Sandvik launches new exploration drill

With safety a major priority in any mining operation, Sandvik have released its newest addition to its range of DE700 series surface exploration drills.

The DE712 is based on the established DE710 drill and includes all the necessary safety, health and environmental requirements for CE certification. The company says that this highly productive and reliable rig offers customers peace of mind with increased safety on an already proven design.

George Tophinke, Sandvik Mining’s global exploration equipment manager, said the new rig has the right features to get the job done.

“This rig has the right balance of world class design, high quality components and robust construction to minimise downtime and risk. It is based on the reliable DE710, which has sold nearly 500 units across the globe. There are new safety features in line with Sandvik’s ongoing focus on integrating environmental, health and safety solutions into our products”. 

Other additional safety features include lever guards to reduce risk of accidental operation, mast access package comprising of fall arrest system and mast platform, and alarm for jack leg operation. Rig access has been improved for easier maintenance and extra guards have been fitted for safer work environment.

The DE712 features a more powerful engine with power rating of 142 kW (190 hp) at 2200 rpm. High quality pumps and motors in independent open loop circuits, and larger hydraulic valves and piping provide high energy efficiency and precise control of critical drilling functions.

Off the grid solar solutions

Energy hungry mining companies are increasingly looking for off-grid power solutions, in an effort to reduce the use of diesel generators, bring down electricity costs and minimise carbon footprints.

Solar power solutions company Photon Energy told Australian Mining that solar power, particularly in remote locations is proving to be an attractive alternative which lowers electricity costs.

“Solar power is a clean, sustainable, and cost effective way to produce power and has a stable and calculable cash flow,” Photon Energy’s Australian managing director Michael Gartner said.

Gartner told Australian Mining that he is starting to see the emergence of an “industry-wide realisation” when it comes to managing energy consumption, costs, supply, and risks.

Most commonly diesel is used for remote electricity generation on mine sites, a practice that weighs heavily on the environment, health, bottom line and reputation.

A recent report from the World Health Organization says diesel fumes cause cancer.

The new ruling puts diesel fumes almost on par with second hand smoke.

And while the risk of cancer is fairly small a science panel said raising the status of diesel fumes to carcinogen from a 'probable carcinogen' was an important move.

This WHO finding may have significant repercussions throughout the mining industry, where workers are constantly exposed to high levels of diesel fumes, particularly underground miners.

It's on the same order of magnitude as passive smoking," Kurt Straif, director of the International Agency for Research on Cancer (IARC), said at the time.

"This could be another big push for countries to clean up exhaust from diesel engines."

Gartner explained that the cost of solar technology has in the last two years dropped significantly.

“Today solar is now the cheapest form of power at the point of consumption,” he said.

“This means self-consumption or avoiding the grid is now the most cost competitive way to provide solar power.”

Gartner said that in an off-grid situation the cost of diesel generation is significantly more expensive than electricity from a solar photovoltaic plant.

With the refinement of solar technology, it can now be seamlessly integrated into either a grid, off-grid or hybrid system delivering both power reliability and cost savings.

Discussing solar power reliability Gartner stated that the elimination of moving parts in a solar system means that in comparison to a diesel generator it requires less maintenance.

“When combined with diesel or gas generators in a hybrid system, solar helps reduces the total cost per kWh while the whole system takes care of a 24 hour power supply,” he said.

Solar power can also act as a booster for off grid power generation, run in parallel with gas or diesel generators to cover peak power requirements on site.

He explained that one of the company’s strengths is its ability to integrate demand management, so the site’s power system can be optimised; one example of optimisation is giving preference to solar throughout the day and diesel at night.

“We can just as easily integrate a solar PV plant with existing infrastructure and do a thorough analysis of the existing generation equipment, power demands and decide on how best to implement integration,” he said.

However the initial financial outlay for a mine to install an off-the-grid solar system is still proving to be a barrier, especially when it comes to existing operations.

“Financing is proving to be a significant barrier, especially for existing mines,” he said.

To combat this Gartner said Photon Energy has devised finance packages and power-purchase-agreement [PPA] solutions.

A PPA is an agreement between the power producer and the power consumer that sets all the conditions of the power supply agreement including price per kWh, the minimum kWh to be supplied and purchased, the quality of the supplied power, up-time and performance guarantees and what happens in the case that either party would not meet their obligations.

These solutions mean mining companies do not need to invest heavily in building a local photovoltaic plant, but can buy electricity on the basis of the power-purchase-agreement.

“We are aware that with any new technology customers will be cautious and to get over this barrier we are willing to put our money where our mouth is,” he said.

“The solar potential in Australia is huge, not harnessing it with today's technology is just pure wasteful.”

In 2011 Australian Mining reported Galaxy Resources received an award for its solar tracking panels at its Mt Cattlin lithium mine.

The miner won the Energy Generation and Distribution Award from the Sustainability Energy Association of Australia.

Mt Cattlin was the first mine in the country to have real time solar tracking panels installed to generate power on site.

By having solar tracking, the panels are able to follow the sun in all directions, providing 15 per cent more power than a single axis system.

Galaxy has 14 solar trackers and two wind turbines operating at the lithium mine, which create 226MWh per year of renewable energy and accounts for a sixth of the daily energy at the site.

The system was designed by Swan Energy.

“Policing” TML in the Pilbara with the MoistTech CCS-3000 Moisture Analyser

For the first time in 40 years iron ore is being mined below the water table in the Pilbara.

Exacerbated by the wet season, TML (Transportable Moisture Limit) is now a crucial concern for major producers. 
Delays to loading and also unloading non-compliant ore or customers rejecting product, costs millions of dollars.

The MoistTech CCS-3000 Moisture Analyser “polices” TML in real-time as iron ore fines is conveyed on a belt.  Interventions can then be made to select or combine suitable stockpiles to comply with TML requirements.

Extensive and successful repeatability and reliability trials of the MoistTech CCS-3000 with major producers in the Pilbara have set the CCS-3000 apart as the technology of choice to measure free moisture accurately, consistently and in real-time.

Recent fatalities from ocean-going bulk carriers capsizing due to liquefying iron ore fines, have focused the attention of the International Maritime Organisation (IMO) on its classification. A two-year, $2m research project into the liquefying phenomenon is being completed by the Australian Mineral Industry Research Association to be completed in May 2014 for submission to the IMO.

In the meantime, the MoistTech CCS-3000 Moisture Analyser “polices” TML effectively, efficiently and economically. Money and time are saved by determining the instantaneous percentage moisture content of the ore.  Moisture content can be viewed in real-time, alarms can be automatically raised and monitoring can be conducted via smart phone also so appropriate people can intervene.

 “The MoistTech CCS-3000 Moisture Analyser employs a non-hazardous technology, emitting rapid energy pulses 7,000 times per second from a specifically designed energy source onto the iron ore fines using forward optical reflection and collimated energy techniques, to succeeded in accurately measuring moisture to “police” TML effectively” Andrew Game, Sales Director, JW Industrial Instruments.

Cutting it fine – moisture measurement

The Pilbara is iron ore.

The region is a story of massive material movement and bulk handling.

In moving iron ore, every hour wasted can cost a company thousands; so even when companies are facing an issue as seemingly simple as wet iron ore fines it seriously harm a miner's bottom line.

If a shipment of iron fines is suspected to be wet, the ship must stay in port until they are dried, or face the potentially dangerous problem of these fines turning into a slurry during transportation – a slurry which has been known to overbalance and roll transport vessel, putting them at risk of capsizing.

The best way to avoid this is to monitor and recognise the moisture levels in these fines to begin with.

However current methods are either too time consuming or require high level technical knowledge.

Speaking to Aidan Harmon and Andrew Game from JW Industrial Instruments, they told Australian Mining "typically moisture measuring instruments take between three and eight hours to get a result, which is a massive cost in time for miners".

In addition to this other methods which use radiation to measure moisture content, though slightly faster, are more likely to draw environmental criticism, on top of the need for its results to be taken to a laboratory. 

So what can be done?

JW has released MoistTech's new CCS 3000 online continuous moisture analysis system which it says cuts the time down from hours to mere seconds.

Already on trial with an iron ore miner in the Pilbara, this non-hazardous approach emits rapid energy pulses 7000 times per second from a specifically designed energy source onto the fines using an optimised optical design using forward optical reflection. 

This is returned in a beam of collimated energy CE to its detection system.

By using this "miners can get an instantaneous measurement, as it can give a reading nearly every second" prior to the material being loaded on the ship.

This also saves time as wet ore does not have to sit in the ship and wait to dry, instead being able to be dried out prior to loading.

The technology is designed "to be a policeman, it can stop the material from being wet but here there is a big slug of wet material going then this technology can pick it up".

Rio commissions Chinese designed 230t dump trucks powered by German engines

China-based Xiangtan Electric Manufacturing Corporation (XEMC) has recently shipped four of its SF33901 mine dump trucks to the Pilbara for use at Rio Tinto’s Mount Tom Price site.

The 230 tonne dump trucks are powered by the MTU 16V 4000 C11 mining engine provided to XEMC by engine building business MTU Hong Kong, a subsidiary of Germany based Tognum Group.

“This world-class propulsion package was specifically requested by Rio Tinto for its iron ore mining operations in the Pilbara because of its best-in-class fuel efficiency and great reliability,” MTU stated.

MTU was originally Motoren und Turbinen Union GmbH and has been building engines for over 100 years.

The MTU 16V 4000 C11 mining engine produces 2300 bhp (1,715 kW), and is built to withstand the harshest of mining conditions in order to operate reliably and efficiently.

The engines incorporate common rail fuel injection, double-walled fuel lines, carbon scraper pistons and oil system security filters.

In addition, the engine’s class-leading fuel economy is enhanced by an efficient oil cooling system, which optimises oil temperature.

“The working conditions in the Pilbara may be the toughest in the world, with extremely high temperatures and a challenging natural environment,” said Neil Coney, general manager for Fleet Strategy and Delivery, Rio Tinto.

The quick delivery of the trucks left a lasting impression on Coney, Mineweb reported.

“Obviously, the trucks we use on site must be able to withstand such harsh conditions and deliver the best fuel economy possible. Because our reliability and fuel economy standards are very high, we insisted on the MTU Series 4000 engine for each truck. It was amazing to see XEMC produce four trucks that can meet our strict requirements within one year,” he said.

Scott Woodruff, director of global mining sales at Tognum America explained that it is important companies like Rio and Tognum continue their work together into the future to develop the best suited machinery possible.

“As mine operators continue to tackle the issue of rising fuel costs, we continue to work with our OEM partners to deliver the most robust and efficient mining equipment available,” Woodruff said.

“Our focus on customer requirements enables us to provide MTU mining engines that perform at the highest level in any environment.”

The MTU engines in Rio Tinto’s new XEMC mine trucks will be serviced by MTU Detroit Diesel Australia, the exclusive distributor and service provider of MTU engines in Australia.

Deep drill rescue rig

As the mining industry expands globally the easy to access high grade ores have already begun to diminish.

The remaining high grade and even low grade ores are contained deeper and deeper underground.

To uncover these deep ores specialist equipment is needed.

With this in mind Bauer has ­unleashed PRAKLA Bohrtechnik's latest rig – the RB-T 90.

This new rig is designed to drill deeper, faster.

However is it not just the discovery of new ores for which the universal deep drilling rig is being utilised.

As miners go deeper the risks onsite increase, and the potential for dangerous incidents rises.

The first six rigs, which have been sold to China, have been used to sink emergency rescue shafts to reach trapped miners quickly and safely.

According to Bauer "a key feature of the newly developed machines is their great mobility; built on a truck trailer, they can be towed quickly to any location where they may be needed".

The mobile deep drilling rig's maximum small diameter drilling depth is 3000 metres, and with 700 millimetres the rig is able to sink bores down to depths of around 1500 metres.

However this is not the only drill Bauer has released this year.

It will use the upcoming Bauma exhibition to highlight its other new developments.

Bauer's subsidiary RTG Ramm­technik GmbH is using the event to showcase two rigs.

On show will be the revamped RT 21 T pile-driver mounted on the BS 65 RS base carrier with Eco mode, and features technical advances incorporating new sound-proofing systems. 

The rig has an automatic hatch opening device which cuts sound emissions by six decibels during operation. 

This represents a major reduction compared to conventional sound-proofing measures. The relaunch of the RT 21 T also features a number of other significant detail enhancements. 

Bauer will also launch new technology at Bauma.

The RM 20 is a completely new rig from RTG, designed specially for hydraulic hammer applications, and features a 20 metre usable length. 

Its designers paid particular attention to ensuring a light transport weight during operation. 

The telescopic mast can be tilted 18.3 degrees in all directions. 

Another key feature of the rig is its patented rope tensioner.

Compact hydraulic drifters for underground roof bolting

Roof bolting is considered by many as one of the most significant developments in underground coal mining in the last century.

And rightly so, it’s always good when a mine’s roof doesn’t collapse.

Introduced in the late 1940s and ‘50s, the process replaced timber supports and is now absolutely necessary in underground operations for the prevention of rock fall accidents and advancement of a section.

Technological improvements in the way of machine design and engineering has made the cumbersome task of roof bolting a little safer, a lot easier, and more productive.

Traditionally roof bolting was hard work, involving miners lifting heavy metal into awkward positions.

Luckily the manufactures of roof bolter machines, bolts and resin cartridges are looking at ways to improve their product.

Improving roof bolting machines

This year’s Bauma exhibition in Munich saw TEI Rock Drills launch its new TE160 Hydraulic Drifter

To date most rock drills have been long and thing, whereas the TE160 is short and fat standing at only 17 inches high it is much easier to manage then its predecessors.

Incorporating a uniquely short design the TE160 is being dubbed “the drifter for roofbolters,” the company said in a statement.

Made in the USA, TEI Rock Drills has managed to include its patented percussion section within the compact unit.

The overall smaller profile is tipped to make the roof bolting experience easier with less work and labour required.

Rhinoloc underground mine roof supports

Increasing safety in underground mining is paramount.

Since the mid ‘90s Resources Timber has focussed on improving roof support products in mine shafts.

Technological advancements have assisted the company’s strategy, with the launch of the patent pending Rhinoloc.

Rhinoloc has been designed in Australia to provide a strong, durable connection between timber, eliminating the need for bolts, fixings or fasteners.

Holes are precisely machined into the timber during manufacturing so Rhinoloc can be easily inserted and securely locked into place.

Using an interlocking system, Rhinoloc is capable of any configuration including square, rectangle or triangle.

When roof supports are fashioned in a triangle shape Rhinoloc uses 25 per cent less timber which saves labour time and money, and doesn’t compromise on safety in any way.

Boasting 100 per cent contact, Rhinoloc maximises load bearing capacity.

Rhinoloc is an eco-friendly, high performance roof support solution.

Atlas Copco launches new underground LHD

Atlas Copco has released a new carbon emission free LHD loader.

The new Scooptram EST1030 is the latest addition to the company's range of Scooptram underground loaders.

According to the company the new LHD's electric motor means that it now consumes less energy compared to a diesel engine, while at the same time producing less heat and lower noise levels.

It uses approximately 40% less energy and produces 40% less heat during 'general operations'.

As the motor is electric it also directly addresses one of the key issues faced in operating heavy machinery in underground mines – diesel particulate matter, as well as only requiring minimal ventilation and air to operate.

Lars Bergkvist, Atlas Copco's global projects manager explained that “as mines go deeper, heat and ventilation becomes more and more problematic. At the same time the price of fuel is rising. We strongly believe that efficient electric vehicles will be the key in future mining operations.”

While there are concerns over the range of an electrically powered motor underground, cable powered electric loaders are not a new concept, and have demonstrated operatability underground for sometime.

However the issue of cable and cable control still remained, with high tension causing the cable to wrap around corners – causing cuts and high levels of cable wear.

The EST1030 has now solved this problem with a new cable control system that minimise cable tension as well as cable wear.

Despite the change in power supply the controls remain the same, with the same system as the ST1030 diesel version.

Safety has also been a focus, with the new LHD including spring applied hydraulically released (SAHR) brakes as well as an ISO and ROPS/FOPS approved cabin.

The cabin has been more ergonomically designed with increased leg room and better control placements, while the cabin itself is placed on rubber mounts to reduce vibrations.

Economical multipurpose drilling rigs

Boart Longyear has improved safety features, track mounting on its latest integrated mineral exploration drilling rig.

With a more compact design the LX11 is an addition to the existing line of the company’s multipurpose LX^ and LX16 drilling rigs.

The medium sized LX11 is capable of performing both reverse circulation (RC) and diamond core drilling, enabling exploration drillers to use just one drill rig in various ground conditions.

This also lowers initial capital investment and eliminates the need to switch rigs to match drilling conditions.

“The multipurpose LX11 drilling rig is the culmination of many years of hands-on experience, advanced engineering and field testing,” Justin Warren, Boart Longyear global product manager said.

“The versatility of the LX11 allows drilling contractors the ability to supplement the roles of multiple rigs with the simplicity of one, saving on equipment costs.”

This drill rig can reach depths of up to 1,450 meters using NQ rods via diamond drilling and depths of 325 meters using 114-millimeter rods via RC drilling.

The LX11 also purports to increase productivity by enlisting a 7.2 meter mast and a top drive head which allows for 6-meter rods to be pulled directly under the head.

The top drive single rotary drill head features 1,200 rpm and has a maximum torque of 7.8 kNm (5,800 ft-lbf) at 100 rpm.

The LX11 also incorporates a number of safety features, including a strategically placed control panel for enhanced visibility, remote control operation so the rig may be driven at a safe distance, and an interlocked safety cage to protect drillers from the rotating drill string.

As an optional extra the LX11 can be equipped with a rod handler to assist with the safe and efficient handling of both RC and diamond coring rods.

The compact design of the LX11 simplifies both site access and manoeuvrability.

It is also designed to fit into a 12 meter high cube container, making transportation of the rig more economical.

The improved track mounting not only lowers the environmental impact of the rig it also enhances the mobility of the LX11 as it can now handle steeper grades.

Synchronisation of drives for overhead cranes

Modular Cranes Pty Ltd, a Melbourne-based crane manufacturer, were presented with an unusual problem to solve for one of their customers.

Modular’s customer, a heavy truck trailer manufacturer, already had two 22-metre-wide overhead cranes installed in their factory which ran on the same set of rails.

Each of the cranes was rated at 12.5 tonnes and had given reliable service for many years.

They were identical in their specification, and were synchronised with both their slow and fast speeds, as well as the elapsed distance they travelled to slow down and stop.

The customer’s new production process now required that a third crane was included on the same set of rails to move very long, heavy trailers along the factory, with the load shared between two of the cranes at any one time.

The cranes would be actuated simultaneously, as required, using a wireless handheld remote control.

The problems faced by Modular Cranes were that the existing overhead cranes were no longer available to be sourced, and that an alternative needed to be installed and synchronised to match the existing cranes. Importantly, Modular Cranes were looking for a solution that also needed to be economical for their customer.

Modular Cranes sought the expertise of NORD Drivesystems, the German Helical geared motor and frequency inverter manufacturer, for the two travel drive Helical geared brake motors on the new crane.

To solve the synchronisation problem, NORD Drivesystems’ de-centralised frequency inverter technology was also employed.

To further enhance the economy requirement, NORD Drivesytems proposed a conventional 4 pole electric motor with a 10Nm electromagnetic brake mounted to each of the NORDBloc.1 series inline Helical geared brake motors.

The NORD SK205E series de-centralised frequency inverter was also included, complete with internal 24 Volt power supply cartridge, and an external brake resister to accommodate the re-generative current produced by the cranes’ weight when slowing to a stop.

The high-precision accuracy of the NORD Helical gear set and the flexibility of the de-centralised frequency inverter software allowed this new crane to be synchronised with the existing cranes, without the requirement of rotary encoders.
Furthermore, utilising the two de-centralised frequency inverters eliminated the need or any shielded cable in this installation. Modular Cranes commissioned the new crane in 2012 and met their customer’s expectations regarding their requirement for an economic solution.
For all further information regarding NORD Drivesystems products and services, please go to www.nord.com , or phone 1300 – 00 NORD ( NORD ), or email au-sales@nord.com

The TIPPING point

It is not rare to see overbalanced haul trucks on site.

The sudden weight of the load leaving the tray has been known to tip it backwards, making the truck stand up on its rear wheels. While it may seem like a funny occurrence, it causes serious damage; both to the truck, the driver, and the miner's bottom line.

And as long as truck bodies remained the same, the issue remains a problem.

With this issue in mind, Australian company Austin Engineering created a new haul truck body designed to give miners back control over their material flows.

Speaking to Austin Engineering's Joe Kelly, he explained that "it started when Peabody Energy came to us, as they found that when discharging their loads their trucks' front wheels would come off the ground and damage suspension when coming down and putting an operators' safety at risk".

The solution to this weighty issue was relatively simple: "[Austin Engineering's subsidiary] Westech solved the problem by creating a new flow control body design," Kelly said, adding that "the body goes up at an angle, and has multi-level kicks which work to create a pocket of material in the tray, so it stops all of the material flowing out in a single heavy load that slides out from the bottom".

He went on to say that "instead it now has a continual flow that starts from the material on the top, unloading it at the same speed as before, this not only negates the tipping risk the truck faced as it removes the overbalance issue but also the problem of damaging bins it is being unloaded into; creating less wear on both the bins and the truck's tray."

The kicks in the tray are at angles of 12°, 22°, and 8°, he added.

In addition to reducing wear "the continual flow instead of a single material dump also reduces dust on site, increasing the mine's green footprint," he said.

Mainpac and SYSPRO collaborate to create new asset management solutions

The simplified asset management offering from Mainpac and SYSPRO promises to deliver significant cost savings to mining companies through the reduction of maintenance costs and improved plant reliability.

The pre-integrated solution incorporates enterprise resource planning (ERP) software provider SYSPRO and enterprise asset management (EAM) software provider Mainpac.

SYSPRO general manager Asia Pacific Shaun Butler said the joint offering will give customers control over key assets and business processes.

“Both Mainpac and SYSPRO have had a single solution focus for more than thirty years and both have invested heavily in ongoing development and continuous improvement.

"This partnership now enables SYSPRO ERP users to gain interactive dashboards, workflow capability across an entire enterprise, accessibility from anywhere and anyhow, flexibility in deployment, total scalability, and a complete out of the box solution that works seamlessly across all areas of the business without the need for any customised integration,” Butler said.

Mainpac’s executive chairman James Kirk said the combined offering is unique in the mining industry.

“Mining is an asset-intensive business and maintenance can account for anywhere between 30 and 50 per cent of a mine site’s overall costs. This makes it a key area in which companies can gain efficiencies and a competitive advantage,” Kirk said.

“As well as being asset intensive, mining is also a heavily regulated industry. Equipment is frequently audited to make sure the correct parts are in place and the equipment is well maintained. For example, it’s essential to manage AFFF or FFFP fire suppression systems and on board fire suppression systems to prevent sparks or flames that could lead to fires or explosions.

“Maintenance managers must be able to provide accurate records for compliance and auditing purposes. This process becomes much faster and less labour intensive with the use of an effective, best-of-breed EAM system,” he said.

A recent Aberdeen Group report suggested that a mine’s performance is directly affected by the management of its assets.

The report highlighted that performance can be characterised by overall equipment effectiveness, unscheduled asset downtime, maintenance costs and return on assets.

“Many ERP providers offer a solution that includes asset management capabilities, but the asset management component is usually an afterthought and is often inadequate to meet the requirements of asset intensive businesses.

“The initial outlay and ongoing costs of these ‘all-in-one’ solutions can be very high, especially when the purchased solution is inadequate, and the company must return to market to find an asset management solution that meets their needs,” Kirk said.

By partnering with SYSPRO, Kirk believes the company has created a ‘best of both worlds’ solution.

“With a comprehensive ERP system and a specialised, best-of-breed EAM system working together in a pre-integrated solution, mining companies will start seeing benefits almost immediately,” he said.

Pre-integration also makes implementation of the system both easier and more efficient, it also allows for scaling so companies can start small and expand use of the system across multiple sites or divisions as needed.

According to Kirk the ability to track and manage asset availability and performance and apply maintenance strategies according to an asset’s criticality to the business delivers substantial cost savings and operational efficiencies.

“The integrated system lets you see everything down to the finest detail so you can make smarter decisions about maintenance, faster,” he said.

“You can balance maintenance costs against replacement costs, for example. With a best of breed asset management system in place you can identify warranty opportunities, reduce unplanned downtime and reduce the number of spare parts and consumables held across multiple sites.”

The SYSPRO/Mainpac solution is available from January 2013.

Compact coal transfer chutes

The robust construction and time saving design of T.W. Woods Group’s coal transfer chutes provides for a smooth flowing, low-height transfer when in operation.

These chutes are built to overcome space, spillage and conveyor bulking problems common in coal handling facilities and have been commissioned in underground coal mines in the Hunter Valley.

“The chute’s major advantages are its simplicity, ease of installation and robust design,” the company said.

Discussing the simple installation process, a company spokesman said it takes about four hours to install a chute.

“We put in one new chute and a couple of refurbished chutes recently and it was very straightforward. It takes one shift about four hours to perform the complete installation,” he said. 

Plant manufacturer T.W. Woods’ services the mining, energy, construction and materials handling industries throughout Australia and has used its extensive experience across multiple platforms to devise this coal chute.

“The design more than covers what we do. It’s a robust simple design that’s pretty wear resistant and easy to adjust for our operations, which involve about 1200 tons and hour with throughput containing lumps up to 300-400mm,” a team leader who recently had the chute installed on his site said.

“We use it on left and right hand 90-degree turns, where it is easy to adjust for throughput flow. The chute hangs off the jib frame, sitting on bearing blocks, taking discharge from the upper belt. It’s straightforward to adjust back and forward for throughput as you require.”

The low-height transfer chute features a conical head developed especially for mining applications, enabling high volume rates, of up to 2000 tonnes an hour, to be maintained when conveyors change direction either underground or on the surface.

“Frequently in underground mines you get 90 degree turns as coal conveyors emerge from one shaft and have to transfer into another within very tight spaces,” T. W. Woods director Tom Woods said. 

“It is usually very difficult to get coal to turn that quickly without spillage and bulking up on the conveyor belts as coal is dropped from the belt above onto the one below while changing direction.”

The company’s transfer chutes are manufactured to overcome this issue through the compact design which allows the chutes to be fitted into lower overall heights than conventional designs, operating with a separation distance between belts of 1200-1500mm.

The chutes’ conical head is also configured to provide a smooth transition through the turn for coal moving at typically three metres a second and dropping up to 1500mm onto a belt below.

“Drawing on our designer’s highly respected problem-solving expertise and our own hands-on experience over scores of mines, we set out to eliminate the spills, splatters and bulking that can disrupt production in mines where time truly is money. Eliminating frustration, delay and cost is vital in today’s economic climate,” Woods said.

“The design has already been proven service with some of Australia’s leading coal producers. A bonus of the design also is that it has been quality engineered in our own extensive metal working facilities to easily outlast conventional designs and far exceed typical warranties.”

T.W. Woods also manufacture products for mineshaft development including shaft liners, drilling tooling and wear plate materials, as well as custom-fabricated wear plate kits.

MICROMINE’s specialty coal exploration and mining software

MICROMINE’s latest coal mining software solution 'Coal Measure' is a dynamic and integrated software solution for coal data management and processing.

Released last September at MINExpo, Coal Measure allows for advanced 3D seam modelling, resource categorisation, resource reporting, pit optimisation, pit design and scheduling.

This application has been built for both coal exploration and mining purposes, designed to deliver cost reductions through improved planning and increased operation efficiency.

Coal Measure has combined elements from the company’s data management software Geobank and exploration and mine solution software, Micromine.

As part of the software’s development, MICROMINE carried out rigorous, real-life testing to ensure the end product met the demands of the coal mining market.

“With coal becoming an increasingly critical energy source, our clients have been demanding a more sophisticated solution that takes into account the complexities of coal and the ways in which it is mined,” MICROMINE’s CEO Kevin Fitzpatrick explained.

“It has become very clear to us that we needed to develop a world-class solution that was both sophisticated enough to take into account these complexities, whilst also ensuring it remained both user-friendly and was easily transferable,” Fitzpatrick said.

Coal Measure approaches coal deposits in a new manner, differing from metalliferous and irregular deposits, replacing interpretation and wireframing with modelling seam morphology using griddling based on stratigraphic sequence.

This process is quickly followed by direct conversion into a seam block model.

MICROMINE participates in the Coal Industry Standards Committee, whose charter is to design and implement standards for coal mining and production. 

Ibo Mango, MICROMINE’s Geobank data management specialist, is a member of the panel and was responsible for the release of ‘CoalLog’ Version 1, a Borehole Data Logging Standard for the Australian Coal Industry designed to improve the accuracy of borehole data.

“The best thing about the Coal Standard is the benefits it will provide MICROMINE’s clients. A universally consistent system will be more transferable within the industry and will allow operations to record and manage higher quality and more accurate borehole data,” Mango said.

“MICROMINE is excited to be driving this data standardisation improvement and being in a position to introduce the new standard within clients’ operations,” he said.

MICROMINE’s software solutions have been developed specifically for coal with strong industry involvement so resources may be optimally mined.

Air Suspension Leaf Helper Kits for the new Ford Ranger and Mazda BT-50

The increased towing and load carrying capacity of the new Ford Ranger and Mazda BT-50 has inspired All Air Suspension’s new Air Suspension Rear Leaf Spring Helper Kit.

These supplementary suspension kits allow the driver to maintain the correct vehicle height, with no spring sag, even under a heavy load.

“It is a bit of a trap for drivers new to towing, or carrying bigger loads, because a vehicle suspension that is perfectly good for normal lighter service can change markedly when it is more heavily loaded,” All Air Suspension’s general manager James Maslin said.

The company claims the kits will also decrease tyre wear and more evenly distribute natural brake wear.

Although the suspension kit doesn’t increase a vehicle’s load capacity it does improve both steering and handling of a vehicle which is typically compromised under a heavy load.

“Heavily or unevenly loaded vehicles can be subject to increased sway because of lateral forces, while trailer-imposed ball weight will cause headlights to shine up into the trees or blind other drivers,” Maslin said.

Manufactured by Airbag Man using reinforced Firestone air springs which fit between the chassis and axel, these kits improve the ride, safety and durability of work vehicles carrying heavy and uneven loads or towing trailers.

The adjustable airbags are used for front-to-rear and side-to-side levelling control of a vehicle.

“A perfectly good familiar vehicle can become a safety nightmare if its suspension is not properly set up to tow or cope with varying loads,” he said.

The importance of mine site vehicle safety has again been brought into the forefront of the industry’s mind as BHP joins the list of resource companies stipulating that entire vehicle fleets must have a minimum 5 star NCAP safety rating.

Widely used in the mining industry, these suspension kits have been specifically customised to fit the new Ford Ranger and Mazda BT 50 utilities.

MineARC launches ‘next generation’ refuge chambers

MineARC Systems has launched its latest range of refuge chambers specifically developed for the hard rock mining industry.

On display at both MINExpo in Las Vegas and GME in Kalgoorlie, industry response has been encouraging, MineARC general manager Mike Lincoln said.

Building on its predecessor, the Series III, the new HRM Series IV is made for the metalliferous mining industry; featuring the very latest in safe-refuge technology Lincoln added.  

“The HRM Series IV builds on the success of the Series III.  It’s now even safer, it’s smarter, and it’s easier to maintain and service.  We’ve also included a number of structural modifications that make it easier to position onsite,” he said. 

Making its mark on the mining industry the MineARC HRM range has already been deployed in over one hundred operations, in forty different countries, across six continents.

System upgrades include the new Series IV CO/CO2 (carbon monoxide/carbon dioxide) scrubbing system and the elimination of ‘free-pour’ chemicals, replaced with easy to load and handle pre-packaged chemical canisters.

“The prepackaged chemical canisters are already widely recognised and accepted within the industry.  The popular MineARC HRM-ELVP (extra-low-voltage-portable) range of refuge chambers already uses the canister system,” Lincoln said. 

The new refuge chambers have the Intelligent Voice Audio Navigation system (iVAN) built in which acts as an onboard guide, talking occupants through operating procedures and providing alerts when action is required.

“With the HRM Series IV we feel we’ve taken emergency refuge to the next level.  The self diagnostic capabilities, the new digital controller interface and the simplicity of the new scrubbing system are key to this,” Lincoln said.

Developed in cooperation with some of the world’s biggest mining companies, the Series IV complies in full with the 2009 Western Australian Department of Mines and Petroleum Guideline: Refuge Chambers in Metalliferous Mines.

Other features include an advanced digital controller interface with full chamber diagnostics capability, increased scrubbing and air flow capacity, improved structural housing and simpler transport features.

The New Series IV HRM is available in both standard and custom-engineered models in various capacities.

Thermal imaging cameras

The Flir Axx-Series of thermal imaging cameras can monitor continuous processes and collect information on product quality and/or efficiency.

Such information is difficult to capture using conventional means such as thermocouples or visible light cameras.

They are intended for applications that require the benefits of a thermal image but do not need exact temperature measurement. Compact and complete, they can be integrated in a machine vision environment.

There are three versions available – FLIR A65, FLIR A35, FLIR A15, and FLIR A5. Each produces images of a different quality.

They visualize temperatures between –40°C and +550°C.

Temperature differences as small as 50 mK become clearly visible on a crisp thermal image. Since they come with Power over Ethernet, communication and power are supplied with only one cable.

They work seamlessly with FLIR Tools. This allows for viewing and analysing thermal images and includes functions such as time versus temperature plots.

Flir Systems Australia

1300 186 834

www.flir.com/thermography/APAC/au/

TURCK introduces the B2N-360-Q42 3D inclinometer

Users can set individual vibration filters that precisely mask out the vibration frequencies of their machine as well as defining the zero point, switch points or switch windows according to the mounting position and requirements at hand.

As well as vibrations, the sensor also suppresses potential error sources such as accelerations or shocks. The extensive range of assignable parameters and the maximum sensing range of 360 degrees on two axes enable the sensors to be suited for virtually any application, reducing the number of inclinometer variants that need to be kept in stock to a single type.

The B2N-360-Q42 can also be used for measuring vibration or shock.

TURCK offers two variants of the sensor: the industrial variant and the e1 variant.

The industrial variant features a temperature range from -25 to +75 degrees C, making it ideal for inclination measuring on solar panels or robots.

The second variant is designed according to the e1 specification for use in utility vehicles and construction machinery. The e1 variant is resistant to extreme temperatures from -40 to +85 degrees C and operates with the standard vehicle electrical power supply of 8 to 30 V.

Both variants come with protection to IP69K. The output signal can be defined individually, for example, to the standard signal ranges of 0 to 10 V or 4 or 20 mA.

TURCK Australia

1300 132566

www.turck.com.au

High speed linear position sensor

Designed for closed loop applications, new electronics architecture in the device increases the effective output rate of the sensor from 1 to 5 kHz.

In conjunction with the short signal run time (130 µs) and the highly resolved SSi output, the inductive linear position sensors can achieve the performance of potentiometers but without their disadvantages.

Unlike potentiometers, the LI sensors offer permanent protection to IP67, provide non-contact measuring and are absolutely wear-free.

The magnetic field immune sensors are suitable for measuring axes with high-speed controls such as is used in injection molding machines.

Other application areas include axis measurement in packaging machines, presses or machine tools.

With the high speed and precision of the sensor (system resolution of 1 µm), machine builders can keep the position error in motor control applications to a minimum. As with all inductive linear position sensors, the high-speed variant has very short blind zones and can tolerate up to a 4 millimeter offset of the positioning element (perpendicular to the measuring axis). As well as the high-speed variant with an SSI interface and 16-bit resolution, the analog variant of the sensor will also be offered in the future with the higher output rate of 5 kHz.

The analog sensor has a 0 to 10 V or 4 to 20 mA output.

Turck

1300 132 566

www.turck.com.au