TO THE MOVERS AND SHAKERS IN AUSTRALIAN INDUSTRY, THIS TIME WE TALK TO MATT HOBDEN, THE NEWLY-MINTED GENERAL MANAGER OF ATLAS COPCO AUSTRALIA, ABOUT WHERE THE LOCAL INDUSTRY IS HEADING FOR COMPRESSORS AND BLOWERS, AND WHAT THE FUTURE HOLDS FOR ONE OF THE WORLDS’ ICONIC COMPANIES IN THAT FIELD. Australian Mining (AM): In terms of how you managed to get into your role, how has your experience from where you started helped in terms of how you approach your current role?

you a unique insight into how the company functions or perhaps, should function?

of the company and have those directions or ideas been shaped by your experience?

AM: For many years, Atlas Copco was well known for its rental business - is the rental side still a big part of the business?

Matt Hobden: My first role at Atlas Copco was as a sales engineer and I think that really gave me a good understanding of the sales process.

So I had a couple of sales roles and then transitioned into a local product manager role so starting to support the sales reps in the field and being a little bit more involved in the management of the business so product managements gave me a good feeling for developing products, promoting products, and pricing, and I had another role which was engineering manager.

Matt Hobden: I think so, and you could include commercial as well too because one of the things that’s changed dramatically in the last 10-15 years locally is the commercial and legal landscape. So 10-15 years ago, you could do a deal on a handshake and now with the changing nature of investment in the country, I think for the better of course, commercial and legal contracts have become a lot more onerous, so I think my last position as engineering manager gave me a good understanding of engineering contracts, which I think is absolutely essential now.

Matt Hobden: So we have a changing environment, as I mentioned previously, we see mining and oil and gas transitioning into production so we need to make sure we align our business with that potential. We are also seeing some pent up demand

Matt Hobden: It wasn’t our largest business but it was quite significant, because if you take the business 10 years ago, we had more of a what we call a general hire focus so we had a product range not as broad as anywhere near as broad as say Coates

AM: So with a technical and sales background, would you say that gives

AM: What would be some things that you are looking at for the direction

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OUR HUBS ARE QUITE WELL ESTABLISHED WITH CAPACITY FOR GROWTH.” coming from manufacturing and hopefully this will be released if the Australian dollar softens a little bit more and the country becomes more competitive. So we need to make sure we’re aligned with that potential.

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Hire but similar so we’d offer quite a diverse range of equipment like compressed air, lighting generators, lighting towers, pumps, welders, even hydraulic and air driven construction tools. But that all changed in 2007,

INDUSTRY OPINION

so we had a significant divestment where we divested everything aside from the compressed air to Coates Hire and we had a refocus on the core of compressed air. So the business now does predominantely large compressed air, large power, high volume nitrogen generators and there’s just been a recent acquisition of a nitrogen generator rental business and also steam boilers.

AM: Are there other geographical areas where you’re seeing growth?

Matt Hobden: I think at the moment most of the growth is in the northern part of the country, purely because of the investment in energy and minerals. Mining’s is currently facing a downtun or levelling out if you like, and the company has traditionally been quite strong in this area.

AM: Have the challenges in the mining environment affected you and are you looking for growth in other areas?

Matt Hobden: The changes in the mining environment have impacted

us from an investment perspective so obviously mining investment’s peaked, transitioning into production and at the moment we’re just starting to see greenshoots in exploration.

So where it has affected us slightly overall with the business is we don’t see the big multi-machine projects – the big investments.

However there are significant opportunities now with production because all that investment now is transitioning into production.

If you look at the statistics, we’ve never been producing more iron ore, never been producing more coal and talking to a mining business, there’s greenshoots already in gold so I think the focus is shifting more into production related opportunities which have never been better.

AM: Are you looking to expand this site itself to other areas?

Matt Hobden: Probably not in Sydney. In the Sydney region we already have quite a good deal of capacity with this location. We probably see ourselves maybe

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expanding more in the regional areas with additional coverage of the market. So our hubs are quite well established with capacity for growth, but probably the regions is where we can leverage that and the good news for us is if you take the mining sector for instance, well the mining business has in the order of 17 locations nationally. So in quite a lot of instances we have remote people from the compressor business in the mining locations with the mining business so we get great leverage in synergies from the other business areas.

AM: What is the one thing you would tell your potential successor about the business and what they actually do?

Matt Hobden: I would tell them to focus on our people. You need to daily keep your people engaged – that would be the first lot of advice.

Maybe if I break it down into three things: the second lot of advice I would say is focus on your customers, make sure you have promoters of your business. And the third thing would be, expect change in the

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environment and make sure you’re continually adjusting the organisation to that changing environment.

They’re all quite broad things but I think that’s the advice I’d give that I’d give. AM MATTHEW HOBDEN, GENERAL MANAGER OF ATLAS COPCO AUSTRALIA.

CORROSION

CORROSION – THE PROBLEM GRATING AWAY THE AUSTRALIAN INDUSTRY CORROSION IS COSTING THE AUSTRALIAN ECONOMY BILLIONS OF DOLLARS EACH YEAR, BUT THERE ARE WAYS FOR BUSINESSES TO EASE THE PAIN.

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ithin industrial environments, exposure to things like water, acid or salt causes corrosion of geared motors. This, in turn, reduces the strength of the corroded parts and inevitably means they have to be replaced.

In corrosive environments the need for replacement is more than just occasional. Gear boxes need to be replaced as often as every six months. Apart from costs and downtime, such a maintenance regime presents businesses with all too frequent gearbox mounting challenges.

For obvious reasons, businesses in the food and beverage sector are required to maintain high hygiene standards. To do this, they need to follow strict wash-down procedures which have the unfortunate side- effect of increasing the rate of corrosion.

Similarly, corrosion is a problem for operations dealing with chemicals, those located offshore or near the coast, and others (such as car washes) which just can’t avoid water.

Historically, businesses looking to

deal with this problem have had two options: to use stainless products or products with a protective coating.

The attractions of stainless steel for this purpose is obvious.

It eliminates the need for harsh cleaning chemicals and decreases the instances of leaks, rust and corrosion.

To date, stainless steel has rightly been regarded as a better anti-corrosion solution than the alternatives, namely paints and surface treatments.

The problem with such coatings is that when used on original painted aluminium surface, they simply lie on top of the aluminium substrate and may even bridge across pores in the metal. In other words, they do not form a permanent bond to the substrate. They can easily be removed if bumped or scratched, and therefore offer only limited corrosion resistance.

For its part, NORD, recently released the NSD tupH Sealed Surface Conversion System in Australia that is designed to provide protection at a molecular level and that has been hailed as a breakthrough in corrosion protection.

Unlike surface coatings, NSD

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tupH includes a base layer that is permanently bonded to the aluminium substrate and provides a powerful foundation for adhesion of the surface sealant. This foundation provides excellent roughness, is six to seven times harder than the aluminium substrate and up to 1000 times harder than paint.

In other words, the product is superior to surface coatings and is a genuine alternative to stainless steel. Indeed, according to the company, it offers two advantages when compared to stainless steel.

Firstly, it is significantly cheaper.

NSD tupH delivers similar levels of corrosion protection at a fraction of the cost.

Secondly, products coated with the system are much lighter than stainless steel products. This makes mounting and maintenance easier.

The surface treatment creates an easy to clean surface which is resistant to acids and alkalis of wide pH range. Free from chromates, it prevents the spreading of corrosion, even in cases where machinery is physically scratched or damaged.

NSD tupH drives can be used in demanding atmospheres much beyond the usual service life of paint-coated systems. Since no

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coating is applied and only the surface is hardened, contamination of products or process media is avoided, which is not possible with chipping paint.

The system conforms to FDA Title 21 CFR 175.300 and has successfully undergone ASTM D714 and proven its resistance to blister formation. Similarly, it has proven its effectiveness against corrosion through ASTM D610-08, and scribe per ASTM D1654-08 according to DIN EN ISO 2409.

Further tests performed on the system included ASTM B11709 Salt spray test, ASTM D3170 Gravelometer test, DINEN ISO 9227 Salt spray mist test, and DIN EN ISO2409 Cross-cut test.

It is approved for food applications according to FDA Title 21 CFR 175.300 with treated systems resisting cleaning agents in the pH2 to pH12 range.

The company said it uses NSD tupH on a range of products, including its Helical gear units, Bevel gear units, UNIVERSAL worm gear units, Smooth motors, and Electronic SK 1xxE. All gearboxess are supplied with stainless steel hollow shaft and fasteners. AM

NOMINATIONS NOW OPEN 11 MAY 2017

MELBOURNE WWW.ENDEAVOURAWARDS.COM.AU

MAINTENANCE AND MONITORING

ADG ENGINEERS INTEGRATED SOLUTION FOR MACLEAN MANUALS ABSOLUTE DATA GROUP’S (ADG’S) R4I SUITE OF SOFTWARE HAS HELPED TRANSFORM THE BUSINESS OPERATIONS OF MACLEAN ENGINEERING.

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eeping more than 1000 manuals for operators, training, maintenance and parts continuously upto-date and accurate is an arduous task for even the largest mining equipment companies.

Include the need to make daily updates, and to translate manuals into languages like French and Spanish, and the task becomes near-impossible.

But for Canada’s MacLean Engineering, implementing Absolute Data Group’s (ADG’s) R4i suite of software has transformed the business and halved the manual publishing time.

A developer of underground mining equipment for more than 40 years, MacLean’s products and support services are found in 23 countries on six continents. The company’s diverse product line covers ground support, ore flow, explosive handling vehicles, shotcrete sprayers, and support vehicles and attachments.

MacLean supports its marketplace with a global distribution network of branches and dealers, a parts support hotline, a technical support hotline, an online technical publications portal, an online order tracking portal and the provision of recommended spares packages.

Outdated publishing system

MacLean provides an essential suite of multilingual technical publications in a variety of formats for its equipment. In growing the business, while also taking its expertise to the

fields of municipal infrastructure maintenance, hazardous materials recycling, construction and contract manufacturing, MacLean’s need for superior, integrated technical documentation has never been greater.

This meant MacLean technical publications manager Bruce Mackereth was faced with a hurdle from his first day with MacLean, as the existing system could not cope with the required output.

“When I started at MacLean, there was a backlog of 219 sets of new manuals outstanding, which equated to around 4300 hours or two years of work using our old system,” Mackereth said.

“Customers were left waiting to receive their manuals well after they had received their machines, which frustrated both our customers and us.”

With MacLean constantly trying to get through the backlog, the company couldn’t focus on developing manuals or be more innovative with documentation.

“Instead we had a system that not only took an inordinate 20 hours to create one manual, but a system that didn’t even allow our staff to have access to digital content online,” Mackereth recalled.

updating content, re-use data more easily, enable authors to focus on content rather than formatting and provide on-line access to documentation.

ADG’s R4i product suite delivered these requirements by providing tools to create, manage and leverage information that is vital to the operation and maintenance of complex assets.

The integration between the R4i products allows for the same information to be used across various business areas consistently and quickly.

By having one source of content, it saves time and money, ensuring information out in the field during maintenance and in training is changed at the same time.

Mackereth said the full suite of products was implemented two years ago. “We can now produce detailed parts and operator manuals with minimal effort. What once took 20 hours to complete, now only takes eight to 10 hours, from CAD output to a published manual,” he said.

Since the implementation, MacLean has structured and published 302 manuals, and cleared the backlog in the first year. The documentation is produced in XML and published in both electronic and print mediums.

Realising the benefits

ADG chief executive Tammy Halter said many mining, transport and defence companies were seeing the same benefits as MacLean.

Write it once, re-use it everywhere

MacLean needed a solution that would halve publishing time, reduce the cost of AUSTRALIANMINING

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“Benefits can be gained in data planning and management, authoring and delivery. By utilising an S1000D compliant database, our CSDB, at the core of the system, data can be exchanged and re-used more easily and common data can be identified,” Halter said.

Mackereth believes the publishing speed and the cost savings gained from re-using content have been the greatest benefits.

“We receive our data from CAD CAM systems and automatically import that into the CSDB, for multirepurpose across customers and across delivery types. We would re-use about 75 per cent of our content, in terms of data modules and images,” he said.

“That’s a huge saving to our business when we have over 42,000 modules and over 125,000 images in our database.”

After further developing documentation, producing new products and exploring opportunities for greater innovation in the past year, MacLean is looking ahead with excitement.

“With a fantastic system supporting us, we are now completing the creation and population of around 300 modules that can be used to create any one of 61 different English operator manuals for our equipment,” Mackereth added.

“But the most exciting development is our foray into creating standardised e-learning for both maintenance and operating instructions for our customers.” AM

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PRODUCTS

TAKE-UP WINCHES FOR INCREASED SAFETY Vector Lifting has designed and implemented improvements on its take-up winches for enhanced safety and productivity.

The winches have been designed to ensure easy installation and operation onsite, with a focus around ease of use for operators.

The design and fabrication is focused around compliance to AS1418 Australian Standard Electrical requirements as well as ensuring compliance to the sites particular standards. The safety features assist in ensuring an efficient shutdown of the conveyor and reduces downtime in production.

The winch is designed to have interchangeable parts with all Vector winches and easy access lubrication points.

Each new product is re-assessed to ensure that the conditions and requirements of the new site and operating location is considered, as well as applying client specific prerequisites. A focus around ease of maintenance of the winches was taken into consideration to minimise downtime.

• Vector Lifting (08) 9417 9128 www.vectorlifting.com.au

RESISTIVE TOUCH MONITORS FOR INDUSTRIAL APPLICATIONS Backplane Systems Technology has released faytech’s Resistive Touch Series Monitors designed for demanding applications.

Its features include lockable standard connectors, a unique cable channeling back cover, LED backlight, 4-wire resistive touch screens, extra robust components, wide range power supply (8-36VDC) multiple video inputs and extended temperature range.

These sunlight readable (1000Nits) rugged monitors are dust and water resistant to the IP65 protection rating and sealed in an aluminum enclosure. For connection, faytech provide an all-in-one cable solution with HDMI or VGA picture connection, USB for touch, and 8-36VDC power connection. The operating temperature is -25°C to +75°C. High-performance LCD panels with LED backlighting, extreme long life, coupled with specialty films and enhanced polarisers, allow an ideal picture even under direct sunlight. Buttons are available on the front to change brightness levels. A 5-wire resistive touch screen is fitted to the monitors. Mounting is VESA 75.

The IP65 Monitor Series are available in a range of sizes from 7” to 15”. For projects, individual customisations are available in the cable connections, colour, logos, housings and fixing points.

• Backplane Systems Technology (02) 9456 6400 www.backplane.com.au

RIG-MOUNTED HYDRAULIC BREAKER WITH INCREASED IMPACT ENERGY International construction equipment manufacturer Chicago Pneumatic has launched the RX12, a rig-mounted hydraulic breaker for carriers between 9-15 tonnes.

C o mp a r e d t o it s predecessor model, the RX12 offers increased output power and impact energy.

With a service weight of 625kg and a tool diameter of 90mm, the RX12 delivers a combination of high reliability and efficient performance. It is suitable for a range of light demolition, landscaping, building renovation, mining, and road construction applications.

The RX12 features an innovative mono-block design, with the cylinder and tool holder integrated in one piece.

This reduces the total number of parts, and eliminates the need for side bolts, to increase overall reliability. The inclusion of a replaceable cylinder sleeve also cuts repair time and costs.

The new breaker’s double tool retainer bars ensure optimal working tool guidance, with a one-piece floating wear bush enabling quick and easy field replacement of the working tool. It has a central lubrication point for manual greasing, but can also be equipped with an automatic lubrication device called CP-Lube.

The RX12 also has a breaker box guidance system that dampens noise and vibration levels. As with all hydraulic breakers in the RX range, the RX12 features gas/oil hybrid technology, an internal control valve, and a Power Booster mode that reuses wasted recoil energy for increased efficiency and performance.

• Chicago Pneumatic www.cp.com

AUSTRALIANMINING

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NOMINATIONS NOW OPEN FOR 2017 2017

For more information and to nominate visit www.paceawards.com.au

EVENTS XXX PRODUCT SHOWCASE

CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@ AUSTRALIANMINING.COM.AU

MINERAL EXPLORATION ROUNDUP AME 2017 23-26 JANUARY 2017 VANCOUVER CONVENTION CENTRE VANCOUVER, CANADA This year’s conference will bring together geoscientists, prospectors, investors and suppliers to share ideas that will help shape the future of mineral exploration and development. As the mineral exploration and development industry continues to work through the current downturn, we reflect on the importance of networking, professional development and relationship building with our partners, stakeholders and competitors. Mineral deposits are becoming harder to find meaning companies must travel to more remote locations, search deeper beneath cover, and sometimes settle for lower grades. These aspects, coupled with the challenging market conditions, serve as a reminder to be more creative and collaborative during exploration and the

development of new mineral deposits.

•Association for Mineral Exploration (AME) (604) 630 3930 roundup@amebc.ca www.roundup.amebc.ca

2017 SME ANNUAL CONFERENCE & EXPO AND CMA 119 NATIONAL WESTERN MINING CONFERENCE 19-22 FEBRUARY 2017 COLORADO CONVENTION CENTRE DENVER, COLORADO The 2017 SME Annual Conference & Expo and the Colorado Mining Association (CMA) 119 National Western Mining Conference provides a forum for more than 6500 industry professionals around the world to share innovative ideas, best practices, and research.

It will include 120 sessions and will provide an expansive marketplace for more than 650 exhibiting companies.

Industry leaders will share their vision, expertise and experience, while mining professionals will explore key insights needed to thrive in an era of rapid economic and market change.

•SME 303 948 4200 cs@smenet.org www.smeannualconference.com

GOLD17@ROTORUA 21-23 FEBRUARY 2017 DISTINCTION HOTEL ROTORUA, NEW ZEALAND Gold17 will be held for the first time in New Zealand, after commencing with Gold’82 in Zimbabwe. The event will focus on developments in gold mineral systems, exploration technologies, opportunities as well as Pacific margin geology and mineralisation. It will feature speeches, workshops, excursions and

social programs as well as networking opportunities.

•Gold17@Rotorua Rotorua2017@geosymposia.com.au www.rotoruagold17.co.nz

SA MINERALS & ENERGY SERVICES FUTURE FORUM 28 FEBRUARY 2017 LOCATION (TBA) The South Australian Chamber of Mines and Energy (SACOME) will jointly host the forum in collaboration with a range of organisations including Austmine and METS Ignited. The Department of State Development is developing an industry wide South Australian Minerals and Energy Services Strategy with consultation from industry to ensure future industry, academic and government initiatives are aligned for optimal growth of this sector. This full day event will bring providers of goods or services together with other industry stakeholders in a program that presents the themes of the strategy, aiming to share ideas, generate discussion and build knowledge. The day will include speakers, panel discussions, and networking sessions.

•SA Minerals & Energy Services Future Forum www.sacome.org.au

17TH ANNUAL MINERAL SANDS CONFERENCE 15-16 MARCH 2017 HYATT REGENCY PERTH, AUSTRALIA This event is Australia’s only meeting place that offers comprehensive analysis of the Ti02 and Zircon markets and brings together Australia’s Mineral Sands leaders to discuss latest industry developments and future outlook. The 2017 event is supported by the Zircon Industry Association and provides expert views from international guest speakers, leading industry analysts, updates from Australia’s current projects and operations, and details on the key issues for mineral sands industry.

•17th Annual Mineral Sands Conference 02 9080 4030 www.informa.com.au AUSTRALIANMINING

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DECEMBER 2016

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© 2016 Apex Industrial Technologies LLC. All rights reserved. Apex Supply Chain Technologies and its mark are registered trademarks, and Smarter Spaces and ACTYLUS are trademarks of Apex Industrial Technologies LLC.