In its 23rd edition, released at the beginning of March, the annual special report from SNL Metals Economics Group for the PDAC International Convention reported that “after sitting in second place for exploration spending for more than a decade, Canada dropped to third place in 2012 after being overtaken by Africa.  Allocations were up just 4% from 2011—the smallest percentage and dollar increase of any region—and accounted for 16% of the worldwide total budget. However, more companies had budgets for Canada in 2012 than for any other region, and 91% of the companies covered are headquartered in Canada. Ontario accounted for more than a quarter of allocations to Canada, while British Columbia replaced Quebec in second place. Gold allocations dropped for the first time since 2009, lowering its share of Canada’s total to 49% from 55% in 2011, while the percentage devoted to other targets, with an emphasis on potash, rose to 19% from 12%.”

In his presentation to the PDAC last month, British Columbia & Yukon: Gateway to the Pacific – Can momentum be sustained?, Tom Schroeter, President of Fjordland Exploration explained that half of Canada’s proposed new mines (>25) are in British Columbia. Potential new mines and major mine expansions, totaling over 50 over the next five to six years will require $28 billion in capital expenditures and result in 13,000 new jobs. More than 1,200 (or 65%) of Canadian exploration companies and 2,400 service companies are based in BC, “truly a world-class centre for exploration and development,” he said.

“In 2011, BC companies raised ~ 40% of Canadian exploration dollars (C$3 billion); BC accounted for 15% of Canadian exploration expenditures. BC solid mineral production over the past 150 years is estimated at greater than C$700 billion.

“Current annual production is valued at around C$10 billion includes C$500 million in government taxes. In the past two years two new, large metal mines (Copper Mountain and New Afton) have come on stream. The Mt. Milligan and Red Chris mines are scheduled for production in late 2013 and 2014, respectively. Several new coal mines, particularly in the northeast, are also scheduled to open. Five major mine expansions currently in progress will result in increased mine lives and cost over C$2 billion and provide over 1,100 direct new jobs.

“New discoveries in BC have been rare, however, three significant ones (Kwanika, Woodjam and Blackwater) over the past five years are encouraging. Exploration at Blackwater during 2012 was estimated to be $130 million alone. In addition, huge resources continue to be outlined at known occurrences such as KSM and Brucejack. The momentum is staggering.

To keep up and adjust to projections, major infrastructure improvements are required, as well as new workers. For example, preliminary construction of the C$561 million, 287-kV, 335 km Northwest Transmission Line is underway. At the port of Prince Rupert, major expansions are in progress to allow for giant cargo ships especially delivering coal from northeast BC.

Over the next five to ten years over C$35 billion worth of projects will be underway across northern BC.  “Challenges with First Nations’ engagement and government land use planning and permitting remain works in progress. What will the BC election in mid-May 2013 mean?  “In the Yukon, a new gold rush is taking place. New mine developments are proposed at Brewery Creek and Dublin Gulch. Recent discoveries of Carlin-style gold and silver mineralisation in the Conrad-Rackla Gold Belt, together with previous discoveries in the White Gold and Coffee Creek areas, are leading the way in renewed enthusiasm. “Infrastructure needs (roads and power) will present challenges to early developments.” Ontario was covered in detail last December (pp3-4) and its new, exciting Ring of Fire mining camp in January 2013. 

Canadian technology and services cover a wide range of mining industry sectors but the nation is perhaps most recognised for excellence in exploration. For example, Resonance Technology International says the Resonant Drill is “the most advanced high frequency (sonic) drill on the market.” It uses a revolutionary piston-cylinder design that makes it possible to tune the drill to the resonant frequency of the drill string and to maintain independent control over both frequency and power. Most importantly, the Resonant Drill produces full power and full force at any frequency. The company says “conventional sonic drills use rotating eccentric masses that produce only a fraction of their rated power and peak force at lower frequencies. This means the Resonant Drill delivers more power than equivalent sonic drills throughout the 60 to 120 Hz range, where most drilling is done.”

The objective of sonic drilling is to achieve resonance in the drill string to enhance drill bit amplitude and striking force, fluidise the soil along the drill tooling and increase production.  The Resonant self-tuning algorithm constantly tunes to the resonant frequency of the drill string and reduces the burden on the driller to determine the correct frequency. Self-tuning accelerates Resonant driller training to mere days and reduces equipment wear. Independent control over both frequency and force allows the driller to deliver peak power at any frequency or reduce power for maximum production and reduced tooling wear. Independent frequency control eliminates start up or shut down shaking of the drill mast and base machine. This drill can ‘idle’ at the target frequency without vibrating during rod changes and start up, saving time and preventing wear and fatigue of the base machine. In addition, the maximum amplitude of the drill is limited to safe levels by the flow rate of the power pack. This prevents galloping oscillation (unintended high amplitudes) at resonance and consequent catastrophic stress and drill tooling failure. “Conventional sonic drills (which use eccentric masses) cannot offer such protection. No Resonant driller has broken drill tooling,” the company reports.

During the 2012 summer season Foundex Explorations used a heliportable Resonant Drill in Alaska to advance 60 holes to depths of 60-120 m in very dense glacial tills including: clays, sandy silts, gravels and boulders and artesian conditions. Resonant drilling produced 100% recovery cores and proved bedrock to 10 m in many holes. Auto-tuning allowed the training of local drillers within a short period of time, meeting local labour requirements. The drill head and frame weighed less than 1,000 kg allowing A Star heli-lifts. Resonance developed the holes using a minimum of flush water and low spoil; critical in the fragile tundra for reduced environmental impact. The scheduled drilling program was completed early and additional holes were added prior to winter shutdown. Core samples of 105 mm diameter with 150 mm diameter casings were drilled. 2012 was the second successful season for the Resonant Drill in Alaska, and it says “mining exploration is increasingly moving to sonic drilling of the overburden.”

Geosoft is a market leader in earth exploration software. “We have maintained our leadership by staying connected to our roots in exploration, and by delivering software and services that contribute to knowledge and resource discovery,” said Tim Dobush, Geosoft CEO. “After 27 years, we are still a company of explorers, passionate about creating solutions for exploring through data.”

Innovations in mobile technology and instrumentation over the past few decades have made data collection easier and more efficient.  Extracting meaningful results from the resulting data has become a major challenge for modern day explorers. Furthermore, discovery rates have declined partly because of the challenge of finding more deeply buried or remote deposits. This has made the ability to “see” beneath cover increasingly important.

Turning large volumes of diverse data into discovery advantage is at the core of Geosoft’s offering. “Geosoft provides a complete 3D technology solution for subsurface exploration of geology, geophysics and geochemistry, with extensions across GIS and interoperability with specialist mining systems,” said Dobush. “The benefit for explorers is that they are able to complete the A-Z of exploration within an integrated exploration environment, from early assessment through to targeting and resource discovery – and they can easily share and build on results across GIS and mine modelling systems”

Dobush points out that beyond the technology, Geosoft’s strength is the depth of expertise delivered through its technical support, professional and training services.  “Geosoft was founded by geoscientists and explorers, and these highly skilled individuals continue to form the core of our company,” he says. “Because so many of us have been right where our clients are today, we understand their challenges and we speak their language.”

New Geosoft technology released in 2012 included VOXI Earth Modelling, a cloud-based service for creating 3D earth models from geophysical data. By harnessing the cloud, VOXI effectively delivers super-computer performance to run models quickly. Ian MacLeod, Geosoft Chief Technologist explains: “Explorers are routinely creating earth models in minutes.  Models as large as 12.5 million voxels are being processed in under an hour using VOXI. This type of modelling could consume a full day of people and computing resources using traditional technology.”

VOXI’s speed and ease of use, means interpreters can rapidly iterate and improve the accuracy of their models. The end result is improved 3D modelling of geological structures and potential mineralisation. “VOXI is most impactful for companies trying to get a handle on what is causing the geophysical anomalies over their prospects in the early stages of exploration, when time is of the essence” says MacLeod.

With its latest advances Geosoft has boosted its 3D modelling power, adding geological subsurface modelling to its exploration technology platform. The company also introduced advances to VOXI Earth Modelling, including new techniques for reducing processing time and sharpening 3D inversion results.

“Geosoft has taken a data-driven approach to help explorers build 3D models that explain all of their observations, supporting the best possible exploration decisions,” said MacLeod.  “Our focus is based on simple and useful workflows that integrate drilling information, geophysical modelling and both surface and down-hole geochemical/geological mapping.  This is all done in three dimensions together with important links to 2D sections and maps.”

“This approach is evident in VOXI Earth Modelling,” said MacLeod, “which starts with a 3D viewing experience, and includes a simple workflow to get models integrated with other data, in a 3D environment. With the new geological subsurface modelling workflows, we’ve introduced 3DV, a new file for containing everything 3D in Geosoft, and improved integration within Geosoft’s 3D geology workbench.”

The new 3D wireframing and interpretation tools was included in Geosoft’s March update of Oasis montaj and Target exploration software.  They will be added to Geosoft’s Esri Extension, Target for ArcGIS, later this year, enabling the integration and sharing of wireframing results as 3D geosurface files across both Geosoft and Esri GIS platforms.  Additionally, VOXI Earth Modelling now includes automated Iterative Reweighting Inversion (IRI) which saves processing time and can be used to model sharper contacts in the inversion result, providing more refined targets. When combined with Magnetic Vector Inversion, IRI improves the geological modelling of unconstrained potential field data.

“We are entering the era of power modelling,” said MacLeod “where both the technology and exploration expertise exist to deliver deeper 3D insight into the subsurface for faster discovery.”

Work crews and equipment must have the freedom to traverse miles of undeveloped wilderness to prospect, conduct environmental surveys and manage drill rigs during any time of the year over an endless variety of solid and semi-liquid terrain. ARGO’s flagship XTI and Centaur are ideal for operating in remote areas.  These unique machines have a low relative cost, in comparison to tracked hydrostatic vehicles or helicopters, and balance a low terrain impact with a high payload capability. They provide extreme-terrain capable solutions for delivering work crews and equipment anywhere it is needed. Areas inundated with temporary flooding, criss-crossed by small streams, or dominated by a tailings pile are no problem for these vehicles.

One amphibious ARGO, carrying cargo and up to six passengers, can achieve multiple tasks.  Fully enclosed cab and track kit options ‘will allow work to be completed in an efficient manner regardless of the environment’. In addition, ARGOs have a variety of accessories and custom solutions that capitalise on the expansive rear cargo area (ARGO) or mounting frame (Centaur). Options for exploration and drilling fleets are almost limitless, including cargo boxes, drills, cranes, and tool kits.  Mounting systems for extra fuel or a spare tyre, a winch, or a cargo bed liner to protect the vehicle from abrasive tools and mineral samples are also available.

ARGO has outfitted its top-of-the-line 2013 ARGO 8×8 XTI with the advanced features.  These include lighter steering effort for all-day ease-of-use, a more powerful drive train for accomplishing the most rugged tasks and comfortable seating. The 2013 XTI and Centaur fleet is fuel efficient, simple to maintain, and environmentally friendly due to its very low ground pressure.

The patented ADMIRAL transmission takes the driving experience of the full skid steering system to a new level. The all season 2013 ARGO 8×8 XTI pairs the triple-differential ADMIRAL steering transmission with a 23-kW fuel-injected engine to create an all-terrain, amphibious off-roader that turns with ease in high gear, while maintaining on-the-spot maneuverability in low gear. For 2013, ARGO is introducing a new high torque alternative, allowing the operator to improve performance and mobility in extremely difficult terrain conditions.

The heavy duty Centaur 8×8 DT, with its threecylinder liquid cooled 25 Kw turbo diesel engine, provides more power and load capacity when the mounting of cranes, drills, cargo boxes and fire & rescue equipment is required. In addition, the Centaur comes with a wide range of track solutions for extreme terrain performance. ARGO’s unique 25 in off-road amphibious tyre, provides greater ride comfort, all-terrain traction and propulsion over water. In addition, ARGO offers a wide selection of extreme performance tracks that virtually go through any terrain. Large triplesealed outer bearings and heavy-duty axles enhance durability and life expectancy in demanding off-road conditions. 

Fordia has introduced the next generation of White Rhino reaming shells to the international market. With new manufacturing techniques, Fordia says it “has created reaming shells with better concentricity and increased durability, and thereby improving the products’ overall performance.

“Available in both 10 and 18 in, (254 and 457mm) these products have a greater number of contact points than standard reaming shells and are specially designed for optimal straightness, which helps to minimise drill hole deviation. They are built for drilling the deepest holes.”

These specialised shells are made with high-quality, synthetic and natural diamonds, embedded in a highly resistant matrix.  Additional protection is provided by wear-resistant tungsten carbide to maximise lifespan. The 10-inWhite Rhino is equipped with two rings fully covered with diamonds, while the 18-in model is equipped with two diamond rings that cut into the rock to widen and efficiently stabilise the drill string, as well as two additional rings to reduce friction and achieve optimal straightness.  Concentricity measurements are taken on the shell rings to ensure proper alignment. These measurements result in greater stability, increased lifespan and ultimately help to reduce drill hole deviation.

Underground innovation

RDH Mining Equipment’s versatile utility carriers can be configured for custom built machines, fuel/lube transport, mobile workshops, scissorlifts, material transport, concrete re-mixers, boom trucks, shotcreters, ANFO loaders, and personnel carriers.  An important member of that support team, the Haulmaster 600-30P, has been designed specifically for moving workers or materials long distances underground. With optional ride suspension, the Haulmaster 600-30P personnel carrier provides a quick and comfortable commute for workers, preventing fatigue and ensuring productivity. The design can be reconfigured to meet the specific requirement of individual customers, accommodating between 12 and 30 passengers. The rear compartment of the Haulmaster 600-30P can move up to 30 passengers with additional passenger seating in the driver’s compartment.

Safety features include two emergency exits, an ANSUL fire suppression system, and safety door interlocks in the rear passenger compartment. Safety door interlocks prevent accidents by automatically applying the brakes in the event a door opens during travel. The rear compartment includes comfortable bench seating with independent seat belts.  As with all of the products in its line of utility vehicles, the RDH Haulmaster 600-30P also includes the following standard features:

■  Articulated carriers with heavy duty frame construction

■  Reliable, proven power train components with engines that comply with strict emission regulations 

■  Four-wheel drive and powershift transmissions providing superior traction

■  Easy maintenance and accessible service points 

■  Organised and accessible management of hydraulic and electrical system components 

■  Carrier arrangements to accommodate front or mid-ship seated ergonomic operator stations

■  Ride suspension option for extra comfort. 

MTI’s new test mine is a strategic investment allowing, in particular, product development and training. Cementation is one of MTI’s partners here and there is a shaft sinking section to this test mine that is perhaps unique in the world. Here a new shaft excavator made by MTI was undergoing final tests when IM visited the test mine last October. MTI’s shaft jumbo drills provide innovative, highly versatile solutions that feature Montabert drifters and patented automated control technology. Each jumbo uses MTI expertise in customising equipment to achieve high cycle time and increased efficiency.

Shaft mucking relies on durable, efficient systems to remove material from the site. MTI’s Vertical Shaft Mucker (VSM) advantage is the improvement in operational safety. Singleoperator control allows for a pared-down team at the shaft bottom during the mucking process.  This allows for significantly faster cleaning and contributes to the overall reduction in lost time.  The test mine has five main purposes:

1. Allowing mti to demonstrate its machines to customers

2. Product development

3. Precommissioning of equipment before it is delivered

4. To participate in third party research – there are various commercial partners conducting R&D in explosives (Orica), ground support (DSI and 3M) and other technologies

5. Training – there is the partnership with Cementation for shaft sinking training and there are training programs with two local Sudbury colleges.

The mine last October compressed 400 m of 5 x 5 m incline development at a grade of 15%.  The shaft sinking training is conducted in an area driven off the decline.

In 2011 MTI successfully trialed a 1.2 m3 hybrid LHD at the CANMET experimental mine in Val d’Or.  Now it is developing a 3.1 m3  hybrid loader. The smaller machine is equipped with a metal hydride battery pack and a two cylinder, 25.7 kW Deutz engine. “The machine puts out a lot more torque than we initially anticipated,” said Bob Lipic, MTI’s President and CEO. “When it gets into the muckpile, it’s a real hog. It grabs a full bucket on the first pass, so it’s a fast mucking machine and has a lot more power compared to a mechanical drive machine.”

 “There’s virtually no exhaust compared to a conventional machine,” explains Randy Wilson, MTI’s Systems Group Supervisor.  “It’s ideal for a mine with very limited ventilation. This loader requires half the ventilation of a conventional unit.”

NORCAT and HLS Hard-Line Solutions have entered into a partnership to offer remote mining equipment training at NORCAT’s Underground Training and Technology Testing Centre in Onaping Falls, Ontario.  The program, designed in partnership with industry, will train participants in the remote operation of an LHD using Hard-Line’s Muckmaster™ radio remote control system. The Muckmaster system is designed and produced to achieve superior performance while being exposed to the harsh conditions of underground environments. Bi-directional controls allow not only the control of the machine, but a responsive touch that gives the operator the ultimate level of security and safety.

Hard-Line will also be utilising NORCAT’s worldclass underground training centre to test and validate new remote equipment packages for industry.  “NORCAT’s partnership with Hard-Line demonstrates the innovation broker role NORCAT plays to the global mining industry and private company partnerships that that drive technology and innovation,” said Don Duval, NORCAT CEO. “Our partnership with Hard-Line is a natural fit, whereby we are providing an opportunity for the mining community to learn and train in a new technology, while concurrently supporting a client to further its product development, testing and validation.”

“Hard-Line is very excited in regard to our partnership with NORCAT,” said Walter Siggelkow, Hard-Line President. “It provides us with the opportunity to have our technology at the forefront of mine training, while enabling us to utilise facilities that will further benefit our research and development of cutting edge products for the mining industry.”

Established in 1996, in Sudbury, Ontario, Hard-Line is a leading supplier of remote and tele-remote control systems to the industry. Hard-Line develops its products from the ground up, using years of experience in mining, electronics, electrical design, software development and mechanical design. The manufacturing process has enabled Hard-Line to develop new and innovative products that save lives while increasing production in the global mining industry.

CTL Industries is a division of Hard-Line and its patent-pending fill containment system designed to replace shotcrete fences after a stope has been filled has attracted the interest of several large mining companies. The existing process is very labour and material intensive, with extensive manpower, materials and machinery required to begin the 16 hour-long process of making a shotcrete-fill fence. It becomes a case of playing catch-up because too few construction crews are assigned to keep up with the demand for fence construction, which slows stope turn-around time.

A slurry mix of typically 70% fill fines to 30% water is used to fill the void. Normally, a shotcrete fence is constructed to hold the fill in place so mining can continue on the next cut after the stope is filled.  CTL’s custom-made fill containment system is a high-strength geotextile bag weighted for 27.6 bar with puncture strength of 6.5 bar. It hooks up to the ventilation system, causing the bag to inflate to fit the space. An access hatch allows a miner to feed the fill pipe through the hatch and into the stope. The bag can be as long as 6 m and becomes part of the process of filling the stope.

This three-hour process involves filling the bag first, which becomes like a dam. Then the fill line is opened, allowing slurry to occupy the space. The use of bursting disks in the fill line, which explode at a certain pressure, permits the stope to gradually fill from the back face to where the bag is located without plugging the line.  The biggest advantage is that it is a ready-made, ready-to-go product. There is no wait time for shotcrete teams to build fences. It is a quick, easy process that takes about three hours to set up, inflate and fill. The bag remains in place once the stope is filled.

A new cavity monitoring system developed by GeoSight is gaining a lot of interest. The MINEi is a ruggedised, wireless laser system with built-in battery pack that performs 3D scans of open stopes and ore passes. “The market was crying for a robust, wireless solution for the underground survey market, so I registered GeoSight and started doing some R&D in 2006,” said John Lupton, President. “We worked on it for five years and launched our first prototype in 2010. Since then, we’ve built 22 systems for customers around the world.”

The laser is introduced into openings at the end of a series of 1.5 m rods extending from a wheeled buggy. The benefit of being wireless is that there are no cables to get twisted, hung up or run over, explained Lupton. The laser communicates wirelessly with a tablet or laptop, capturing geospatial data that can be imported into the mine plan, and overlaid with the design rings and geological data.

“Cavity monitoring allows you to determine the amount and value of the ore that was left behind and how many tonnes of waste rock came in that shouldn’t have,” explained Lupton.  “Forget what you planned or budgeted. This is the gospel truth, and it’s available to you before the mill calls up and tells you what you sent. You’ve got some data now that says you didn’t send 100,000 t, you only sent 80,000 t, and the grade wasn’t 4.5, it was 3.5. A survey will tell you if $1 million of ore was left in a corner and allow you to come up with a plan to retrieve it, rather than walk away from it.”

Lupton performed contract surveying in Sudbury for Vale, FNX (now KGHM International) and other mining companies in Northern Ontario while the MINEi was in development. “They needed contract surveys because their systems were down so much,” said Lupton. “Until now, lasers were delicate. Their internal workings were high-maintenance and the turnaround time for repairs was slow.”

The MINEi by comparison is ruggedised, waterproof and can be calibrated by the user. Lupton also advocates the use of his lasers for surveying ore passes and other raises to determine the cause and location of hangups.  He cites one example that had been “blocked up three years ago for four weeks and last year for two weeks, and they had no idea exactly where and no idea why,” said Lupton.

Lowered into an ore pass along with a camera and lighting, the laser takes a scan every 16 m or so. The images are patched together and provide 3D, geospatially accurate picture of the blockage. “The video helps to get the scanner over any hurdles and obstacles because we could be laying out cable and not know that it’s hung up. The video helps us maneuver the laser and get around obstacles.”  A camera alone wouldn’t be sufficient to identify the location of the blockage because it’s only a 2D image, so “you’d never know if you’re looking at something that’s 4 m away or 10 m away from the camera.”

“With a laser scan, there’s no guesswork about the precise location of a hangup, but even more important, the scan can help determine the cause of a blockage and what needs to be done to prevent further blockages,” said Lupton.

Celebrating its 20th anniversary later this year, ESG Solutions continues to develop solutions to help manage and understand induced seismicity. Micro seismic monitoring presents a critical tool to improve production and mitigate risk in underground and open-pit mine operations. ESG develops instrumentation and provides geophysical data processing services to detect and record continuous seismic signals to reveal what is happening behind walls and in areas not accessible to mine workers. In particular, this information may be used to deploy workers in less hazardous regions of a mine, adjust ground support and calibrate or confirm numerical models used for mine design and sequencing, to better manage seismicity and improve mine safety.

Micro seismic monitoring has been used in Canadian mines since the 1980s. Typically, induced seismicity is measured on a micro-scale at levels equivalent to very small earthquakes measuring from -3 to +1 in magnitude, however the addition of surface-based strong ground motion (SGM) sensors are often used to record larger magnitude seismicity.  Micro seismic systems provide continuous monitoring of seismicity induced during mining operations, and serve as an essential tool to quantify and understand stress-induced rock mass behaviour. When integrated into wider mine operations, micro seismic data can provide the best possible information to influence short term and long term process decisions.

Released in 2012, Paladin IV 32-bit digital seismic recorder reflects the state-of-the-art in micro seismic acquisition. Underground and surface-based units are time synchronised by GPS to ensure that all recorded events are located accurately in space and time. Each Paladin unit is a web-enabled device (for remote access/calibration) and is capable of providing continuous and/or trigger-based data acquisition. It introduces plug-and-play functionality for improved ease of use, and remote diagnostics capabilities keep tabs on sensor health, speeding up system maintenance. Coupled with web-enabled global data streaming, powerful new on-board processing enables stand-alone units to perform advanced triggering and analysis without a PC, supporting a diverse suite of new remote monitoring applications.

To provide high resolution micro seismic systems, sensors may be installed in deep boreholes from surface as well as in shorter boreholes from underground tunnels to build an optimal 3D sensor array. ESG has considerable experience in deep borehole installation for mining, geotechnical, oil and gas applications, with current installations deployed as deep as 2,285 m. These installations are very valuable when monitoring cavingoperations and for evaluating slope-stability in open-pit mines.

3M Canada continues to develop the Polymeric Composite Membrane (PCM), a two-part thin, sprayable liner for underground mines based on polyurea chemistry. PCM was born in response to a customer request for a more flexible ground support solution to contain loose rock from slow-rate deformation.

The material is intended to be used in the mining cycle, and applied autonomously by a robot that will first scan the drift, and then apply the primer and topcoat membrane layers. The recommended topcoat thickness is 4 mm. Bolts are installed in a standard pattern, as determined by the mine’s ground support engineer.

Unlike shotcrete, the membrane can stretch under load – its elongation is better than 250% – meaning that rocks can move without the ground support failing. Gel time is two to three seconds, achieving a tensile strength greater than 25 MPa (at full cure). At full cure also, toughness is 50 MPa and tear resistance >500 pli.

Laboratory testing at 3M Canada’s London,  Ontario headquarters preceded the first underground sprays at NORCAT’s Fecunis adit in Sudbury, followed by further trials at Xstrata Nickel’s Nickel Rim South mine. Testing was coordinated by the Deep Mining Research Consortium (DMRC), an industry-funded research group whose members include Xstrata, Vale, Rio Tinto, Barrick, KGHM and Agnico-Eagle.  The robot and programming was provided by ABB. Much has been learned, but implementation of the in-cycle application still lies in the future. Work remains to be done on the scanning and programming, and to date, funding for a custom-built carrier vehicle has not been secured.

A critical element of the underground testing was gathering the data to show that the material could be sprayed safely underground, since PCM uses isocyanates to achieve its performance. 

Isocyanate properties are well-understood, and they are used to make everything from clothing to building materials. They are routinely and safely handled by many industries, including mining, where they appear in products like grouting. PCM uses MDI, the least volatile of the commonly available isocyanates, but it is not benign. Its very low vapour pressure reduces hazards during handling compared to other major isocyanates. Plus, the very fast reaction which occurs in the PCM system means there is little free isocyanate remaining after spraying.

Rigorous environmental and safety testing was conducted by third party consultants during underground trials of PCM to determine the full implications of its use. Measurements were taken in the spray area, and at 5, 10, 20 and 30 m down the drift. Values were captured during the application, and continued to be monitored after the spray was turned off.  The levels of isocyanate present in the working area during the spray are easily managed with personal protective equipment, and drop to zero within minutes of the spray ending. With proper safety protocols in place, PCM can be used safely underground.

The testing has also shown that PCM may greatly enhance the strength of shotcrete.  Additionally, mining contractors have suggested that PCM might be successfully applied in ventilation raises, safety bays, and underground workshops.

A.J. Hyett and Pierre Ballester, Director of Business Development, YieldPoint comment that “an explosion in rock bolting innovation is in progress, driven by the demands of bulk mining at increased depth and in poor ground.” In 1997 500 million units were installed (Tadolini S.C., Mazzoni R. A. (2006). Proceedings of the 25th International Conference on Ground Control in Mining, August: Twenty-Four Conferences: more than one-hundred seventy papers; understanding roof bolt selection and design still remains priceless.  Morgantown, WV: Lakeview Scanticon Resort & Conference Center, pp. 382-389).

“That number has ballooned to well over 1 billion units in 2011 which, assuming an average worldwide cost of $25/installed unit,” they continue, “amounts to a significant industry investment in technology that remains very poorly understood. In many countries roof bolting is mandatory, but as mining is forced to greater depth and as safety regulations stiffen, the economic opportunity associated with improving and even optimising roof bolt design can positively impact the economic viability of many mining projects.

“Over the last 25 years the most widely used type of rock bolt has changed from endanchored mechanical bolts to fully grouted resin rebar. Today in US coal mines over 90% of the bolts installed are fully grouted resin rebar (Windsor, C. R. (1997) Rock reinforcement systems. Int. J. Rock Mech. Min. Sci., 34(6): 919–51). Even though an increasing proportion of these bolts is tensioned during installation (typically to 3-4 t), fully grouted bolts primarily depend on mining-induced ground movements to induce load in the bolt. The rate of load increase caused by each increment of ground movement is referred to as the bolt stiffness. Geotechnical engineers recognise that this is the most important property affecting performance. Whereas in shallow mines the high stiffness of fully grouted resin rebar is ideal, at greater depth higher ground movements around excavations can result in excessive loading which may result in rupture at the faceplate. Under this scenario it is advisable that a ‘softer’ rock bolt system be implemented because geo-mechanical theory tells us that installing enough bolts to arrest ground movement will be uneconomical: in other words, the optimal approach is to engineer a rock bolt system that can ‘go along for the ride’.  Accordingly frictional stabilisers such as split sets and Swellex bolts can be more effective that stiffer, stronger types of bolt.

“Another category of innovative rock-bolts have been developed to control dynamic movements associated with seismic events.  These include the Modified Cone Bolt (Mansour Mining, Canada), the Yieldlok Bolt (Jennmar, US), and the D-Bolt (Normet Group, Finland).  The concept with these bolts is to absorb the energy associated with rock ejection into the excavation. However, such ‘dynamic’ bolts also need to perform well when subjected to static mining-induced movements and hence their deployment must be carefully engineered. In some mines engineers use alternating rings of resin rebar and cone bolts in an attempt to leverage the benefits of each bolt type.

While innovative bolts have positively expanded the hardware options in the rock bolt ‘toolbox’, the additional choices do complicate the rock-bolt design process. However, a hi-tech solution is providing answers.  YieldPoint’s innovative Instrumented Rock Bolts can be used to evaluate new hardware designs, especially since the new measurement technology has been applied to almost the entire range of bolt types: mechanical bolts, rebar, the YieldLok bolt, DSI Threadbar, D-Bolt and cone bolt. The YieldPoint instrumented rock bolts are based on up to eight miniature inductive strain gauges recessed in two thin grooves diametrically opposed along the bolt to compensate for bolt bending under shear. Strain and displacement are temperature compensated and read via the microcontroller in the instrument head. Every instrument is individually calibrated, coefficients are written into onboard microcontroller memory, and a piecewise linear function is used to provide a linear relation between the output signal and applied strain. The instrumented bolts are installed just like the regular bolts. The value of the data is greatly enhanced because real-time monitoring solutions can be implemented that ‘piggy back’ on existing mine-wide communication infrastructure, and transmitted to the engineer’s desktop or the consulting company’s server. Since the technology is reasonably priced, ‘clusters’ of instrumented bolts can be used to delineate the deformation pattern around excavations: for example, preliminary datasets reveal that the loading of bolts in the roof may be quite different from those in the wall.

Additionally, research is currently underway using distributed optical sensing that can detect the detailed loading along bolts with millimeter resolution. Such technology is ideal for coal mines since it is intrinsically safe.  These new technologies provide engineers with “rich” data that can provide a feedback loop to evaluate design changes that incorporate new hardware options.

WipWare recently came to an agreement with Konvels Automation to represent and distribute WipWare products in the former Soviet Union.  “This agreement is the culmination of a number of years working with Konvels and solidifies four years of ongoing relationships within Russia,” said WipWare President Tom Palangio. “It gives us a local presence in that market and the ability to communicate with customers in their own language and allows us to apply our experience in the mining, mineral processing and aggregate industries.”

The principal activities of Konvels are equipping and upgrading industrial automation process control systems, and the selection, integration and delivery of technological and analytical equipment, test equipment, special diagnostic tools. WipWare says “blast models, formulas, expected results, we all know that this approach to predicting blast results is useless without the tool to quantify what really matters; fragmentation.” It says of its fragmentation analysis technologies that they “root deep in the explosives industry, we understand the steps required to improve blast fragmentation, and the infinite number of variables which effect the results.” The technology provides the tools to collect historical data, establish a statistical baseline and track subtle changes throughout the optimisation to enable decisions to be made based on fact, instead of theory.  Momentum and Reflex are automated real-time fragmentation analysis systems for measuring particle fragmentation on multiple conveyors and moving haul or LHD vehicles. Solo is a portable analysis system for measuring particle fragmentation on a conveyor. 

Golder Associates has been leading the development of Discrete Fracture Network (DFN) technology since the 1980s with the development of its code FracMan®.  A key motivation behind this development was the recognition of the generally poor way that conventional geotechnical characterisation methods handle discrete fracture data. Fracture properties are often crudely incorporated into a rock mass quality value or represented by very simplistic geometric properties. In contrast, DFN modelling attempts to model the rock mass fabric realistically, using statistics derived from drill hole logging and mapping. By building geologically realistic models that combine the larger observed structures with smaller random fractures that conform to the statistical data, DFN models capture both the geometry and connectivity of the fracture network. Many practical problems can be addressed when the geometry of intact rock blocks defined by these fractures is understood.

Mining can benefit in several ways from the insights of a DFN approach. Underground excavation support and open pit benches can be optimised if the likelihood of free blocks of a given size and shape are known. Groundwater depressurisation holes can be oriented to have the greatest probability of intersecting key fractures. A major investment has been made in the use of DFN techniques in block caving assessment. With the performance of the cave so critically tied to fragmentation of the orebody, DFN modelling offers a stepped change in the ability to estimate the size distribution and shape of in situ rock blocks. The impact of conditioning methods, such as hydrofracturing, can be investigated to find the optimum spacing of holes and frequency of hydrofracs. With the ability to define the natural fracture network, and incorporate this directly into finite element stress analysis, true predictive modeling of mass mining is close to being realised. 

In recognition of the growing interest and use of DFN technology across a wide range of rock engineering applications, Golder is helping to organise the First Discrete Fracture Network in Engineering (DFNE) conference in Vancouver in October 2014. An international committee of leaders in the field has been assembled and planning is already under way to create a stimulating forum for industry practitioners to share their knowledge and discuss the challenges ahead (www.dfne2014.ca).

BESTECH, specialising in engineering, automation, software development and energy management, offers three solutions to help mines address the challenges of conserving energy, reducing environmental impact and improving workplace safety: NRG1-ECO™, AQM™ and RopeInspector™.  Created by BESTECH itself, NRG1-ECO is an innovative mine-wide energy management system. It provides system control strategies, such as Time-of-Day Scheduling, Event-Based and Asset Tagging, that, the company says, “dramatically reduce a mine’s energy consumption while maximising productivity, profitability and worker safety. The NRG1-ECO system is configurable to each mine’s unique requirements and designed with an open Industrial-Plug-and-Play™ interface that allows system integration with existing or new equipment. NRG1-ECO can be customised to reflect each mine’s needs and protocols.

Consider a mine ventilation system that usually operates at peak capacity 100% of the time. The NRG1-ECO ventilation module enables active control of the system’s air flow with respect to time and location. “This ability allows a mine to reduce its ventilation costs by as much as 30%, which can represent millions of dollars for some mines given that ventilation usually represents 50% of a mine’s energy costs.”  Furthermore, the implementation of NRG1-ECO lessens the strain on the power distribution system and diminishes greenhouse gas emissions.

Using BESTECH AQM (Air Quality Monitoring) technology, mines can improve how they manage emissions. AQM is an ambient air monitoring system used as a tool to monitor environmental impact on surrounding communities, enabling mines to manage their production accordingly. The system delivers data rapidly from various field locations providing instant feedback to current and ongoing production systems required to control emissions stemming from operations. AQM collects, processes, compiles and stores data so that it is easily available for regulatory reports, public information websites or daily operational reports.

AQM is currently in place at the largest SO2 monitoring network in Sudbury, Ontario, as well as in Labrador City, Newfoundland. With its 99.9% data acquisition rate, redundant network connections and automatic alarming capabilities, AQM ensures that mining companies within the community do not exceed their maximum thresholds for SO2 emissions.  Moreover, BESTECH offers a complete service package with AQM: the team will manage the total operation and maintenance of the air quality systems. This package includes instrument calibrations, on-going sites visits and maintenance, assisting with regulatory audits and regular reporting.

The RopeInspector system automates regulated visual rope inspection by providing continuous 360° coverage at full hoisting speed. While defect analysis is performed, RopeInspector increases hoisting output and worker safety, as well as makes more time available for preventative maintenance. It conveys early detection of potential rope failures by scanning hoist ropes 24/7 at up to 20 m/s. Rope defects, such as necking, birdcage and fraying, can be identified. “With a return on investment of less than five weeks, implementation of the system improves efficiency while meeting safety legislation requirements,” BESTECH says.  With RopeInspector, mines have an alternative to the legislated mandatory task of hoist rope inspections. Hoist maintenance personnel are removed from rope proximity and put in an office setting where they can be responsible for multiple hoists. As a result, mines are meeting and surpassing current regulatory requirements as well as increasing hoisting output and using additional time for maintenance, people and materials movement or extra production. The third generation of RopeInspector is under development in order to further address the needs of the mining industry. 

 

Nett Technologies is an innovative emissions control company that specialises in the design, development and manufacturing of pollution control solutions for today’s compression and spark-ignited engines for both the OEM and retrofit markets. With almost 20 years of emission control experience using the latest of software, engineering and manufacturing techniques, Nett was approached by Sifto Canada to assist in dealing with its underground NO2 challenge.

Located in Ontario, Goderich mine is the world’s largest underground salt producer and recognised as a leader in the business. Using a drill-and-blast mining technique, salt is extracted from a large deposit located approximately 540 m below Lake Huron. The mine produces about 7,250,000 t/y of salt that is destined for use in various retail and commercial applications. Operating large diesel equipment, as this mine does, higher than desired ambient NO2 levels can occur. Part of the solution to managing the elevated NO2 levels is a custom engineered urea-SCR (Selective Catalytic Reduction) system from Nett that uses the same innovative technology currently offered in its EPA (Environmental Protection Agency) verified BlueMAX™ 100 product. Nett says “this technology is available at a fraction of the cost when compared to other solutions such as repower, equipment replacement or increase in mine ventilation rate.”

The urea-SCR (in the form of a 32.5% waterbased solution) system is the same technology currently used in today’s newest Tier-4 engines being introduced to the off-road market. Using strategically placed sensors throughout the exhaust system of Sifto’s diesel equipment, Nett’s SCR system continually monitors NOx, air flow and temperature levels. An onboard system computer calculates and disperses a controlled amount of urea into the exhaust stream. When measured, this industry’s one of a kind urea-SCR solution for Sifto, provides greater than 80% reduction in overall NOx emissions. The sensorbased system is suitable for both OE and retrofits and can easily be custom engineered to fit into a wide range of diesel equipment. In addition to the emission benefits, the direct-fit design of Nett’s SCR system meets safety requirements by not obstructing or impeding an operator’s view.

Nett says that “in 2009, Sifto evaluated one other supplier’s technologies and Nett’s SCR system was the clear winner. Not only was it a winner for its performance but also for design durability and esthetics point-of-view. The engineering challenges to overcome were also greatly increased by the limited space available, visibility requirements and a harsh salt environment. To-date, the system has accumulated over 12,000 hours of operation.  Since then, Sifto has decided to go with additional SCR installations on nine of its largest NOx engines.”

Maestro’s AirFlow system provides real time measurement and diagnostic functions in order to provide maximum system uptime and superior accuracy over other measurement techniques. Maestro sensors are digital which provides unique multivariable functions and allows a maximum separation distance of 1,220m to the transmitter. They are non-contact sensors that are not affected by dust, humidity and dirt, and provide an average air velocity across the complete drift or measurement path.  They are able to detect mobile equipment in measurement path and to detect cable or sensor failure.

The AirFlow system can be integrated in any communication environment. Maestro says it is “the world’s first airflow system that is configured with a web page and requires no additional expensive software, software licenses or hardware.”

Simsmart’s ventilation modelling, simulation and control technology, SmartEXEC 3D, is being implemented into Goldcorp’s Eleonore mine in Northern Quebec. The tool was initially used to verify and validate the planned ventilation system. The original design of the push-pull system included two 1,470 kW exhaust fans to achieve 1,020,000 m3/h.  While using SmartEXEC 3D to run production scenarios, it was determined that by implementing the (Ventilation On Demand) VOD technology, procurement of the second exhaust fan was not necessary to achieve its production air flow requirements.

Simulations also determined that by implementing SmartEXEC energy consumption would be reduced by 50% for a total savings of 10,614 MWh. The energy savings alone equate to annual savings of $530,000.  This value does not include the additional capex savings achieved from not purchasing a second exhaust fan.

 SmartEXEC 3D integrates into ventilation systems by connecting directly to Process Logic Controllers (PLCs), Variable Frequency Drives (VFDs), actuators, starters and other controllable devices via existing communication infrastructure. Once communication is established, SmartEXEC maintains all control information for a given piece of equipment regardless of location. Using dynamic linking, as ventilation equipment is added or removed, altering the process control is a simple database change. This change is done by the end user through the SmartEXEC system: no programming or infrastructure change is required.

 

Manufacture Adria is expanding its global presence with the addition of a new distributor. Located in Mongolia’s capital, Ulaanbaatar, Erchim Import, is now offering Adria’s products and services there. Erchim is a division of the Namir Group, which specialises in mining services.  Adria is currently developing a 4000 kVA portable substation for underground mines and says “clients should expect the same quality and reliability as their standard smaller units, but with the gain of higher power output.”

A recently completed project was at Kumtor mine, located at more than 4,200 m above sea level, in the Kyrgyz Republic part of the Tian Shan belt, about 60 km north of China. Because of the high altitude, electrical equipment needed to be specially designed for the lack of oxygen and air density. Overheating problems and dielectric strength are highly affected in that type of environment. Standard equipment is not expected to perform well and to survive in those locations – likely to fail over a short period of time. Adria designed and built 6.3 kV portable substations that would work properly in a low oxygen and high altitude environment.

Adria specialises in underground mining electrical equipment. Some of the most popular products are: portable substations, mine power centres, monobloc skid mounted substations, portable switchgears, portable medium voltage switches, junction boxes, etc. Other products also offered consist of: single or multiple output power take-off panels (PTO), motor starter and controls and automation control panels (PLC). Adria is an ISO 9001:2008 certified company.

The Rail-Veyor® underground haulage system at Vale’s mine at the 114 orebody in Sudbury was described in detail in the January issue of IM.  Kate McLaughlin, Vale, Manager Technical Systems Development Canada noted: “The thing that impressed me most with the Rail-Veyor here at 114 orebody was how quickly it was constructed. There has been a tremendous amount of work done engineering all the different components, and because of that they go together very quickly and construction happens much more rapidly than I ever thought would be possible. Because of that I think the real benefit is your ability to get into production and development much quicker than with some other historical systems.”

Provix provides both analogue and digital and both wired and wireless video camera solutions for almost every aspect of mining. Customer driven, with the ability to respond quickly to user specific designs and requirements, Provix has built a reputation based on systems that offer increased productivity while enhancing safety.

Provix mobile equipment cameras effectively serve as both safety camera systems for manned operation and remote operation video systems for remote mucking and inspection. The Provix Remote Mucking Camera system is also available as a portable system that can easily be moved from scoop to LHD, using quick disconnect power harnesses. Integrated battery packs are also available for cameras and transmitters, allowing for the remote video system to be used without connected machine power.

The portable system transmits video from two rugged HD quality cameras to a 12 in monitor for full or split screen viewing. User feedback indicates that the 2.4 GHz transmitter receiver combination is capable of providing wireless video around corners and up to 300 m away in line of sight applications. Cameras can be mounted on vertically adjustable pedestal mounts to allow for rapid changes in the cameras’ field of view to suit operator preference and the layout and approach to the work area.

The Provix Loading Process Monitoring Video System is a user defined modular system that can support visual monitoring of loading pockets, chutes, bins or, breakers with camera images being transmitted to haul trucks, loaders, operator towers and network nodes for surface or control room viewing. The multi camera system is able to transmit real time video to multiple vehicles equipped with wireless monitors; therefore the camera system ensures that all relevant personnel are apprised of the current status of both transport and processing equipment. The result is maximum uptime for production and processing equipment, as well as optimal use of haul trucks, rail depots, shuttles and other related equipment.

The Provix Portable Drill positioning system (aka the Bucket Cam) is a multi function HD camera system that packs down neatly into a 5 gallon pail that houses the mag mounted camera with its 61 m retractable camera cable.  The IR LED HD video camera quickly connects to a 12 in AC/DC powered monitor with an integrated battery in a waterproof Pelican style case. In Sudbury, Vale’s Creighton Mine uses them for drill positioning in no go areas. The close up focus of the rugged camera lens allows for quick determination of patterning when drilling blast holes.  Rapid relocation of the drill rig, consistent blasthole configuration and safer drilling are side benefits. Other mines use the same camera in other configurations for breaker monitoring; ore pass and stope inspection and even remote operation. 

At Dumas, a contractor specialising in underground services, safety is taken very seriously and is a core value, with every employee empowered to proactively solve safety challenges. This well-engrained safety culture has led to several industry safety awards in both Canada and international locations. These include the 2012 Safety Innovation Award from the Ontario Mine Contractors Safety Association (OMCSA) for developing a ‘Re-railer Bar’ to safely and efficiently re-track derailed underground locomotives, as well as receipt of the Plaque of Honor for Underground Mining at the XV National Convention of Mining Safety, organised by the Institute of Mine Safety in Peru.

Dumas credits its success to both the culture that has been developed within the organisation and the tools and processes that have been implemented company-wide. These include use of a Zero Harm risk card, analysis of leading and lagging indicators, supervisory and employee training, safety process implementation tracking, and communication.

It has been said that planning is the key to ensuring safety for workers, allowing them to be productive and confident about the work they do. Dumas employs the use of a Zero Harm card to itemise and evaluate the job, identify risks, and enable employees to identify controls to eliminate or mitigate the risks.  Leading and lagging indicators provide management with a clear line of site to how the organisation is performing. By monitoring safety statistics on a monthly basis, what is measured gets special focus and gets done.  Training has also been a  major factor in reducing risk. Dumas has a detailed process with certified trainers and approximately 100 training programs.  Each employee must undergo specific training prior to being allowed to go underground or perform a specific task. All training is tracked and monitored on a monthly basis. Computerbased training has also recently been implemented to provide consistent, convenient access to basic safety training from every region, improve efficiency, and reduce training time and costs.

To track implementation of safety processes, site management is required to provide a detailed weekly status report. This includes outlining what each supervisor has conducted as part of his/her HSE requirements. Peer pressure helps to ensure that projects conduct their compliance and organisational responsibilities.  Communication also plays an important role in nurturing a safety culture. By implementing communication tools such as bi-weekly safety shares in all languages that the company operates in, Dumas brings focus to key themes that may be defined by environmental factors or accident lessons learned. Each share is reviewed with all employees, who are required to acknowledge reviewing the information, and then posted on site bulletin boards for future reference.

Binding all these elements together is the Dumas leadership team. With management’s support and guidance, employees never lose sight of what is important….to get the job done safely, on time while meeting the quality requirements.

Surface mines

Penguin Automated Systems is providing robotic innovations, both underground and on surface.  A recent major delivery was to Codelco, a Telecommand system for the leach pad at RT that will get the stacker operator into a clean, safe environment. The Penguin control cabin for the handling system for RT’s 0.5 km wide by 2km long leach pad was shipped last October.  The leach pad Telecommand system uses WiMax and is a result of the first trials of optical communication, which is now able to transmit great distances. The high bandwidth optical communications system creates VPN for mining terrestrially, underwater and even in space.

The Optical Virtual Private Network (VPN) has been designed to allow the teleoperation of multiple telerobots in surface and underwater environments. Its demonstrated capability is 160 Mb/s in direct sunlight over a distance greater than 150 m and 30 Mb/s in littoral ocean waters over 10 m in highly turbid waters.

As Dr Greg Baiden, Chairman and CTO, explains, Penguin’s early work was in teleautonomous operation of fleets of mining machinery from surface operation centres any distance away. That work continues. Back in the days of Inco, Baiden and his team achieved a great deal in automation. The remote operation by one man of two LHDs in Sudbury from as far away as Ottawa – something not equaled anywhere else yet. That team also produced an autonomous electric truck of 70 t capacity that operated underground between 1989 and 1994 and moved over 2 Mt of ore.

Technically, he says this is really “autonomation” – one person runs multiple machines with a “human touch”. Since those early days at Inco, Penguin’s VPN is eminently suitable for a comprehensive system to control surface vehicles (which could have one operator, for example, running as many as five trucks).  Overall, Baiden feels this is safer than a fully autonomous option.  Back underground, Penguin has developed a telerobotic reconnaissance system, with Codelco again being a prime user. The company has used these robots to visually map various drives in the different levels of a block cave, to check the infrastructure’s ability to perform for the best caving. Geospatially positioned 3D scans have been taken of the drilling levels, for example. The technology may also be used the machines to go into stopes to map the cave.

Westport Innovations, a global leader in natural gas engines, is currently working with OEMs to develop engines for applications that would benefit from using Westport™ highpressure direct injection (HPDI) technologies, including mining trucks and locomotives. Many of these products consume large amounts of fuel and operate in regions where natural gas offers a significant cost advantage over diesel, providing substantial savings in operating costs while lowering greenhouse gas (GHG) emissions. HPDI technology retains the power density, transient response, and efficiency of diesel engines in demanding mobile applications.  Westport and Caterpillar are actively codeveloping natural gas technology for off-road equipment, as announced in June 2012.  The initial focus is on engines and fuel storage systems for large mining trucks and locomotives. 

K-Tec Earthmovers has a new Mine Version 25.2 m3 (33 yd3) scraper.  K-Tec says its aim is “to provide the mining sector with a rugged and durable solution for moving materials such as rock, gypsum, and coal and an ideal solution for removing overburden in an efficient manner.”   The Mine Version scraper has thicker hightensile plate steel, enabling top-loading of heavier rock. K-Tec scrapers are backed by a three-year structural warranty, to minimise costly downtime for critical jobsite operations.  The 1233ADT Mine Version scraper features KTec’s exclusive gooseneck which hooks up to the truck frame of ADT power-units. The use of an ADT power-unit provides higher speeds on haul roads, while the functionality of the K-Tec scraper enables precision grading and dumping, the company says.

Altering the design of the popular 1233 model was possible with the assistance of 3D CAD and stress testing computer programs to provide the basis for a prototype mining unit. The scraper design was further refined and “rock-proofed” after a period of on-site research and development testing. 

Two 1233ADT Mine Version scrapers are working in an open-pit gypsum mine. Site contractors have found a variety of ways to use the scraper units in an efficient manner. The average size of gypsum rock being transported in these K-Tec mine scrapers is 178 mm diameter but they can range up to 406 mm in length.  Using a Cat 740 rock truck to pull a 25.2 m3 mining scraper, operators can self-load the unit to remove overburden and pick up loose material. The gypsum mine also uses Cat D8 dozers to push-load the scraper units when quicker load times are required. Also loaders and excavators are frequently used to top-load the K-Tec scraper units with gypsum. The scraper makes for a low and large target for rock dumping. The cycle-time to move rock with this setup is rapid, when considering the ease ofloading and unloading,haul road speed, and overall flexibility.

Generation2Filtration™ notes “maintenance costs are far too high; breakdowns too costly; production downtime tips the negative scale of daily profits. We must find ways and means to control contamination within our equipment to improve the oil quality and keep component wear at a minimum in order to keep the equipment running longer under cleaner conditions to increase our bottom line.” It says its product line of bypass filtration systems “can do just that. Whether being installed on engines, transmissions or hydraulics Generation2 Filtration will generate new found savings that go directly to your bottom line.”

“You need more than good quality oil and standard filters to extend component life and time between filter oil changes. Contamination in a system arises from many sources including that of contaminated ‘new unused oil.’ With today’s close tolerance in hydraulic components and the post 2009 engines having greater emission standards while the engines operate at higher temperatures there is definitely the need for Generation2 Filtration.

Generation 2™ bypass filtration has the ability to polish small volumes of oil at slow flow rates, down to 1 μm, through the precision multi-ply ‘axial flow’ cellulose element. This removes ultra-fine contamination and water normally missed by standard full-flow filters. With four stages of filtration in design, Generation 2 elements “are designed to meet the contamination levels associated with the new generation of engines and hydraulic and transmission specifications, with today’s sophisticated components while maintaining a strong T.B.N. or an ISO code of 15/13/10 cleanliness code.”

Motion Metrics International’s advanced monitoring solutions are the result of over 13 years of research and development focused on solving challenges faced in mining operations around the world – aiming to make mining easier, safer, and more connected.  The growing product portfolio includes solutions to monitor the safety and performance of shovels, loaders, and conveyor belts. These customer-driven solutions have been proven to pay for themselves in less than three months of deployment and are currently being used by some of the industry’s biggest names in copper, iron ore, gold, diamond, nickel, platinum, coal, and oil-sands mining.

For shovels and loaders, Motion Metrics is well-known for solutions which help prevent broken teeth and adapters from reaching the crusher. They also offer solutions that can predict when tooth change-outs are required, prevent collisions, analyse blasting efficiency, and monitor equipment productivity. These solutions have been installed in a variety of configurations on over 200 shovels and loaders across the globe.

For conveyor belts, Motion Metrics has recently introduced a revolutionary belt monitoring solution, BeltMetrics™, which senses numerous vital parameters including material size distribution, volume flow, and mass flow in real-time. The unification of this valuable information provides management with a complete overview of the material flow, allowing high-accuracy optimisation of processes.

All the equipment monitoring solutions developed by Motion Metrics have been specifically designed for the mining environment and typically involve the use of rugged cameras and/or advanced sensors connected to a specially-designed embedded computer system which runs customdeveloped intelligent software in real-time.  The design process ensures that each product holds up in the tough mining environment where the equipment must sustain constant shock and vibration, heavy dust and mud, and extreme temperatures.

With shovel and loader monitoring from the pit and conveyor belt monitoring to the mill, the tremendous benefits of correlating this information to optimise operations is obvious.  To create this link, Motion Metrics has designed a robust centralised data server solution, MMIServer, which puts all the vital equipment information at your fingertips. 

By using the existing IT infrastructure of a mine to connect directly to all of the Motion Metrics monitoring systems, this groundbreaking solution makes critical safety and productivity information accessible throughout the mine network. The  simple MMIServer web interface allows any device on the mine network, whether it is a laptop, a tablet, or a smartphone, to instantly access a wealth of equipment KPIs and the health status for the shovels, loaders, and conveyor belts. When productivity benchmarks are not met, customised alerts can be configured to immediately notify the appropriate personnel. This complete monitoring solution from Motion Metrics saves precious time and money, and provides a collection of unparalleled information to monitor and streamline mining operations.

Since 2009, Cypher Environmental’s EarthZyme has been applied to many kilometres of haul roads at a large oil sands mine in Fort McMurray, Canada. The treated roads demonstrate a high level of density and perform extremely well during rain and spring break up as compared to the non-treated roads, Cypher reports. Due to the improved quality of the treated roads and the reduced dust generated during the use of the roads from traffic, haul trucks are able to increase their speed, improving overall productivity. The treated roads are also able to withstand the constant traffic and heavy loads of the haul trucks. The EarthZyme treated roads have also proven to have less rolling resistance and less rack events on the haul trucks due to the increased density of the treated roads and overall more consistent and smooth road surface.

Another benefit is that the use of EarthZyme allows for quality roads to be built with high clay content soils that are normally not thought of as quality road building materials. In many cases the EarthZyme treated clay roads have outperformed roads built with gravel, which is a much more expensive resource.

EarthZyme treated roads eliminate the need for constant grading/maintenance due to the stabilized soil and improved engineering properties resulting from a single application.  On untreated roads at mine sites, graders are frequently deployed to maintain road conditions, especially after rain.

Simlog now provides an augmented simulation experience using the Simlog branded Operator Chair. The modular design of its Personal Simulators ensures that the right tasks are simulated and measured the right way in order to both train heavy equipment operators and evaluate candidates to measure operating proficiency.  Simlog’s Operator Chair was developed in response to demand from customers for a chair-based simulation experience that leverages the versatility of  Simlog’s Multi-Purpose Replica Controls – widely used with Simlog’s unique table-top mounting option.

The Operator Chair is a cost-effective way to train heavy equipment operators in a safe and realistic environment, featuring an authentic, industrial operator seat with air suspension and moveable headrest. It is fully adjustable in positioning (forwards/backwards, up/down) and the armrests can be configured to various heights and angles.  It is configured with dual consoles which house USB Replica controls that can be used with Simlog’s mining truck, off-highway truck, and wheel loader Personal Simulators.

Instantel’s Micromate™, a low-cost fourchannel unit, is designed to monitor and transmit event data with one triaxial geophone and one air overpressure microphone. It has been designed to withstand the mining environment.  The rugged design includes a high-impact protective boot, fully sealed top panel, and noncorrosive, impact-resistant connectors. Micromate is easy-to-use with a touch-screen interface including intuitive menus, colour display, and an associated keypad.

The real-time operating system provides uninterrupted event monitoring ensuring zero dead time between events. The flexible sample rates, from 1,024 to 4,096, offer programmable record times from 1 second to 30 minutes dependent on the selected record mode, and the expansive memory offers a capacity for over 1000 one-second events at a sample rate of 1,024 S/s. USB communications allow high speed data transfer of recorded events and uploading of setup configurations. Important features like Auto Call Home™ remote monitoring and an enhanced Histogram Combo™ recording mode are also included.  IM