FLSmidth SAGwise™ to revolutionise mill liner protection

Posted by Paul Moore on 12th January 2018

FLSmidth has just launched a new SAG mill liner protection solution called SAGwise™ total process control, with an estimate of less than six months ROI. It has been shown in tests that it can reduce damage to the liners by over 40%. FLSmidth told IM: “Extending the life and availability of mill liners is crucial. Weighing up to 4 t a piece, mill liners require a lot of effort to replace when they are worn out, and SAG mill downtime can be around $130,000/h, while lead times can span months. Overall it can cost well over $1 million dollars for a liner package.”

As stated, test results of the new product show reduced damage to the liners of 40% and an ROI of six months (without factoring in reduced unscheduled maintenance). Added this are reduced energy consumption of 6% – significant considering that mills use the by far largest amount of power required for minerals processing. The new solution also saw a production increase of 6% and reduced process variability up to 30%. The SAGwise™ total process control solution employs state of the art process control technologies to reduce critical impacts to the desired targets, stabilising and then optimising the operation of the SAG mill. Multiple process control technologies, such as model predictive control and fuzzy logic are embedded into the solution, modelling both the process and the human operators.

The system is based on acoustic sensors and proprietary process control software to predict and adjust the SAG mill operation according to impacts on the mill and other main process variables. King Becerra, FLSmidth Global Product Line Manager – Process Optimisation told IM: “There are eight audio sensors on a bidirectional mill, four on each side. These have embedded microphones that listen for so-called critical steel on steel impacts between balls and liners rather than between ore and liners. Today, plant operators rely on the personnel close to the SAG mill listening to the mill load and undesirable steel-on-steel impacts to manually adjust the SAG mill operation, reducing undesirable impacts, and run the mill smoothly. But the FLSmidth SAGwise™ system takes this digital audio data and uses techniques such as model predictive control and fuzzy logic rules to assess the mill process parameters.”

“Within seconds it has analysed the audio frequencies as well as taking on board power usage, mill weight and bearing pressure. It can then automatically take corrective action if needed and adjust parameters such as the mill ore feed rate, mill speed or water usage. Whereas an operator might make adjustments every few minutes, SAGwise™ can make more frequent (every 20 seconds or less) and less drastic adjustments.” The reduced damage improves mill availability and reduces downtime. “This can translate to literally multiple millions more tonnes of ore milled,” says FLSmidth.

Jack Meegan, FLSmidth Global Product Line Manager – Mill Liners and Wear Parts told IM: “We took technology that we already have and mated them together to make a solution. We can say to the customer, of course we want to sell you mill liners, but at the same time we want to make sure you are getting more value from your liners as well as your media. With many mines using $10 million or more of liners per year and three or four times this cost in terms of grinding media, the savings  can be huge.”

Where are Australia’s major mining projects?

The number of committed mining and energy projects in Australia has increased by 21 per cent over the past year.

A rise in copper, gold, nickel and other minor commodity prospects has lifted the amount of overall committed projects to 47, according to the Department of Industry, Innovation and Science’s latest Resources and Energy Major Projects report.

Publicly announced projects (58), as well as projects moving to the feasibility stage (139), also increased over the past 12 months, in line with higher exploration expenditure and higher resource and energy commodity prices, the report added.

“While the past few years have been characterised by cutting costs to ensure the commercial viability of existing assets, 2017 has seen some renewed optimism for market conditions and increased producer interest in brownfield expansions and new projects,” the report explained.

Australia’s gold sector added several newly committed projects in 2017, including Dacian Gold’s Mt Morgans project in Western Australia, Gascoyne Resources’ Dalgaranga project in WA and Diversified Minerals’ Dargues Reef project in New South Wales.

Two copper projects were also approved ­— OZ Minerals’ Carrapateena project in South Australia and Capricorn Copper’s Mount Gordon project in Queensland.

Coal, meanwhile, has the highest number of committed projects amongst Australia’s key mining commodities with nine — all of which are in Queensland and NSW.

Location of projects at the committed stage. Source: Department of Industry, Innovation and Science (2017)

2018年移动式破碎、筛分设备

QUARRY’S 2018 GUIDE TO MOBILE CRUSHERS AND SCREENS

This year’s edition of Quarry’s 2018 Guide to Mobile Crushers and Screens lists more than 300 mobile crushers and screens from 17 suppliers to the Australian quarrying market. 

Welcome to the 2018 Guide to Mobile Crushers and Screens. This year’s edition is again divided into eight categories (e.g cones, jaws, incline screens, scalpers).

All equipment, irrespective of brand, has been sorted by maximum output (tonnes per hour) to enable readers to compare and contrast the capacities and capabilities of the machines. It’s a comprehensive format that seeks to highlight maximum performance!

This year the guide lists more than 300 mobile crushers and screens from 17 suppliers to the Australian quarrying market.

Some of the brands featured are popular and specialised multinational icons, eg Astec, Kleemann, McCloskey, Metso, Powerscreen, Sandvik and Terex. Other brands boast impressive international credentials but are perhaps lesser known to the Australian market (eg Keestrack, Superior Industries).

In addition, local manufacturers are increasingly developing new specialised equipment for the Australian market including Precisionscreen, Rocktec and Striker.

Buyers should be mindful of multiple distributors for some brands. The Terex Finlay range, for example, is distributed in the Australian Capital Territory, New South Wales, Queensland, South Australia, Tasmania and Victoria by Finlay Crushing & Screening Systems. OPS Screening & Crushing Equipment handles Terex Finlay orders in Western Australia and the Northern Territory.

Therefore, when you are making inquiries about mobile equipment, be sure to contact the right distributor in your State or Territory!

As much as this guide strives to meticulously list all suppliers and brands, some are not featured, either because of obsolete, inaccurate information, or some distributors chose not to participate in the compilation of this book.

Finally, while I recommend you keep this guide close to your desks for easy reference, I encourage you to use it when you’re out of the office too. The beauty of technology today is that this guide is never too far from your fingertips.

When you are on the road, bookmark this page to view this guide on your laptop, smartphone or tablet.

Good luck with your purchases in 2018!

Damian Christie
Editor

READ NOW

Metso and WEARX join forces to unlock potential

WEARX and the Metso Corporation recently finalised an agreement that will bring the two companies together.

The combined strengths of both companies and knowledge of their people is expected to bring even more value to the mineral processing and material transfer market sectors.

WEARX is a privately-owned wear solutions provider with a range of its own products. The company addresses its customer’s needs by implementing the right technologies to deliver wear protection solutions designed to exceed plant availability goals.

The company’s offer includes: wear liners, rubber and ceramic lining, skirting, chutes and bulk material handling equipment. Its services include: design, engineering, site services and project management.

WEARX chief executive officer and Metso’s senior vice president – Australian market areas addressed WEARX staff to explain the change at the company’s head office in Thornton, located on Australia’s east coast, 25km north-west of Newcastle.

Commenting on the reasoning behind the deal, WEARX CEO Gary Newman said, “Over the last few years, we have worked hard to develop WEARX into an agile service provider that delivers high value solutions to our customers.

“Our board and shareholders knew that at some stage we would need the backing of a much bigger company to unlock our full potential. With the funding of the next phase of our company’s growth in mind, we decided that a full trade sale to a large, likeminded company was the best way to continue the evolution of our business.”

“There were several interested parties, but when it came down to making our decision as to which company we wanted to move forward with, our key considerations were: cultural fit and clear synergies between the two companies.

“I’m very pleased to say, that we found an ideal fit in Metso. Joining forces with Metso is a historic step in our company’s development.”

Metso’s senior vice president for the Australian market areas – Ross Wotherspoon said there was an excellent cultural fit between the two companies.

“From our very first meetings with WEARX executives, I was impressed by their great culture which is very similar to ours,” he said.

This move is part of Metso’s growth strategy, which includes both organic growth, as well as growth through acquisition.

Wotherspoon said over the last seven years the company evolved its business through several powerful initiatives that have helped to improve service levels.

“We have agressively expanded our services footprint and committed to regularly measure and actively improve the satisfaction of both our customers and staff. In parallel to these initiatives, we have developed an acquisition strategy designed to broaden our offering and bring even more value to our customers,” Wotherspoon said.

“As for synergies, combining the strengths of our companies and knowledge of our people will allow us to bring even more value to our clients in the mineral processing and material transfer market sectors.

“We want to make sure that the transition goes smoothly, especially for staff and customers. The retention of WEARX’s agility and entrepreneurial spirit is a fundamental success factor.”

The companies have assembled a dedicated integration team which will now work on all aspects of the integration. It is expected that the group has around six months of intense work ahead.

Mining data to improve safety and cut maintenance costs

We have over 3,000 machines in our operations, from trucks the size of houses to shovels that move millions of tonnes of material every year. When equipment fails it can put our people at risk, disrupt production, increase costs and reduce our ability to provide resources to customers. So, maintenance is a priority, and we spend US$3.5 billion a year on the upkeep of our plants and equipment.

BHP has created the Maintenance Centre of Excellence to partner with our operations to deliver safe, sustainable improvement in our equipment performance. The Centre leverages BHP’s scale to draw on the deep expertise, data and systems we hold across our business to reduce cost, cut unplanned downtime, improve production and ensure our equipment is safe and reliable for our people.

Over the last 18 months we’ve formed a team of data scientists to examine how we can predict problems and improve the reliability and uptime of our equipment.

The team uses experience from outside the resources industry to find ways to improve our approach. For example, Boeing developed a tool that analyses real time black box data from aircrafts in-flight to predict what maintenance they’ll need when they land. This is used by airlines to prevent cancellations and ensure equipment is in the right place at the right time. We’re developing similar systems to improve BHP’s maintenance.

Our teams have developed algorithms that predict how a piece of equipment is likely to fail and when to best schedule preventative work.

We use over 780,000 different kinds of spare parts and our analysis can better inform how we buy them, preventing delays and unnecessary spending.  The team is also working with our operations to determine how they best time routine maintenance to minimise disruption to production.

The results have been impressive. We analysed 5.6 million data points gathered from 20 shovels and identified how preventative maintenance could stop the risk of gantry and structure failures. The team also used data from 300 haul trucks to develop new maintenance strategies, improve supply chain management and set operating limits for how the vehicles are used in the field. This has improved availability and reduced costs by a projected 20 per cent across the remaining life of the fleet.

The number of variables that influence the performance of an individual piece of equipment made it very difficult to do this sort of analysis before these systems were developed. Operator behaviour, weather conditions, machine usage and maintenance history all affect how a truck or shovel performs. Maintenance plans used to be developed on a site-by-site basis. Now we can draw on data from across the company and update them more frequently.

The more data these systems are fed, the more they learn and the better performance becomes. BHP’s combination of large operations and standardised equipment, processes and technology are a critical advantage in the continuous improvement of their forecasts.

Of course, these systems are only as smart as the people that use them. As they become more common they will enable a step change in safety, equipment availability and performance.

Rio Tinto launches Far North Queensland recruitment drive

Rio Tinto is seeking more than 100 workers for a variety of roles at its bauxite operations in Far North Queensland.

A recruitment drive has been launched for positions at Rio’s existing Weipa mines at Andoon and East Weipa and the Amrun project south of the Embley River between Weipa and Aurukun.

Rio is aiming to build a workforce in the region capable of supporting the developing site at Amrun.

The Amrun project includes a range of infrastructure to support mining, including a processing plant and port near Boyd Bay, a dam, roads and tailings storage facility. A ferry terminal on Hey River will transport workers from Weipa to the mine.

Rio is seeking workers to fill positions for electrical and instrumentation technicians, operators, plant fitters and in maintenance.

The company said some Amrun roles would start immediately, while others would gradually take effect between 2018 and 2019. Rio is aiming to ship first bauxite from Amrun during the first quarter of 2019.

Rio Tinto Weipa Operations general manager Daniel van der Westhuizen said it was exciting for the company to offer so many roles that would ultimately support the bauxite operations.

“It’s an exciting time for our people, business and community with Amrun becoming a part of a strong and sustainable future for the region,” van der Westhuizen said.

Weipa will remain the residential base for the three mines in the region, with Andoom and East Weipa employees returning home after every shift, according to the miner.

Rio Tinto East Weipa superintendent and future Amrun employee Scott Tass said: “A couple of years ago when I heard the Amrun project was going ahead, I knew I had to start looking at making my way back to Weipa because I wanted to be part of it.

“Aside from moving the first bit of ore, I’m most looking forward to the facilities there. I’ve been in a number of camps and Amrun stands above the rest,” Tass said.

Rio roles in demand at Weipa:

  • Fixed plant operator maintainers
  • Heavy equipment personnel
  • Crew leader
  • Plant operators
  • Electrical maintainers/operators
  • Electrical maintainers
  • Heavy equipment fitters
  • Dozer and loader operators.

TEREX TRUCKS

Terex Trucks has teamed up with Porter Group to distribute its articulated haulers.

Terex Trucks has teamed up with Porter Group to distribute its articulated haulers.

ARTIC TRUCK PRODUCER BRANCHES OUT WITH NEW PARTNERSHIP

Terex Trucks has teamed up with Porter Group, a leading supplier of heavy equipment throughout Australia and New Zealand, to distribute its articulated haulers throughout the region.

According to a Terex Trucks statement, the partnership allows Porter Equipment – Porter Group’s sales division – to maintain its position as one the largest dealers of rental and sales equipment and gives Terex Trucks a “stronger foothold” in Australia and New Zealand.

“Porter Equipment is delighted to represent Terex Trucks across Australia and New Zealand as we share Terex Trucks’ commitment to the brand’s success in the region,” Porter Group sales and marketing general manager Darren Ralph said in a company statement.

“Terex Trucks has a strong pedigree in design and manufacture of robust haulers, and Porter Equipment provides a distribution network in Oceania that dates back over 70 years.”

Terex Trucks APAC sales and marketing director Clement Cheong echoed similar statements.

“Terex Trucks is excited to be part of this new journey of growth by partnering with Porter Group to serve the Australia and New Zealand markets,” Cheong said in the statement, adding, “We are confident that Porter Group will bring the same success story to Terex Trucks”.

Porter Equipment is set to distribute two models of the manufacturer’s articulated haulers – the TA300 and Generation 10 TA400.

Of these two, the highest specification model is the Gen10 TA400, which was launched in 2016 and described as “the first of a new era of haulers” for Terex Trucks.

The TA400 features magnetic suction filters that reduce the risk of contaminants entering the system, improve the cleanliness of the hydraulic oil and reduce wear and downtime.

The previous distributors of Terex Trucks products in Australia were OPS Equipment in Western Australia, South Australia and the Northern Territory, and Terrequipe in Queensland.

Terex Trucks, now a division of Volvo Construction Equipment and headquartered in Motherwell, Scotland, is a manufacturer of off-highway rigid and articulated haul trucks that are used in mining, quarrying and construction applications worldwide.

 

Mount Gibson off-take agreement with Chinese falls through

Mount Gibson Iron has terminated an off-take agreement with Xinyu Iron and Steel Group because the Chinese partner did not comply with the terms of the arrangement.

Perth-based Mount Gibson, which owns the Iron Hill project in Western Australia’s Mid West region, is now free to offer the production previously committed to Xinyu to alternative customers. Mount Gibson also has rights to pursue Xinyu for any resulting losses.

“Ther termination follows Xinyu’s failure to comply with a fundamental term under the off-take agreement,” the company said in an ASX announcement.

“Mount Gibson has already successfully sold Iron Hill material into the spot market, and fully expects to continue to place all production from Iron Hill with customers as it becomes available.”

According to a November 2016 ASX statement, Xinhu committed to buy about one quarter of the first year of production from Iron Hill under the off-take agreement.

Mount Gibson launched development of the Iron Hill project in the first quarter of 2017 after securing final approvals for the iron ore operation.

Iron Hill is about 3km south of the company’s now depleted Extension Hill open pit mine.

Australians flock to Toronto for PDAC

The world’s largest mining trade show (http://www.pdac.ca/convention) this year again attracted a slew of Australian mining companies, services exporters, government officials and investment promoters. Peter Diekmeyer writes.

Exhibitors, participants and presenters, including a platoon of Australians. attribute increased traffic at the Prospectors and Developers Association of Canada’s (PDAC) annual conference to renewed interest in the sector.

More than 24,000 prospectors, geologists, sector suppliers and investors, from more than 100 countries, crammed the Metro Toronto Convention Centre, earlier this year.

Every major Australian company is here,” said John Shanahan, president and chief executive of Tintina Resources, which is developing a high-grade copper deposit in Butte, Montana in the United States.

Canada is the place for mining companies to do business. People here understand that.”

Tintana is a case in point. At first glance the company has little connection with Canada. Shanahan grew up and went to school in Australia. Tintina’s majority shareholder, Sandfire Resources, is Australian-based.

Tintina’s major asset is in the United States, where Shanahan, also lives. However, Tintina is listed on a Canadian stock exchange and is nominally domiciled there.

“It’s much cheaper to list on a Canadian exchange than it is in Australia and Canada’s 43-101 mineral resource disclosure standards, have unparalleled international credibility,” Shanahan said. “For us a Canadian listing is a no-brainer. But we also use PDAC to meet our Canadian shareholders, seek out future partners and keep abreast of industry developments.”

Doug Ramshaw, a director at Vendetta Mining, which is looking to build interest in the company’s zinc/lead exploration play in Queensland, agrees that PDAC’s attraction is in part due to the fact that it is a great place for developer to connect with financiers.

This puts PDAC in the same playing field as the Diggers and Dealers event, which will take place in August in Kalgoorlie, Western Australia.

Sector suppliers focus on innovation

As usual, the PDAC halls were packed with sector suppliers, who used the event to plug their wares to a global audience.

According to Monika Portman, a spokesperson with Boart Longyear, a drilling services, tooling and equipment provider, innovation remains a key theme.

“Mining has gone through hard years and companies have been tightening expenses to maintain profitability or cut losses,” said Portman. “That means they need to do more with less.”

Boart Longyear, which regards Australia and North American as its two top markets, has been increasingly refining a “complete automation suite,” to help bring down perennially high sector labour costs.

This year Portman’s team was using PDAC to talk up the company’s hands-free rod handling, which she says makes the drill preparation less accident prone. 

“Safety isn’t just an operational cost,” she explains. “Most successful mining companies regard it a core social responsibility. Our goal is to help them fulfill that role.”

Caterpillar, which has been increasingly developing and marketing autonomous trucks, and whose banners and advertising adorned the PDAC walls, also used the event to great effect.

A turnaround in sight?

The strong PDAC attendance, which was up nearly 10 per cent relative to 2016 levels, provides an effective signal that the mining industry may be turning around, following a major trough.

According to data accumulated by S&P Global Market Intelligence, 2016 marked the fourth consecutive year of declining exploration budgets.

Australia accounted for 13 per cent total gold exploration. Gold’s share of Australia’s total budget jumped to 57 per cent from 48 per cent in 2015, due in part to falling base metals budgets.

Australia’s US$510 million (A$677 million) gold budget overtook Canada as the top gold exploration destination for the first time in more than a decade.

The yellow metal’s attraction among PDAC conference goers was further strengthened by a nine per cent increase in prices since the start of the year in US dollar terms.

This, coupled with the fact that production costs are often priced in local currencies that have weakened relative to the US dollar in recent years, has significantly increased potential profitability levels.

Australia minerals seek investment

Western Australia received more news at PDAC, when the region was named the world’s third best mining jurisdiction in the prestigious Fraser Institute’s annual rankings.

The only two regions ranked higher were Saskatchewan and Manitoba, two provinces in Canada, where the Fraser Institute itself is based, a factor which may have influenced survey methodology. 

Nevertheless the strong results provided momentum to Australian Government officials, such as Richard Blewett, branch head, mineral systems, resources division, at Geoscience Australia, who used PDAC to drum up investor interest in the country.

“We are open for business,” said Blewett. “Our data show that companies that invest in Australian exploration get a far better investment return than they do in other jurisdictions. We are here to get that message out.”

Investment will come back

As usual, PDAC’s most popular event with insiders was the Letter Writers presentations that took place the Sunday before proceedings started.

Rick Rule, president of Sprott U.S. Holdings, as has been the case in recent years, gave the keynote presentation, which set the increasingly optimistic tone that would prevail in the coming days.

“How many people in this room believe that in six years, when you go into the garage your car will start?” asked Rule rhetorically.

“Well then you have to believe that oil prices will go up. The IEA says that the average cost of producing oil is US$60 a barrel, when you include explorations and write-offs.

“If oil is US$50 per barrel now, that means the price has to go up. The same thing applies to many rare minerals and base metals. The cost of producing them is higher than existing selling prices. That means, over time the pressures on prices will be upwards.”

PDAC will be back next year between  4-7 March.

Peter Diekmeyer is a Canada-based business journalist, specialising in mining and resources.

Reducing The Environmental Impact On Mines

There are two main issues to consider when it comes to the environmental impacts of a mine:

  • The erection of plant, and its ongoing effect on its surrounds; and
  • How the site is rehabilitated after the mine has been decommissioned.

A fixed plant typically requires land being cleared, walls being built and roads being established. Then there is the plant assembly itself, which involves conveyor belts being constructed, material processing equipment put in place and draglines being set up, plus a range of peripheral considerations.

Sizing ore or minerals is a key component in mining operations. Setting up a permanent plant to allow processing and its affiliated operations can have a massive impact on the environment.

First, traditional plant used for high capacity crushing is enormous – it can be up to 32 metres high. This means that even before a site is set up, fixed plant has a large carbon footprint due to the amount of material used to construct it.

Then there is the construction of the plant onsite, which can take up large tracts of land due to the equipment itself plus support structures including buildings.

Also, there are the concrete or Reinforced Earth (RE) walls that are necessary for permanent plant. Not only can they have a negative impact on the environment, but they also take time to establish and require a lot of resources to complete.

Finally, there is the rehabilitation of the site. Costs can run into millions of dollars, depending on how much impact a mine has had on an area. If care has not been taken, or the plant has operated outside its agreed parameters, it means the approved remedies decided between state/local government bodies and the mining company might not be met.

Australian state and federal legislation puts the onus on mining companies to return a site to as close to its original condition as possible. The more permanent plant and installations that are set up initially, the more that has to be deconstructed and managed.

Minimising The Carbon Footprint

A piece of equipment that could help alleviate the impact on the environment is a Semi-Mobile Sizer Station from MMD.

For a start, they can be smaller than a permanent station – available in a range of modular designs, currently with a maximum height of 17 metres.

It also negates the need for concrete retaining walls because a fabricated truck bridge is used instead. Like the Semi-Mobile Sizer Station, the truck bridge can be deployed again and again, so there is no fixed plant to dispose of once the mine’s life expires.

Finally, there is no decommissioning of plant. With permanent plant there are concrete walls to be removed and earth landscaped. The area where the plant was located has to be rehabilitated with plants, trees, dirt and other stipulations as agreed.

With a Semi-Mobile Sizer Station, the plant is not in place long enough to cause as much impact. Furthermore, when it comes to moving to a different site, it is simply a case of picking up the unit on a transporter and moving it to its next location. There is no need for plant breakdown, crushing of concrete, or large fleets of trucks to take equipment away.

With modular construction and minimal maintenance, MMD equipment provides greener, more cost effective-solutions for today’s mines.

To read more on the environmental benefits of Semi-Mobile Sizer Stations, view MMD Australia’s whitepaper here.