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Industry Forward

Exhibitions, Mining Shows & Conference Previews

Coal

Renewable Energy Solutions - Solar Power, Lighting & Products

Power Infrastructure & Power Generation

Products & Services

Aviation Services to the Mining Industry

Bearings

Electrical

Environment, Water & Air treatment

Filtration, Exhausts & Emissions

Hand Tools in Mining

Hire Equipment - Winches & Hydraulic Power Units

Hose, Valves & Pipes for Mining

Hydraulics, Lubricants & Solutions

Instrumentation

Milling - Mill Maintenance & Operating Efficiency

Mining Machinery Engineering & Attachments

Optimising Minerals Processing & Performance

Plastic & Composites V’s Metal

Power Transmissions

Professional Mining Associations - Education, Training & Development

Ramps, Walkways & Metal Flooring

Safety in General/Safety - Drugs & Alcohol Testing

Transport & Containers

Tyres, Wheels & Valve Systems

Ventilation

Graphic Designers Michael Griffiths

Kym Reichenbacher

Publisher Garth Wright

Printer Newstyle Printing Co. Pty Ltd

41 Manchester Street Mile End, SA 5031

Phone: 08 8234 6155

APRS Head Office Level 6, 38 Currie Street

Adelaide, SA 5000

GPO Box 1746, Adelaide, SA 5001 Phone: 08 8113 9200

Fax: 08 8113 9201

APRS Queensland Office Level 2, The Mansions

40 George Street, Brisbane, Qld 4000

PO Box 15454 City East, Brisbane, Qld 4002

Phone: 07 3229 9766 Fax: 07 3229 3066

Pre-Press Phone: 08 8113 9206

Email: prepress@aprs.com.au

Advertising Phone: 08 8113 9223

Email: rlambert@aprs.com.au

Phone: 07 3229 9766 Email: cwerb@aprs.com.au

Disclaimer APRS is not committed to nor takes

responsibility for the views expressed in articles or advertisements herein.

The publishers could not possibly ensure that each advertisement

published in this magazine complies with the Trade Practices Act and

responsibility must therefore rest with the person, company

or agency submitting the advertisement for publication.

Industry ForwardMinister for Resources and Energy

The latest data from the Australian Bureau of Agriculture and Resource Economics (ABARE) estimates Australian production of energy and minerals commodities will rise by

3 per cent in 2009-10. Iron ore production alone will rise by 21 per cent. In 2010-11, metals and minerals production will rise by around 7 per cent; energy production will rise by 1 per cent in 2009-10 and 10 per cent in 2010-11 following increased metallurgical coal, natural gas and thermal coal production.

Australian miners are also in a better financial position to invest in increasing production to meet world needs. Over the next five years a large number of mineral and energy investments are expected to come to market.

As at October 2009, ABARE has identified 74 projects under construction or committed to production across Australia (38 energy projects, 31 minerals projects and five mineral processing projects). A further 267 projects are undergoing feasibility studies or approval processes, highlighting the confidence of the sectors – and the confidence Australia has in our trading partners.

The LNG industry provides a perfect example of this confidence.

In 2008-09, Australia exported over 16 million tonnes of liquefied natural gas (LNG) valued at $10.1 billion. More LNG facilities are on their way with the Pluto Project close to completion and the very large Gorgon Project having commenced construction.

There are also a number of other LNG projects at various stages of planning, which includes five coal seam gas LNG projects in Queensland. These will be the world’s first export projects utilising this resource. In addition, the advent of floating LNG technology has the potential to unlock Australia’s stranded offshore gas fields.

The International Energy Agency predicts that from 2007 to 2030, the global demand for natural gas will increase by 43% and LNG’s share of world gas trade will grow from around 34% to about 40%. Australian LNG has a bright future as the Asia Pacific region increasingly becomes the driver for global economic growth with consequential demand for cleaner energy.

In particular, both China and India as high-growth nations will be seeking reliable sources of low-emissions energy. Australian LNG will deliver on both these criteria with our reputation as a dependable supplier with significant gas reserves. Research from the United States shows that, when used for power generation, LNG generates around 73 per cent less CO2 emissions on a life cycle basis than the current cleanest coal combustion technology (IGCC).

Finally I would like to note the leadership role Australia has taken in dealing with one of the most significant by-products of the world’s reliance on fossil fuels to underpin economic growth - carbon dioxide.

Around the world, acceleration of commercial-scale carbon capture and storage is being pursued as a high priority to enable the world to meet global CO2 reduction goals by 2050. In Australia we have taken a number of complementary measures to encourage the use of carbon capture and storage (CCS). This includes the CCS Flagships program to fund a portfolio of industrial scale integrated CCS projects, a National Carbon Mapping and Infrastructure Program which addresses potential storage locations, exploration needs and pipeline requirements, and putting in place a legislative framework to administer access to and usage of carbon storage sites. Australia has established the Global CCS Institute and is committed to providing it with up Au $100 million a year to help progress the G8 goal of 20 full scale CCS plants by 2020.

I am certain that much of the investment needed for Australia to take full advantage of the increased demand for resources and energy that is occurring as growth returns to the world economy is either already occurring or is in advanced stages of planning.

The Hon Martin Ferguson AM MP Minister for Resources and Energy

The global financial crisis (GFC) presented the

greatest challenge to the world economy since the

Great Depression. The swift and targeted action of

governments has buffered their economies from

economic calamity. Australia was a leader in this regard

and as a result, the impact of the GFC was less dramatic

than in other comparable countries. The strength of Australia’s resources and

energy sector contributed to minimising the impact of

the GFC in Australia as well as boosting our recovery.

Australia is now in a better position than most countries to return to pre-crisis growth.

Exhibitions, Mining Shows & Conference Previews

Australasian Mining Review 2010: 1st edition

5

The Mount Isa Chamber of Commerce’s Xstrata Mount Isa Mining Expo is gearing up for the events crystal anniversary as the Expo celebrates a strong fifteen years of working with

industry in the North West.

The primary purpose of the Xstrata Mount Isa Mining Expo is to offer exhibitors the opportunity to showcase their product to key target audiences consisting of managers, purchasing officers, suppliers, business owners and end users within the mining industry. In addition, the Mount Isa Chamber of Commerce has identified an opportunity to further network industry personnel during these three days and have since developed unique and entertaining networking events that provide exhibitors with the opportunity to further business leads in a more informal environment.

A record number of not only exhibitors but people through the gates cements the Expo as a successful industry exhibition showcasing the North West region and as the largest annual Expo on the eastern sea board. Nearly 8000 people flocked through the gates in 2009 completely surpassing 2008’s attendance numbers. The event also defied the resources slump by selling out exhibitor booths in 2009; with organisations fighting for the opportunity to showcase their products and services in one of the richest mineral provinces in the world.

The Expo which has also become renowned nationally for the quality and diversity of the networking events held throughout the week will continue to exceed everyone’s expectations

in 2010 with a special event occurring every night of the exhibition. From the stellar formal cocktail function on the Opening Night to the 80s rock karaoke Buyer and Supplier Networking Dinner- exhibitors, dignitaries and special guests alike will be exhibitors will be provided with valuable, effective and entertaining networking opportunities.

The Xstrata Mount Isa Mining Expo also prides itself on the quality of the ‘Meet the Buyer’ Sessions that give exhibitors twenty minutes to promote their products and services to senior purchasing officers. Purchasing officers from Xstrata Copper, Xstrata Zinc, BHP Billiton and Oz Minerals contributed to nearly 300 Meet the Buyer Sessions over the two days of exhibition in 2009, giving interested exhibitors a number of opportunities to promote their organisation and wares. Purchasing Officers from these and additional new and emerging mines in the North West are currently being sourced and secured to provide additional sessions this year.

President of the Mount Isa Chamber of Commerce Brett Peterson said the Expo’s 15th year anniversary was a great achievement and milestone for the North West region.

“The strength of the Expo is reflective of the resilience of industry in the North West and the vast mineral richness of the region that has protected our local industry from the full effects of the global financial crisis.

“Whilst a full recovery is yet to be reached, there have been a number of economic indicators that suggests Mount Isa has been buffered to some

extent by the global financial crisis and if anything, is one of the leading Australian regions that managed to keep this country out of recession. Our event is therefore an opportunity for suppliers to showcase their products and services to an industry that has survived the downturn and is in fact preparing for the next big boom in commodities,” Mr Peterson said.

Booths for the event are selling very quickly and for those interested in purchasing a site, please log onto www.mountisachamber.com.au or contact the office on 07 4743 9881.

The Mount Isa chamber of commerce

Xstrata Mount Isa Mining Expo

Australasian Mining Review 2010: 1st edition

7

When our last Conference was held, in 2008, the industry was booming and the future looked very bright. Since then, there has been the “Global Financial

Crisis”, and increasing political bickering about emissions trading schemes and carbon emission reductions. As I write this, the way forward is very unclear, and I hope that good sense and good economics prevails, and Australia maintains its vibrant coal industry and low cost energy.

At the same time, plans are being announced to develop major coalfields west of Brisbane, and build new railway lines and new or upgraded port facilities to handle the increased exports. Coal appears to have a sound future.

Meanwhile, the Queensland Government is looking to sell off its Abbott Point coal terminal and Queenslands Rails coal transport business.

We live in interesting times, and it’s more than ever vital to keep up with trends in the industry which provides us with our living.

The format for the Conference will follow the very successful style developed by the Society over the years, with a balanced mixture of technical sessions with some guest speakers, and an interesting social program for partners. There will again be a technical Workshop at the end of the Conference.

Please come to see and hear the latest in coal preparation technology, to view the exhibition, to interact with others with an interest in coal preparation and of course, to enjoy Mackay and Central Queensland hospitality.

The Society continues to grow and improve, thanks to the efforts of the members, the Branch Committees, and the Board. Our membership numbers are again very high, our course

attendances continue to be very good, and we continue to produce new textbooks and, of course, to produce the highest quality conferences.

I would like to thank the members of the Local Organising Committee and Technical Sub-Committee for their work in putting this Conference together and also to the Sponsors of events during the Conference. Their contribution is greatly welcomed.

Please take advantage of the early bird registration fee and I look forward to seeing you all in Mackay on September 12 to 17, 2010.

ACPS National Chairman

Peter MillsSponsorship opportunities and exhibition space still available – contact the conference secretariat Rob Casey - conferences@acps.com.au

The Mackay Conference and Exhibition facilities are just 1 year old & at international standards, the conference technical papers will be their usual very high standard, and the exhibition, with over 30 exhibitors, promises to be among the best ever hosted by the ACPS.

coal Preparation Society conference and Exhibition

at Mackay, Queensland, Australia

National BranchPO Box 2315 DANGAR NSW 2309 Tel: 02 4926 4870 Fax: 02 4926 4902

Email: acpsnational@acps.com.au

AUSTRALIAN COAL

PREPARATIONSOCIETY LIMITED

ABN 74 001 837 145

National BranchPO Box 2315

DANGAR NSW 2309

Tel: 02 4926 4870

Fax: 02 4926 4902

Email:acpsnational@acps.com.au

theme guide 2009 > 2010theme guide 2009 > 2010

theme guide 2009 > 2010

12-17 September 2010MACKAY Entertainment

Convention Centre

MACKAY

Advancing Coal Preparation Technologies For Our Future.

Sunday 12th Registration

Monday to Thursday 13th-16th ACPS Sessions

Thursday 16th Optional Technical Workshop

Friday 17th Optional Field Excursion

For further information www.acps.com.au

National Secretariat – Julie-Anne HomanPhone: +61 2 4926 4870

Email: acpsnational@acps.com.au

LOC Conference Secretariat – Rob CaseyPhone: +61 2 9970 8251

Email: conferences@acps.com.au

Australia is the world-leading exporter of coal and the

clear world leader in coal processing technologies, while

remaining at the focal point for technical advancements and

continuing to set the future directions in coal preparation.

Coal preparation is the vital link between mine, port and the

end users requirements.

From 12-17 September 2010, The Australian Coal Preparation

Society will be holding its 13th Conference in Mackay,

Queensland. Mackay is one of the largest regional cities in

Queensland, with easy access to the Bowen Basin – producing

83% of Queensland coal – making it a significant coal-mining

hub and excellent venue for this important conference.

Leveraging from Australia’s strong coal industry platform,

the conference will showcase the many advancements in coal

preparation, along with focusing on current successes and

new developments, which highlight the opportunities for our

industry in providing sustainable and cleaner technologies

for our future.

Photo Courtesy of New Hope Coal Australia

PROUDLYSPONSORED BY

6TH ANNuAL AuSTRALASIAN ZINC BRIEFING, Sydney, NSW www.informa.com.au/conferences/mining/metals-minerals/the-6th-annual-australasian-zinc-briefingPACIFIC RIM RESouRCES INvESTMENT CoNFERENCE, Sydney, NSW www.informa.com.au/conferences/mining/metals-minerals/pacific-rim-resources-investment-conferenceCoNSTRuCTIoN & MINING EquIPMENT ExPo, Perth, WA www.cmeexpo.com.auMINING THE EASTERN GoLdFIELdS 2010, Kalgoorlie, WA www.regionalminingevents.com.au/mining-the-eastern-goldfields-2010THE 13TH ANNuAL GLoBAL IRoN oRE & STEEL FoRECAST CoNFERENCE, Perth, WA www.globalironore.com.auPRACTICAL RoCk MECHANICS IN MINING, Perth, WAAuSTRALASIAN oIL & GAS ExPo, Perth, WARARE EARTHS & FuTuRE METALS FoRuM, Perth, WA vICToRIAN CoAL & ENERGy 2010, Traralgon, Vic www.informa.com.au/conferences/mining/metals-minerals/victorian-coal-energy-2010

AuSIMM NEw LEAdERS’ CoNFERENCE, Kalgoorlie, WA www.ausimm.com.au/newleaders2010/13TH quAdRENNIAL IAGod SyMPoSIuM 2010, Adelaide, SA www.alloccasionsgroup.com/IAGOD2010xSTRATA MouNT ISA MINING ExPo, Mount Isa, Qld www.michamber.com.au/content/category/6/18/28/SINGLEToN MINING & oHS& ExPo 2010, Singleton, NSW www.singletonminingexpo.comPRECoNdITIoNING woRkSHoP, Perth, WASECoNd INTERNATIoNAL SyMPoSIuM oN BLoCk ANd SuBLEvEL CAvING, Perth, WA www.caving2010.comSAFETy IN ACTIoN TRAdE SHow, Melbourne, VicMATERIALS HANdLING - MELBouRNE SHow, Melbourne, Vic

MARCH11th - 12th

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SkIMBERLEy ENERGy ANd RESouRCES dEvELoPMENT, Broome, WA www.regionalminingevents.com.au/the-3rd-annual-kimberley-energy-and-resources-development-conference SAMPLING 2010, Perth, WA www.ausimm.com.au/sampling2010/AusIMM CoNGRESS, Wollongong, NSW www.ausimm.com.au/content/default.aspx?ID=1883Rd SuRAT BASIN CoAL & ENERGy CoNFERENCE, Brisbane, QldTHE NEwCASTLE-HuNTER CoAL MINING ExPo, Newcastle, NSW www.nhminingexpo.comAMMA 2010 NATIoNAL CoNFERENCE, Perth, WA www.amma.org.au/conference/ALTA 2010 NICkEL-CoBALT-CoPPER, uRANIuM & GoLd CoNFERENCE, Perth, WA www.altamet.com.au/next_conference.htmENvIRoNMENTAL GEoCHEMISTRy oF MINE SITE PoLLuTIoN, Perth, WASEdo SuSTAINABLE ENERGy ExPo, Perth, WA

CoAL TECH 2010, Brisbane, QLD www.iir.com.au/conferences/mining-resources/metals-minerals/coal-tech-2010 AdvANCEd APPLICATIoN oF SEISMoLoGy IN MINES, Perth, WARHEoLoGy woRkSHoP, Perth, WAMINING THE PILBARA 2010, Port Hedland, WA www.regionalminingevents.com.au/mining-the-pilbara AusIMM INTERNATIoNAL uRANIuM CoNFERENCE, Adelaide, SA www.ausimm.com.au/uranium2010/

AuSTRALIAN EARTH SCIENCES CoNvENTIoN 2010, Canberra, ACT www.aesc2010.gsa.org.au/quEENSLANd MINING & ENGINEERING ExHIBITIoN, Mackay, Qld www.queenslandminingexpo.com.auSEvENTH LARGE oPEN PIT MINING CoNFERENCE 2010, Perth, WA www.ausimm.com.auoPEN PIT RoCk MASS ModELLING SEMINAR, Perth, WA www.ausimm.com.au

dIGGERS & dEALERS, Kalgoorlie, WA www.diggersndealers.com.auSuSTAINABLE MINING 2010, Kalgoorlie, WA www.ausimm.com.au/sustainablemining2010/wA SAFETy SHow, Perth, WAGRouNd SuPPoRT FoR uNdERGRouNd ANd oPEN PIT MINES (BASIC LEvEL), Perth, WA

MINING NSw, Orange, NSW www.regionalminingevents.com.au/mining-nswxxv INTERNATIoNAL MINERAL PRoCESSING CoNGRESS, Brisbane, QLD www.impc2010.orgTHE 3Rd GuNNEdAH BASIN CoAL & ENERGy CoNFERENCE, Gunnedah, NSW informa.com.au/conferences/mining/metals-minerals/the-3rd-gunnedah-basin-coal-energy-conference-P10R04 CoAL PREPARATIoN 2010 “AdvANCING CoAL PREPARATIoN TECHNoLoGIES, Mackay, QLD www.acps.com.auGRAvITy GoLd 2010, Ballarat, Vic www.ausimm.com.au/gravitygold2010/MINING THE TERRIToRy, Darwin, Northern Territory www.regionalminingevents.com.au/mining-the-territory TAILINGS woRkSHoP, Perth, WAMINE wASTE 2010, Perth, WA

ALL-ENERGy AuSTRALIA 2010, Melbourne, Vic www.all-energy.com.auGoLdFIELdS MINING ExPo, Kalgoorlie, WA www.goldfieldsminingexpo.com.auTHE SAFETy SHow, Sydney, NSWMATERIALS HANdLING - SydNEy SHow, Sydney, NSW

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Australasian Mining Review 2010: 1st edition

13

Australasian Mining Review 2010: 1st edition

13

The Secret To Keeping Electronics Cool!A bad choice could cost you thousands!

Look Familiar? When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. The operator might choose to simply open the panel door and aim a fan at the circuit boards. In reality, the fan ends up blowing a lot of hot, humid, dirty air at the electronics where the cooling effect is minimal. If the machinery starts functioning again, the likelihood of repeated failure is great since the environment is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHA violation that presents a shock hazard to personnel.

The Real Solution! Stop electronic downtime! EXAIR has a complete line of low cost Cabinet Coolers that are in stock and can ship now. They mount in minutes through an ordinary electrical knockout and have no moving parts to wear out. Thermostat control to minimize compressed air use is available for all models. All Cabinet Coolers are UL Listed to US and Canadian safety standards.

NEMA 12 Cabinet Cooler® Systems

The NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.

Measures 8" (203mm) high •Mounts top, side or bottom•Enclosure remains dust-tight •and oil-tight

Non-Hazardous Purge Cabinet Cooler® Systems

NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits.

Uses only 1 SCFM in purge •modeFor heat loads up to 5,600 •Btu/hr.NEMA 12, 4 and 4X •

High Temperature Cabinet Cooler® Systems

High Temperature Cabinet Coolers for NEMA 12, 4 and 4X applications are available for heat loads up to 5,600 Btu/hr.

Suitable for ambients up to •200°F (93°C)Ideal for mounting near •ovens, furnaces, and other hot locations

NEMA 4 and 4X Cabinet Cooler® Systems

NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. They are ideal for PLCs and modular controls.

Enclosure remains dust-tight, •oil-tight and splash resistantSuitable for wet locations •where coolant spray or hose down can occurSide Mount Kits available•

Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr.

Resists harsh environments not •suitable for Type 303/304Ideal for food and chemical •processing, pharmaceutical, foundries, heat treating and other corrosive environments

Type 316 Stainless Steel Cabinet Cooler® Systems

Mini NEMA 12, 4 and 4X Cabinet Cooler® Systems

The mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads up to 550 Btu/hr. are ideal for control panels, relay boxes, laser housings, electronic scales.

Measures 5" (127mm) high •Mounts top, side or bottom•Enclosure remains dust-tight •and oil-tight

If you would like to discuss an application, contact:

GPO Box 2792, Darwin NT 0801 AustraliaTel: 1300 787 688 Int. Tel: +61 8 8983 3999Fax: 1300 787 637 Int. Fax: +61 8 8983 3900Email: jlindsay@winshop.com.au Website: http://caa.exair.com

“It took us three days to get a replacement computer cabinet and we didn't want to risk another heat failure. Fans weren't an option since they would just blow around a lot of hot air. Freon-type air conditioners like those on some of our other machines were a constant maintenance project of their own. We purchased EXAIR's Model 4330 NEMA 12 Cabinet Cooler System since it was easy to install and requires no maintenance.”Jeff Hauck

Lasercraft Inc.Fairfield, OH

Distributors of

Compressed Air Products for Industry

EXAIR compressed air products for industry are designed to improve the overall efficiency of your operations as well as reduce noise levels and reduce air consumption, thereby helping to reduce your production costs. Our Ultrasonic Leak Detector, EFC Electronic Flow Control for compressed air and Digital Flow Meter are money-saving and energy-conserving tools that can save your company tens of thousands of dollars. The new Digital Sound Meter can help increase safety and eliminate costly fines resulting from high noise.

Some of the products available in the EXAIR range include:

Air Optimization – minimize compressed air use • and detect wasteful leaksSuper Air Knife – quiet, hard-hitting curtain of air • for blowoff, cleaning, drying and coolingSuper Air Amplifier – vent, exhaust, cool, dry, • clean – with no moving partsAir Jets and Nozzles – reduce noise levels and • air costs on blowoff operationsSafety Air Guns – use engineered air nozzles to • reduce noise and air consumptionSuper Air Wipe – blowoff, dry, clean and cool • pipe, cable, extruded shapes and hoseStatic Eliminators – eliminate static and dust, • neutralise and clean at distances up to 6 metresLine Vac – convey parts, materials, waste – with • no moving partsReversible Drum Vac – fill or empty a 205 litre • drum in 90 seconds – with no moving partsChip Vac – vacuums chips directly to a 205 litre • drum – with no moving partsWindow Blowoffs – keep the window of your • CNC lathe clear of coolantsVortex Tubes and Spot Cooling Products – cold • air for industrial spot cooling problemsCabinet Coolers – stop electronic control • downtime due to heat, dirt and moisture; maintain NEMA 4, 4X and NEMA 12 integrity

EXAIR understands this difficult economy can take its toll on our abilities to prioritise or find motivation to work on previously unimportant or unseen problems. But we do have the information and tools to make your compressed air system more efficient:

Measure your air consumption• Locate and fix any compressed air leaks in the • systemUpgrade your end use blow off applications • with engineered products

Turn off the compressed air when not needed • for productionUse intermediate storage of compressed air • near the point of useControl the pressure at the point of use to • minimise air consumptionThese six steps to optimise your compressed air • systems do workEXAIR has the products to make each step • possible. Saving Money and Compressed Air•

Consider the following example where EXAIR’s Model 1100 Super Air Nozzle replaces a ¼” (6mm) open pipe. The compressed air savings is easy to calculate and proves to be dramatic.

(i) Existing blowoff is 1/4” open pipe at 80 PSIG supply. Air consumption is 140 SCFM.

(ii) Use EXAIR’s 1/4” Model 1100 Super Air Nozzle also at 80 PSIG. Air consumption is 14 SCFM.

(iii) Compressed air saved = 140 SCFM - 14 SCFM = 126 SCFM

(iv) Most large plants know their air cost. If you don’t know your actual cost, a reasonable average to use is $0.25 per 1000 SCF.

(v) Dollars saved per hour = SCFM saved x 60 minutes x cost/1000 SCF 126 x 60 x $0.25/1000 $1.89 per hour $75.60 per 40 hour week $3,931.20 per year savings

And that saving is for only ONE nozzle. Payout for EXAIR’s Air Nozzles and Jets is measured in weeks – NOT years as is the case for other cost reduction equipment.

For more information on how EXAIR products can help you, please visit our website at http://caa.exair.com, call us on 1300 787 688 or send us an email with your requirements and contact details to: jlindsay@winshop.com.au

We do our best to earn your business and will continue to do everything possible to see that you are satisfied with EXAIR. We appreciate your interest in our products and look forward to working with you.

Our commitment to you:- “ Rapid response to your enquiries with quality products and service.”

Compressed Air Australia in association with EXAIR Corporation offers high quality, energy-conserving solutions to common industrial cooling, drying, conveying, blowoff, cleaning and static electricity problems. Since 1999, we have supplied the Mining Industry, in addition to the Food, Pharmaceutical, Manufacturing, Agricultural, Pulp and Paper, Chemical, Electronics and Engineering sectors with innovative problem-solving compressed air products.

conserve energy Without the cost of New Equipment

‘Super Air Knife dries stamped parts on a conveyor’

‘High Temperature Vortex Tubes keep a boroscope lens cool while inserted into a boiler porthole’

Western Australia stayed on top by remaining the leading exporter, in fact gaining 24 percent accounting for a majority share of coal shipments to China,

while Queensland jumped 48 percent in exports in the last fiscal year. Gaining elevated coal and energy prices has enabled Queensland to outstrip New South Wales to become Australia’s second largest exporter.

Mining of black coal creates significant employment in regional Australia and makes a huge impact on the quality of life for outback communities. Our coal industry provides fuel for low-cost electricity generation as well as powering steel manufacturing. Australia with its’ forward thinking ethos is the world’s biggest coal exporter. Black coal is Australia’s largest export and was worth more than fifty billion dollars in 2008/2009. In addition to providing Australian consumers with affordable electricity, coal underpins the international competitiveness of the entire Australian economy, as well as being a major force driving the social and economic development of regional Australia.

As far as production goes, Our coal industry comprises six percent of the world’s black coal production. Ever since 2003-2004, Australia’s black coal production has been growing at a steady rate of three point two percent. Australia’s total coal reserves are estimated at 76,600 million tons. Australia holds the enviable accolade of being the world’s fourth largest coal producer.

Nigh on 41% of the global electricity requirements have been met by coal in the last few years and at the current consumption rate the global coal reserves are enough to generate electricity for the coming 300 years. So while Copenhagen might have been a disappointment to many industry outsiders, for us in the coal industry our ongoing quest to develop technologies is as strong as ever as we seek to fulfill the continuing expansive need for the demand for energy usage globally, while substantially helping to reducing emissions. This is a global effort & Australian coal producers need to play their part. An area that needs addressing here is an Australian skills shortage which may impede the development of clean coal technology in Australia. We as an industry need to be mindful that there may not be enough engineers, scientists and geologists to push forward the carbon

capture and storage research that our industry needs in order that we may increasingly be seen to be playing our part. Combating emissions is vital so coal remains as a huge component of the energy landscape for years to come.

Ongoing concern has seen coal mining in Australia transform into a safer and more productive industry where serious occupational health issues have been continually addressed. Numerous environmental and community impacts of coal mining have been brought to the fore by the Australian coal industry’s research program, ACARP. This has led to the Australian coal industry being one of the most technologically advanced in the world. Maximizing yield, minimizing emissions, reducing water consumption coupled with cutting edge water treatment and reducing production costs are the daily focus of coal mine management in this century.

The coal industry here works under the backdrop of our stable political and regulatory environment. This provides a high degree of confidence and certainty for investors. We must continue to play to our strengths and continue to work towards the sustainability of our industry.

Coal seam gas needs a mention here as it is a much talked about component of future energy usage coming from our coal fields. Although coal seam gas is only a relatively small industry, it accounts for a significant and growing proportion of the gas market of Queensland and New South Wales. For now the main issue that holds back growth within coal seam gas sector is the high cost of production relative to the labour intensive methods of extraction required. On top of this is the large numbers of wells that are often required for commercial production to be viable. This being due to the large footprint of our coal seam gas reserves.

The question now remains as to whether the outlook is bright and positive for the Australian coal industry from 2010 onwards and whether we have left the GFC for dust?

Now we know that the coal face played a vital role in Australia’s staving off from

the worst effects of the global financial meltdown, we can look ahead with pride and

a sense of expectation at the role our progressive coal

industry will take in helping to shape Australia’s economic

future. Strong commodity prices have helped us here,

as well as continuing demand from China. Coal has

therefore played its’ part in the buoyant performance of

the nation’s exporters

coal Outlook

Australasian Mining Review 2010: 1st edition

17

coal

In everyday life most people take for granted the fact that help and information is at hand via wireless internet, phone or a radio. Unfortunately this has not always been the case in an underground mine where the

mine structure presents an impenetrable barrier to radio waves and in most cases any system infrastructure will not be fit for purpose as it is not robust enough. Fortunately much work has been done to develop technologies that give the mine operator almost unlimited access to mobile data and voice communications.

The mainstay of any underground metaliferous mine’s communication solution is undoubtedly leaky feeder which has been continually developed over the past 20 years into what is now the most flexible, robust and reliable voice and low speed data solution available. All the strengths leaky feeder provide are now available for use in the Australian and New Zealand underground coal industry as Becker Mining Systems has recently received IS (IEC Exia) approvals for both the leaky feeder infrastructure and handheld radios.

“BHPB Illawarra’s Dendrobium Mine and Peabody’s Metropolitan Mine have both installed the Becker Leaky Feeder systems and are now enjoying the benefits leaky feeder bring such as totally seamless radio coverage from the production and development faces to the mine surface operations” said Phil Jones, General Manager of Becker. Jones confirmed that up to 180m of lateral signal coverage into all cut-throughs is achievable along the whole length of the cable. He said “additionally leaky feeder is immune to shading and multi-pathing issues which typically plague multiple antenna systems such as wifi”.

Leaky Feeder systems are easily installed and maintained by site personnel negating the reliance on highly trained engineers. This doesn’t mean that the systems are limited in functionality though as they offer standard broadcast ability over multiple channels, simple text messaging and telephone connectivity. Most importantly though system redundancy which was historically a weak point of leaky feeder systems has been addressed with 14hour uptimes in a power outage and multiple communications paths are serviced to maintain system operation in a catastrophic event.

Knowing where your people are in the underground coal environment can pay huge dividends in an emergency situation. Being able to pinpoint locations of people can not only speed up a search and recovery operation it can also be used to control access to restricted areas. Increased productivity can be realised by utilising the system to record cycle times, locate equipment underground quicker and identify traffic bottle necks. The Becker Tagging system consists of a software program and database, RFID active tags, tag readers and active displays located in strategic areas of the mine. Becker can offer tag versions for personnel (caplamp mounted and self-contained), vehicle and asset & tools. These tags give approximately an 80m read range and the entire system is now IS (IEC Exia) approved and rated for 14 hours minimum uptime in a power outage.

“A key strength of the Becker Active Tag solution is the fact all tags are fully compatible with the Becker Collision Avoidance system which detects Becker tags and alerts the operator of the vehicle. The latest developments of the Becker Collision Avoidance system incorporate sub centimetre detection, camera control and advanced tag locating solutions. The Becker Personnel Avoidance system takes this one step further and gives the underground worker a mini receiver that indicates when a vehicle is in close proximity.” said Jones.

Being able to access production and maintenance data from the development and production face is becoming critical in an efficiency driven environment. Typically this would be by fibre optics and wifi however the mining environment presents many challenges to these types of “surface” technologies. Becker have invested considerably in the development of suitable wifi and fibre optic technologies for coal mines and have now obtained IS approvals for a Wifi node with a VOIP handset approval pending.

The Becker Wifi node incorporates a fully IS managed Ethernet switch, RFID tag readers and serial buses.

Becker NCS have a range of services and products that suit both the Underground Metaliferous and Coal industries with a focus on Electronics and Electrical.

“The improvements in safety and emergency issues due to a constant and immediate communication around the mine operations should not be underestimated. Similarly, the potential efficiency gains in the mining operations will be enormous” stated Brian Nicholls a veteran Coal Industry consultant when he reviewed Becker’ radio communications solution for Australian Coal mines.

Wireless Voice System

Modern communications for coal

coal

The C4000 Fusion safety light curtain is electro-sensitive protective equipment complying with Performance Level “e” according to EN ISO 13849 and SIL3 in line with IEC 61508 and can be

used for the horizontal or vertical protection of hazardous points-of-operation.

The C4000 Fusion focuses on applications in which optoelectronic and thus barrier-free, protection is desired for process-related reasons, but has hitherto failed to provide the necessary process availability because of the risk of contamination or other environmental conditions.

Intelligent method of function for maximum availabilityAt first glance, the C4000 Fusion operates like many other safety light curtains: the “safe protective field” generated by the transmitter and the receiver detects a person or their limb and immediately switches the machine off.

This switching-off is triggered by the interruption of one or more light beams – a principle that quickly brings “normal” light curtains up against their limits when they are used in harsh environments and exposed to correspondingly high risks of contamination.

The consequence: uncontrolled responses by safety equipment and minimized machine availability. This is not the case with the C4000 Fusion! Here, three features or functions ensure maximum availability: the Multiscan process, reduced resolution and redundant transmitter-receiver synchronisation.

Multiscan is based on an increase in the scanning rate, i.e. querying the uninterrupted light paths of the individual transmitter elements as well as the intelligent evaluation of scan results. This allows the system to reliably distinguish between whether an arm or a person is interrupting individual beams of the protective field or whether, containments are responsible. In addition, this process supports reduced resolution of the protective field down to 300 mm, i.e. allows process-oriented and ergonomic adjustment of the light curtain to body or hand protection. The advantage: operation-related reaching into the machine is tolerated whilst leaning in with the upper torso leads to a safe machine stop. Finally, the redundant synchronisation of the C4000 Fusion contributes towards maximum availability because electronic

co-ordination of the transmitter and receiver modules takes place within the light curtain via several light beams.

Designed for use under harsh environmental conditions, the new C4000 Fusion safety light curtain from SICK succeeds in combining maximum safety at work with optimum productivity, ergonomics and cost-effectiveness.Suppression of contamination in the monitored environment; adjustability of resolution to protect hands or entire persons; as well as redundant, optical synchronization of the light curtain’s transmitter and receiver modules ensure maximum possible availability of the protective equipment, and thus minimized machine and plant downtimes.

The c4000 Fusion:Machine protection with human-material

differentiation in harsh environments

.

coal

Renewable Energy Solutions

Australasian Mining Review 2010: 1st edition

23

Australasian Mining Review 2010: 1st edition

23

The world is changing. Global warming is a scientific reality and ever more companies, governments and institutions are looking into the endless possibilities that renewable energy technology is

opening up as an alternative to polluting fossil fuels. It seems that the marketplace surrounding renewables is swelling, with many providers entering particularly the solar space with products and solutions. Sometimes it can be difficult to navigate through the myriad of products and services on offer. Many renewable energy manufacturers, dealers and installers are only new on the market. Like many new businesses some are great and some will not last the distance. If you have decided to investigate the installation or sourcing of renewable energy technology, it’s a good idea to do your homework and make sure your partner will be there for you when you need them.

Conergy is a globally renowned and established manufacturer and systems integrator in the renewable energy industry and has been operating for over 10 years. The company manufactures and distributes components and systems for generating solar electricity, solar hot water and wind power for domestic, commercial, community projects and industrial applications. Conergy Pty Ltd, with headquarters in Sydney and state office and warehouse facilities located in Melbourne, Brisbane, Perth and Darwin, is a subsidiary of Germany’s stock listed Conergy AG.

Conergy’s Australian operations were established at the beginning of 2005 and its quality products and guaranteed performance warranties have seen the company fast become one of the leading manufacturers and wholesale distributors in the

Australian industry. The company’s focus is solely on renewable energy technology, and it prides itself on a history of successful small to large scale projects. Whether for domestic use, remote area power generation or some of the world’s largest mutli-megawatt solar power farms – Conergy has a track record of successful implementation with high quality products and performance guarantees that are regularly exceeded.

Conergy engineers have over ten years’ experience in building photovoltaic systems – and in the past have already successfully installed thousands of these systems worldwide. Comprehensive consulting, planning, financing and monitoring services complete the Conergy customer service concept.

It is with this product variety and backed by its engineering competence that Conergy also plans its major solar projects. In solar parks, for example, solar components are installed by in-house technicians or approved service providers and handed over to the investor in turnkey condition.

With efficient products, reliable materials suppliers and consistent investments in its international sales networks, Conergy has optimum customer access in all the world’s major renewable energy markets. The solar company thus occupies a key position in the solar value creation chain.

If you are seeking a strong global partner in renewable energy, contact your nearest Conergy state office on 1300 724 531 or visit www.conergy.com.au for more information on its world leading products and services.

The future is renewable energy have you secured a strong partnership?

O U R W O R L D I S F U L L O F E N E R G Y

Your global

partner in

renewable energy

Since the 1998 start up of the Conergy Group in Germany,

our philosophy has always remained the same: to deliver the

best renewable energy solution for every energy consumer

worldwide. The first ten years have seen us follow through

and grow, with many decades ahead to carry on this task.

Our achievements speak for themselves: Conergy’s

commercial and industrial scale solar power, solar hot water

and wind power solutions are delivering real results for our

customers worldwide, using only the resources provided by

mother nature.

As the importance of clean energy generation grows, ensuring

you have a strong, experienced partner in the field has become

more important than ever. Conergy stands for quality products,

solid warranties and the lived experience of operating in the

world’s developing and mature renewable energy markets.

Conergy has remained strongly committed to Australia since

setting up its operations here in 2005. With state office

distribution centres in Sydney, Melbourne, Brisbane, Perth

and Darwin we are your partner of choice - from supply, to

system design and project commissioning.

It’s time to make a change. Contact us today:

Ph 1300 724 531www.conergy.com.au

Renewable Energy Solutions

Attracting keynote speakers from around the world, All-Energy Australia 2010 will be held at the Melbourne Convention and Exhibition Centre on October 6th and 7th and is expected

to attract well in excess of 2,000 delegates and more than 100 exhibitors.

The unique, free-to-delegate, multi-stream conference and extensive exhibition – hosted by the Victorian Department of Primary Industries – is a business-to-business event focusing on all forms of clean energy and energy efficiency.

In 2009, delegates from 15 countries – including representatives from Europe, North America, the United Arab Emirates, China, India, Japan and South Korea – attended.

Regional Director of All-Energy Australia 2010, Boyd Dale, says interest and expectations for this year are even greater, with the event aiming to build upon last year’s success.

Among topics covered during the 2009 event were clean coal, carbon reduction legislation, clean power generation, energy efficiency and the low carbon economy.

As well as forums on transport fuels, wind, geothermal and marine energy systems, the conference focused on finding the money to develop the clean energy industry.

Many of these topics will be further developed this year. In addition, All-Energy 2010 will focus on exposed industry solutions and skills migration.

Mr Dale says active participation in the event by key resource industry stakeholders will be warmly welcomed.

He says the aim of All-Energy Australia 2010 is “to act as a vibrant forum for discussion and networking between those involved in, and exposed to, the energy industry.

“Because mineral processing is energy intensive, a conference such as this – which is dedicated to development and application of clean energy (including electrical power and transport fuel, along with energy efficiency) – should prove of great interest and reward to those attending from the resource industry. I have no doubt that their time will be productively spent.

“We want All-Energy Australia 2010 to be a catalyst for the development of the clean energy sector and for the continuing evolution of efficient, cost effective Australian industries,” Mr Dale says.

He says All-Energy Australia ‘09 received overwhelming endorsement from speakers, exhibitors and delegates alike.

Ian MacPherson, the Non-Executive Chairman of Lightsense Australia – providers of energy efficient lighting equipment – reflected the thoughts of many exhibitors.

“All Energy ‘09 provided a great opportunity to increase the exposure of not just our company but also LED technology in general. The event drew a good mix of industry delegates from both public and private sectors. Enquiries at the conference have already led to business.”

Mr MacPherson’s views were shared by Mark Lampard, Business Development Manager of VEMTEC – an independent and integrated design and project management business, specialising in electrical distribution design.

“VEMTEC found the inaugural All-Energy conference to be an amazing opportunity to discuss our services with a large number of people and organisations. The event surpassed our expectations and we are already looking ahead to next year’s event.”

Delegates too spoke highly about the impact of All-Energy Australia ‘09.

Feedback received included the following: “I really gained valuable information from attending the seminars. There were so many (discussions) on a wide range of topics that I didn’t have any problems finding a relevant topic. I appreciate that this would have taken significant effort to organise. Free entry makes it unique.”

Speaking about industry progress, Mr Dale says: “We look back in wonder at the growth of the safety culture over the past twenty years. In another two decades clean energy and energy efficiency will have become the only way to do business, but to get there we need to follow a path of legislation, education and innovation.

All-Energy seeks to provide an environment where all three can be readily showcased, discussed and disseminated for implementation.

“We encourage those with a professional interest in sustainable energy solutions to attend. Here is their opportunity to mix with other likeminded individuals and companies, to present their concerns and to discuss their solutions.”

Organisers are also responsible for orchestrating All-Energy UK, Europe’s largest clean energy exhibition and conference, which has been staged annually in Aberdeen, Scotland, since 2001.

Organisers of the largest and most prestigious energy conference and exhibition in Australasia see increasing involvement by the resource sector as integral to the continued growth and development of the event.

Mining & MineralsA central Focus for All-Energy Australia 2010

Australasian Mining Review 2010: 1st edition

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Renewable Energy Solutions

Solar Lighting is one of the key power usage items that can readily be implemented across remote infrastructure, bringing numerous benefits over traditional grid fed

electrical based applications. Solar lighting is no more difficult to install than existing forms of lighting yet, it can provide an instant solution in areas where electricity is not readily available, most often because access to the grid is simply not available

Hot water is another key power drain for remote mine sites and can be one of the most energy intensive. By installing a solar hot water system or heat pump, once again mine managers can slash their electricity bills as well as their greenhouse gas emissions.

Sinclair Knight Merz published an article in 2009 by Jody Finsen a senior sustainable buildings consultant discussing how mine sustainability can be improved.

The article outlined how sustainable design practices helped mining companies manage the environment in order to maintain a sound reputation in the international marketplace. Reducing a mine site’s ecological footprint as well as cutting power costs was imperative.

Solar energy is an integral component of the application of sustainable development principles which also can include materials and waste management for mine villages.

“Results to date indicate a reduction per head of 30% energy use” Finsen said.

options open to mine decision makers as far as solar is concerned;

Photovoltaic Solar photovoltaics (PVs) are arrays of cells which contain a material which converts solar radiation into DC electricity. With rapid growing demand for renewable energy sources the manufacture these solar cells has dramatically grown in recent years. Photovoltaic production has been doubling every 2 years, increasing by an average of 48 percent each year since 2002, making it the world’s fastest-growing energy technology. Photovoltaics are best known as a method for generating electric power by using solar cells to convert energy from the sun into electricity. The photovoltaic effect refers to photons of light

knocking electrons into a higher state of energy to create electricity.

Heat pumps for hot water generation A heat pump is very much like a fridge working in reverse. It transfers the heat in the air outside of the unit to the water stored inside the heater through a heat exchange system. This provides massive savings in hot water related expenses over the long term. Heat pump produces between 3 - 5 times the amount of renewable energy than electricity required to power the unit. They are an environmentally friendly hot water option given the reduction in greenhouse gas emissions through less energy requirements. No roof space or panels needed and there is an ease of installation as a solar heat pump uses the same connections as an electric hot water system.

Solar water pumps for moving water around mine sites A typical Photovoltaic powered pumping system consists of a Photovoltaic array that powers an electric motor, which drives a pump. The water is often pumped from the ground or stream into a storage tank that provides a gravity feed. No energy storage is needed for these systems. Pumping water using PV technology is simple, reliable, and requires almost no maintenance.

Solar power; The power generation solution that isolated mine sites can use to keep them energy independent as well contributing to slashing power bills, whilst proving to the community that they are green, responsible and viable businesses that are vital to rural Australia. By reducing mine sites energy consumption and buying environmentally sustainable products, mine managers are in a win-win situation as far as solar is concerned.

Solar power options for mine sites

Solar Lighting

Australasian Mining Review 2010: 1st edition

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Australasian Mining Review 2010: 1st edition

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Solar Power

Solar energy is often branded as a New Age invention, but the reality is the concept of harnessing the power of the sun for fuel has been around since ancient times when Greek and

Roman civilisations used solar energy as a form of heating and lighting.

In 1861 the first solar powered steam engine was built, but at the time costs prohibited the technology from developing further. In the 1950’s scientists once again looked to the sun for inspiration producing the first silicon solar cells that converted sunlight into electricity. These solar cells or photovoltaic (PV) cells are the basis to solar power collection.

But it wasn’t until the early 1970’s that solar energy drew an international focus as nations grappled with the global energy crisis created by the oil embargo of 1973.

Over the next thirty years developments in the technology took solar energy to a new level of accessibility as countries searched for renewable energy solutions to the growing concern around climate change and an inevitable reduction of natural resources.

Today solar energy is truly an affordable and efficient alternative to traditional power sources. Germany and Japan lead the world in the generation and consumption of solar energy, and the technology is growing in popularity with both domestic customers and Industry in other countries including the USA.

In Australia the technology is now widely used by local governments around the country to power lighting in public spaces including carparks, and gardens. This ‘active’ solar energy collection is also used to power mobile phone transmitters in remote regions, farming irrigation equipment such as water pumps and localised lighting.

And Industry is also making use of solar power, which is deemed to be particularly useful in isolated locations where lighting is often required for a finite period of time. In these situations solar lighting is a cost effective, portable alternative to the expense incurred in trucking in generators, erecting sub-stations or connecting to the main power grid.

The Australian outback is ideally suited to harness the power of the sun.

Solar lights require direct sunlight. The more sunlight received during each day, the longer the lighting unit will operate at night.

Australian company Eco Solar Lighting, which is part of the Polite Group, has introduced a new range of solar lighting solutions specifically designed to meet the unique needs of the mining industry. These new generation solar lighting systems can be custom engineered to maximise the local sun radiant hours of any specified location. On average Eco Solar Lighting products can run for up to 3 days operating 10~ 16 hours per day without any sun light.

Sturdy, able to withstand a variety of climatic situations, and terrain, Eco Solar Lighting systems feature the latest battery technology that enables solar lighting to compete with traditional power generation models on mine sites.

The battery technology that powers Eco Solar Lighting’s products delivers long life and extended operation. Cost effective and user friendly these products provide the same luminance and lux levels as traditional lighting. Easy to fit Eco Solar Lighting products do not require a licensed electrician as the lights come as a complete unit and do not need additional wiring.

Eco Solar Lighting units use either Gel or Acid batteries depending on the application. The lifespan of these batteries is between 3-5 years and are maintenance free. And these batteries do not require a separate charger. Power generated by the Eco Solar Lighting systems can be used directly or stored in the batteries for future usage.

And in addition to the financial and convenience benefits of using solar lighting there are also the environmental factors including the reduction of carbon emissions and waste products.

To find out more about Eco Solar Lighting products visit www.ecosolarlighting.com.au

Delivering power to remote locations and sites in a cost affective and efficient manner is an ongoing issue for the mining industry. But with the advancement in solar power technology companies are now able to light and power facilities no matter their location without incurring the expense of traditional power generation.

Affordable Solar Lighting Solutions for Remote Locations

eco solar lighting

Ecological Solar Lighting SolutionsAs a leading designer and manufacturer of solar lighting solutions, Eco Solar Lighting offer an ecological lighting solution to suit every lighting requirement. It’s our mission to bring you the best products on the market for a solution that’s second to none.

Australian Head Office

Eco Solar Lighting PTY LTD

274 Wolseley Place, Thomastown VIC 3074E: info@ecosolarlighting.com.au W: www.ecosolarlighting.com.au

Benefits at a glance:• Cost effective• Environmentally responsible• Portable• Easy to use• Eliminating expensive cable installations• Safer working environment• High quality, durable and reliable products• Extensive choice to satisfy every lighting requirement• Overcomes difficult or isolated areas where electricity is not available.

• Car Park Lighting• Security Lighting• Pathway Lighting• Roadway Lighting

For more information visitwww.ecosolarlighting.com.au

Freecall

T: 1800 069 784

Eco Solar Lighting PTY LTDNew South Wales15 Valediction Rd, Kings Park NSW 2148

Eco Solar Lighting PTY LTDQueensland

3972 Pacific Highway, Loganholme QLD 4129

Eco Solar Lighting PTY LTDSouth Australia

348 Richmond Road, Netley South Australia 5037

T: 1800 069 784 F: 1800 068 788

“Eco Solar Lighting – Benefits at a glance”

Cost effective•

Environmentally responsible•

Sturdy design•

Portable•

Easy to use•

Solar Lighting

Orion’s Managing Director John Holliday told Australian Mining Review that solar lighting had numerous applications in the mining industry. “We started operations

five years ago by supplying other mission-critical industries like marine and aviation for navigation and landing aids. Just as in mining, those industries use our lights in situations where safety is paramount,” he said. “Our first success in mining resulted from the supply of safety warning lights to show the edges of a road or an open cut mine and we have gone on to supply such lights to the operations of Origin Energy, BHP Billiton, Rio Tinto and Placer Dome.”

Orion commenced operations in 2004 when they formed a partnership with Carmanah Technologies, a Canadian company which had developed a world leadership position in solar LED lighting. Carmanah’s technological advantage comes from their total system approach to engineering. They ensure that every step of the energy conversion process is maximised, as shown in the diagram “Energy Conversion”. Built in to every one of our solar solutions is an energy management system which is constantly monitoring the surroundings and adjusting light output to prevailing solar conditions. One advantage of this approach is that Carmanah is able to achieve more capacity

and a longer life from current battery technology than almost any other supplier. Our choice of LEDs as a light source means increased efficiency and lower maintenance cost over traditional lighting technology.

The end result is that Orion’s solar LED lighting solutions provide dependability and flawless performance throughout extremes of cloud cover and temperature variation, providing the brightest solar illumination possible. The solar powered lighting devices are self contained and require no trenching or special power or cable connections, meaning installation and location changes are uncomplicated affairs, not requiring an electrician.

The applications for solar LED lighting in the mining industry are extremely varied. A recent installation of our area lighting illuminates a water truck filling station at Ashton Coal in the Hunter Valley. The engineers at Ashton specified a split time output capability and the ability to perform during 14 hours of darkness in winter. The solution supplied has a battery capacity to last for 10 days without charge and only requires 4 hours of full sun to recharge to full capacity.

Recent rapid advances in ultra-bright LED technology has opened new opportunities for solar LED lighting for illuminating pathways, streets and parking lots to levels which meet Australian standards. In the mining industry, where hard wired power is not always available, this means that areas can now be lit which previously were left in the dark. Parking lot area lights can be equipped with motion sensors to automatically switch the brightness of the light when a person or vehicle arrives.

Orion solar solutions are backed by over 10 years experience in solar LED lighting technology and an installation base that spans the globe. Orion’s rugged construction can withstand the demands of an unforgiving environment, where portability and reliability are key. Customers can be confident that our lights can be placed anywhere they are required without the hassle and concern associated with running cables or changing batteries.

Although not the major reason for selecting a solar LED lighting solution from Orion Solar, all of our lights are environmentally friendly, relying 100% on renewable energy.

Harnessing the power of the sun, Gold Coast-based solar powered LED lighting supplier Orion Solar is increasing the safety at Australian mining operations. Orion’s solar powered LED marking and area lights have been picked up by a number of mines around the country to light mine site roadways, hazards and equipment. Charged during the day, even in cloudy weather, the lights turn on automatically at night, helping to guide drivers and pedestrians through frequently changing site terrain.

Orion highlights safety

Solar Powered LED Lighting Solutions for the Mining Industry

www.orionsolar.com.au

23 Mudgeeraba RoadWorongary Qld 4213

Tel: 07-5559-1666Fax: 07-5525-1906

The Best Lights Under the Sun

Australiandistributor

for Carmanah

Lighting for:Haul road markersObstruction beaconsHazard warningsArea lighting

Aviation lights including:Runway lightsTaxiway lights

HelipadsWindsock lighting

Solar Lighting

http://www.exlites.com.au

In many cases where lighting is required, stand alone solar lighting systems have filled a gap not only in the reduction of the Co2 footprint but the reduction in infrastructure cost due to the diverse and isolated locations that lighting is required.

Stand alone solar lighting has not had the easiest start into the market place historically. For many years prior to 2005 various companies, government departments and even private sector clients have tried various solar lighting systems and in many cases due to poor product design have not performed as expected mainly due to the fact there were no solar lighting systems designed specifically for this purpose.

Most solar lighting systems historically were hybrids made up of multiple components from different suppliers with luminaire’s that were mainly used for on grid applications being inverted from 12V or 24V battery banks to AC to power them and in most cases were very low wattage or they used low grade imported components unsuitable for the harsh Australian environment and they failed very quickly

Realising the market required expertise in the stand alone solar lighting sector, a very small group of companies made commitments to design their own specific solar lighting technologies for Australian environmental conditions, required standards and to suit the diverse applications that these technologies would be utilised for.

Most of these new solar lighting companies liaised with overseas manufacturers who already had products of their own to find the best components that would be near enough to what would be required here in Australia, but these products would still have to be imported and the local company would just be a distributor or reseller. The down side was the technology was not Australian and whenever issues arose the local company would then have to go back to the manufacturer to problem solve.

Only a select few companies have stood out amongst the rest like Exlites, an Australian owned, design and manufacturing company who implemented their design strategy in 2003 realising a complete package of components that were specifically suited to each other was needed to create a standalone solar lighting systems that would out perform all others in the market and offer credibility back to the industry that had been previously lost.

EXlites have a strong understanding of the various light sources available, from the proven H.I.D (high intensity discharge lamps), LED and finally the new Electrode

less or LVD lamps which are still in their infancy compared to other light sources.

Having this prior knowledge EXlites understood the limitations of what each light source had to offer if it was to be utilised in one of their solar lighting luminaire designs to ensure it performed to the required expectation of the end user.

For external lighting applications were an area needed to be heavily illuminated like road ways, security lighting, carpark lighting. conveyor lighting, temporary lighting and solar lighting towers, EXlites chose to work with the HID (High Intensity Discharge) lamp technology but in a way that had not be done previously.

EXlites focused on low wattage lamps that have a smaller light source that could be matched with a specially designed reflector to focus the entire light source created from the lamp circumference out rather than using larger higher powered HID lamps that created massive spill light. This in turn created an effect of a 35watt light source producing a light output up to 3 times its original capability which meant applications previously that were too costly due to the solar power system requirement had become now cost effective, compact and would light the required space effectively.

Not only does the 35watt lamp produce a superior light intensity but also a pure white light which makes the area to be lit more visual and safer.

EXlites focused next on designing suitable LED technologies for other lighting applications but only in low wattage due to the heat issues currently found with the higher power LED luminaire.

LED chips need to cool or the life span of the LED chip will deteriorate exponentially faster than there mentioned 50,000 hour life. This then becomes a costly exercise as most LED luminaire designs need to be completely replaced when the LED chips fail.

To cool multiple LED’s heat sinks need to be used. The locations that create the biggest issue for LED heat sinks are rural, high debris or dusty areas, as the heat sink (fins) collect debris and moisture and foul up and eventually stop performing the required heat disbursement, the LED chip then over heats and burns out.

LED luminaire’s over 36watts are better suited to areas that do not have the extreme summer ambient heat which only adds extra heat load to the heat sinks and a much cleaner environment with accessibility to

clean the heat sinks regularly or used in a mounting position that the heat sink could not collect debris which is very rare.

LED in high power applications over 36watts is said within the LED industry to still be 3-4 years away in achieving longevity and sustained heat control.

2400 SupaLux Solar Lighting System which powers a 24watt LED luminaire for pathways, jetties, laneways, coveryor lighting, and any other smaller lighting applications. Using only 24 x 1 watt LED’s there is never enough heat created to have any major overheating effects as the heat produced is very minimal anyway.

vandal Resistant Solar Bollard which uses only 3, 6 or 9 LED chips which are sealed inside a heavy duty polycarbonate designed housing. The extremely low power of the LED’s elevates the need for any heat sink requirements offering the most cost effective commercial grade pathway and marker lighting in the market today.

4800 SupaLux Solar Lighting System using 45 low power LED chips for shelter lighting, toilet lighting, covered walkway lighting and interior lighting.

Having a good lighting luminary is one piece of the total stand alone solar lighting package. The other crucial aspects that EXlites needed to consider were battery storage, solar charging control and the Solar panels that would collect this initial energy.

Battery storage being the other most crucial as there are many technologies available in the market place today like AGM, Deep Cycle Gel, Lithium and lastly Silicone.

The most crucial requirement for the diverse Australian climate was to find a battery design that works efficiently in lower temperatures below -0C and in higher ambient temperatures up to +50C. Out of all the battery technologies available EXlites decided on a 30year old technology originally from Germany which was enhanced and developed further in the USA and China under a joint venture, “Silicone”.

EXlites with their 2010 product range have designed in their own range of Silicone batteries to complement their individual systems.

The reason EXlites chose Silicone batteries is because they have the following key advantages over conventional Lead Acid/Gel based batteries and why they are far more superior.

• Non-Corrosive

• No Acid Vapour emission when charging or discharging

• Storage capacity as high as 1.75 times of international standards

• Recharge acceptance capacity as high as 2.68 times int. standards

• Low self discharge: after fully being charged the battery can be used within one year at a normal temperature

• Functions normally between -40C and +60C

• Maintenance Free; Sealed with a relief valve

• Optimized for High Current Discharges

• Low Internal Resistance

With all design, assembly and most component manufacturing here in Queensland, this gives Exlites the versatility to immediately adapt to the ever changing markets and client requirements ensuring their products continue as market leaders as a truly “Australian” product.

At EXlites, we make our product, we understand our product advantages, so no matter what your application.... We find a solution!!!!

For further information or application uses visit www.exlites.com.au.

Sustainability now being a requirement for many private enterprises, public companies and government departments, created a necessity for sustainable technologies to evolve to a level of achieving consumer confidence immediately and became the challenge for sustainable design and manufacturing companies over the last 4 years, and most profoundly in the area of standalone solar lighting.

Solar Lighting new alternative has arrived

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Solar Lighting

Solar Products

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Australasian Mining Review 2010: 1st edition

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Take the example of Australian adventurers Geoff Wilson and Garth Freeman, and Kiwis Craig Hansen and world multi-sport champion, Steve Gurney, have just achieved two new

world records: The first trans-Saharan crossing by wind-power alone and the longest kite buggy: over 2100 kms.

From Morocco to Senegal all four men and their eight support/film crew were wearing Solar Light Caps from 2CLight.com as protection from the extreme conditions of heat, wind and sand. In addition to shielding their head and necks from the elements, the solar-charged lights in the cap gave them hands-free light without having to change headgear, wear separate headlamps or worry about batteries.

“With no shortage of sunlight for recharging - each night the bright lights on the caps made late arrivals and digging around camp for gear, easy and painless,” says Geoff Wilson. ”The sun protection during the day, especially with the side flaps, was exceptional and I certainly would not expedition again without a 2C Cap.”

“The caps were a huge hit with the whole team” agrees Steve Gurney. “They all put their names on and were guarding them with their life. The caps are one of five essential pieces of equipment to take if we ever did the Sahara, or somewhere like it again. We were totally amazed how well they were researched – the sun-proof resistance of the fabric; the wrap around the front was really useful; we used them every night!”

The caps were invented by New Zealander Simon Dyer: “It has taken more than four years of product development, dozens of design prototypes and

a host of scientific tests…but now, our unique Solar Light Cap uses superior, sophisticated 2CTechnology to promise unequalled performance and reliability, integrated into an award-winning, world class ergonomic design.”

The two discreet lights underneath the flexible solar panel peak provide a carefully calculated beam angle that ensures it doesn’t shine into other people’s eyes. Even more useful, it has an alert flashing option in case of trouble, to signal your location (or want to be noticed on the dance floor).

The Solar Light Caps have a multitude of uses – outdoor adventuring, camping, fishing, boating, tramping, on the Barbie or reading in bed. By day the cap charges while protecting the user from the sun’s rays. By night it becomes a comfortable headlight, providing state-of-the-art, ultra-bright warm, white LED light that provides over 3 hours runtime on full beam and 36 hours on dim. The long-life batteries are made from Nickel Metal Hydride. No Cadmium means minimal environmental impact and life expectancy of over 5000 hours. No more heavy and expensive batteries.

One use for the caps that is probably unique, was a reluctant bribe to get across a border, as Steve Gurney explains: “The police officer saw our 2C hats on our heads and the others lined up on the car’s dashboard, charging, and wanted one or several hundred dollars as a bribe to get through the police stop!” (Catch more about Madwaysouth’s Sahara Expedition at http://au.tv.yahoo.com/sunday-night/#fop)

For further information please contact www.solarlightcap.com.au soon available at Saddleworld and BCF

There are many times that working in open cut mines in Australia is like working in a desert. As night falls work does not stop and this new innovation in Cap Lighting gives you light when you need it.

From desert to mines light when you need it

Those in the market for solar power installation can benefit from a broad range of technologies, manufacturers and installers. With many new Solar and Wind power businesses, as well as some long established

ones, the renewable energy industry, clearly has significant capacity. But who do you choose and how do you know they have the experience to deliver?

Renewable energy has proven itself in the past 25 years, but there are still many negative stories coming to the fore from large and small installations alike both locally and overseas. Poorly executed renewable energy installations can be a financial and public relations minefield. When such installations have been scrutinised it always comes down to the incompatibility of products being installed, poor design and installation. Renewable energy systems require considerable experience and knowledge to design, install, and maintain.

Peter Bulanyi , Managing Director of Solar Inverters Pty Ltd says , “renewable energy is strictly a science and engineering business. Companies that are serious about renewable energy primarily employ electronics engineers, technicians and electricians.”

Every system, whether large or small requires that the installers understand the limitation’s and component compatibility so as to maximise the life and output for systems. This is the only way that mistakes can be avoided and a long term success can be assured.

Solar Inverters has been actively working in the industry since 1989. It is a company with science and engineering at its core. It employs qualified electronics engineers, technicians and electricians. It trains apprentices in both the electronics and electrical trades. It operates a component level service department that is known in the industry Australia wide for its high tech inverter repair capabilities.

This allows us to provide fast and reliable back up service and repairs for our products, customers and their installations.

Solar Inverters is a vertically integrated company. It is engaged in every aspect of the renewable energy industry including import and export of hardware, design and consultancy, manufacture, tender specification services, inverter repair and calibration services, solar instrumentation and R & D.

Understanding the components that go into putting together a reliable and high performing system has enabled us to select the best quality equipment available, for all of our customers in Australia and overseas.

Mr Bulanyi says that “to us, system performance and reliability is paramount. This was the key factor in our company Solar Inverters recently being awarded one of Australia’s largest solar projects, the design supply, installation and long term maintenance of a 137kW rooftop solar system for Coffs Harbour City Council.”

He added that “not all renewable power systems are the same and using one model to try to cover all installations does not work. We submitted a unique design using Power-One Aurora Inverters and Kyocera Solar panels. We clearly demonstrated that the use of such premium components for a long term result far outweighed the short term gain with low cost equipment. We overcame many unusual technical design challenges in regards to site shading, mechanical fixing of the solar panels to the roof and general integration of the system.”

Solar Inverters manufactures complete containerised renewable energy solutions. Their Solar and Wind Power Stations are built and tested at their state of the art workshop in Urunga NSW before shipping to site and commissioning. Solar Inverters also has a complete range of small and medium sized pre-fabricated stand alone solar and wind power systems that can be easily installed by local electricians. By using landline or satellite communications, monitoring services are also available so that a careful eye can be kept on the deployed system no matter where they are. A monthly report is available that can be used to determine whether pre-emptive maintenance is required thus circumventing expensive system failure and down time.

These pre-fabricated solutions take the worry out of standalone power system installations. With 25 years experience to call on, a solar Inverters Power Station is designed and manufactured to Australian standards and can be relied on for decades. A comprehensive instruction manual complete with a maintenance schedule, operation details and circuit diagram is supplied. In addition quality technical support is always available to assist with any issues that may arise.

Solar Inverters Pty Ltd is an industry leader with a long term strategy that includes training the next generation of solar technician. Our aim is to raise awareness and promote a greater understanding of solar power and the why quality will always outshine the shady alternatives. If you need reliable remote power for monitoring stations, field test sites, accommodation huts, general or UPS power, then our team is here to assist.

Feel free to call us with your technical questions and we will happily assist so that you can make the best purchasing decision.

The market for renewable energy is displaying tremendous growth, this is particularly so with the cost of diesel and conventional energy rising exponentially. Recognising the financial and environmental positives, forward thinking companies are ramping up their renewable energy activities and enquiries. Anticipating strong future growth, many conventional companies are actively investigating expansion into the renewable energy business especially across previously untapped regional markets.

Solar Inverters Pty Ltd

www.solarinverters.com.au sales@solarinverters.com.au 1300 767 761

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Solar Products

Compressors Welders Lighting TowersGenerators

Power infrastructure & Power generation

Power Infrastructure & Power Generation

Even experienced generator operators are often unaware that in most instances, selecting the correct engine size and manufacturer can deliver cost benefits that pay back the capital

cost of generators in a number of months. In most instances, over 90% of the cost of operating a diesel generator is fuel.

The key to achieving savings is to plan. Take the time to assess your power requirements carefully and ensure you have an adequate understanding of the size and nature of the load you require of the generator. The following is an example of a daily load chart for a crib (lunch) room located on a remote part of a mine lease.

As you can see, the load is fairly constant in that it varies less than 5% of around 9kva. A generator engine is typically at it’s most efficient when operated at or around 75% of it’s prime rated load. So in this instance, the correct sizing for a generator to power the crib room is 12.5kva prime. Step two is to review the available engines on the market within this size range as follows:

This particular size generator has a capital cost of approximately $12,000 and costs around $10,000 per year to hire. As you can see, savings of between 4,000 and 10,000 litres of diesel per annum can be achieved simply by selecting the most efficient engine available in the size range. This is true for all size ranges and the fuel savings increase exponentially as the size increases.

This rental power station recently installed in Western Australia by WASP Rentals is comprised of 6 x 1500kva diesel generators. By sizing the engines to suit the load and selecting the

most efficient engines in the size range, this one installation saves the customer over 700,000 litres of fuel per annum.

Many companies are reviewing their existing generators with a view to replacing them with more fuel efficient alternatives. In most cases the cost of replacement is made back in fuel savings in less than six months. Generator companies such as Redstar offer power audits that involve detailed analysis of a sites diesel generators and offer independent recommendations to improve efficiency and save costs.

The other benefit of ensuring the correct sizing and engine selection for generators is the significant reductions in carbon emissions that can be achieved with increases in fuel efficiency. This can also involve reviewing alternative energy alternatives and hybrid systems for power generation. XSTRATA’s Oakey Creek Mine in Central Queensland is currently conducting a pilot trial involving a diesel/solar hybrid system to operate the mine’s dewatering pumps.

The mine currently operates around 40 pumps, powered by 20kva diesel generators. The

generators operate 24 hours a day to ensure the water table is controlled adequately. The current trial involves using a solar panel to power the pumps telemetry and run the generators battery charger. The pumps have been set up with float switches. When the water table reaches a certain level, the float switch sends a signal to the generator to start. This in turn operates the pump and when the water table returns to an acceptable level, the float switch signals the generator to shut down. If successful, the trial has the potential to save hundreds of thousands of litres of diesel per annum as well as significantly reduce carbon emissions.

One of the greatest opportunities to reduce costs and carbon emissions for mining companies is in portable accommodation camps. The fluctuating load produced by camps provides an opportunity to truly customize generator selection to suit the load and reduce fuel consumption dramatically.

To the right is an example of a daily load analysis done on a 300 man camp.

The camp load fluctuates significantly between when the camp workers go to site during the day, sleep at night and then have meals and showers. Meal and shower times produce a dramatic short term spike in load. Traditionally, two generators have been used to power camps. A running machine capable of satisfying the maximum demand and a second standby generator that runs in the event of failure of the first generator. This presents a lot of problems including:

During shoulder and base loads, the larger • machine will use far more fuel than is necessary.

This extra fuel consumption results in • unnecessary carbon emissions.

A generator is designed to operate at a • minimum of 50% of it’s maximum rated capacity. If the unit is used on lighter loads for an extended period, severe and irreversible engine damage will result.

The real key to maximizing efficiency and cost benefits to any accommodation camp is to develop a power plan. Although there are general rules of thumb that can be used as a guide, the more accurate the information that can be obtained about the camps actual load, the greater the fuel savings that can be achieved.

Ideally, a three generator system should be used to power camps. This allows for a smaller machine to operate during the base load in order to maximize fuel efficiency and minimize carbon emissions. Peak load achieved by using two of the machines in parallel. This occurs automatically as the systems detects increases in load from the camp and starts the second generator when required. It also shuts down the second generator as the load drops away. The third generator starts automatically in the event of failure of one of the first two units.

In an environment where stakeholders are seeking ways to streamline operations and reduce costs as well as minimize the environmental impact of their mining activity, placing a focus on reducing fuel usage in power generation provides one of the greatest opportunities for material savings.

Many of Australia’s largest miners are now turning to specialist power generation companies to provide expert guidance on ways to capitalize on these major cost saving opportunities.

The recent financial crisis put a much stronger focus on areas of cost control in the mining industry. With energy being one of the major expenses in any mining operation, many miners are now realizing that dramatic fuel savings can be achieved by taking the time to develop a power plan for diesel generators.

Focus on fuel brings lean and green benefits for generators

Above: Chart 1 - Crib HutRight: Chart 2 - Engine Comparison

Below: Chart 3 - Camp Load

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Power Infrastructure & Power Generation

We have offices in Perth and Brisbane, from which all aspects of the projects are coordinated from, including design, drafting, manufacture, installation and

commissioning. Our services to industry cover acoustic services, dust control and odour control; or as someone recently said – “hear no evil; see no evil; smell no evil”

Everything we do is about providing a better environment. We provide world-class technology to reduce the impact of industry on the environment.

Our range of equipment and services includes baghouse design and supply; wet scrubbers both venturi and dynamic; regenerative thermal oxidisers to destroy odourous VOC’s with no waste products; wet and dry electro static

precipitators; chemical packed tower scrubbers. We can provide a full turn-key package for all projects from the design phase right through to the installation and commissioning of the project.

Our acoustic enclosures can be designed to be built on site or if size permits, delivered as a completed drop over to save site installation, time and cost.

At the completion of a project, our Asset Services team can provide full maintenance services to ensure that the systems that have been provided operate in the manner in which they were designed for many years to come.

ENERFLEX Environmental is a division of the ENERFLEX Australasia Group, which provides environmental solutions to the Mining, Mineral Processing and manufacturing industries in Australia and South-East Asia.

Focus on fuel brings lean and green benefits for generators

Australasian Mining Review 2010: 1st edition

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Products & Services

Products & Services

knowing the industry from the insideIn 2006, Matt McCauley was the Mining Manager for Anglocoal’s Drayton Mine. He was experiencing first hand the effects of the skills shortage on the mining industry. “My surveyors simply weren’t able to keep up with the demands of our engineers for accurate and timely topographic models. I started to investigate some alternative approaches.”

The shortage of mining professionals was having a significant impact on mines all over Australia. Accurate and up to date survey information is essential for planning and forecasting. What was needed was regular surveys of the entire site to better target production and support and give engineers pit shell information that could be used for designs and forecasts. But how could this information be obtained in an accurate and timely manner?

At that time, the mining industry relied on contract surveyors. However, having personnel not familiar with the site, driving in and out of heavy equipment areas was not an appealing option. Existing aerial services were too expensive and the turn-around too slow. To Matt McCauley the solution was becoming increasingly clear - a high frequency laser mounted on an aerial platform.

He recalls “I had not even heard of LiDAR or ALS (aerial laser scanning) but after conducting a lot of research, I realised there were a range of technologies ideally suited to mining applications”. Matt had been a pilot for some time and had always had an interest in technology. “For me, this was a pretty exciting discovery. I believed that here was an opportunity to provide aerial surveying, targeted to the mining industry, at a realistic price. I felt so sure about the business concept that I left Drayton and started Atlass.”

Matt understood that convincing conservative mine surveyors to adopt the new technology would require a compelling argument. Afterall, he had been a conservative mine manager. But he knew what the industry needed and what he could deliver. He adopted three core principles:

Provide a service with accuracy as good or 1. better than current services available to the industry;

Price lower than the current providers; and,2.

Turn around within 3 days for regular surveys 3. – this was the real breakthrough. No-one else in the industry was providing whole of mine information as up to date as this.

The technologyThe key to being able to meet these principles was in the technology. Further research and a trip to Germany allowed Matt to determine the combination of technology required:

Full waveform LiDAR. This is a light detection • and ranging technology capable of maintaining high accuracy in the steeply sloping and complex areas found in open cut mines. “It’s similar to radar, but uses a pulsed light beam instead. As a result it’s much more precise than radar, with the LiDAR laser and navigation system accurate to within a few centimeters. There is nothing else in aerial surveying in Australia’s mining industry that comes close” Matt explains;

Single engine fixed wing aircraft modified • to support the survey equipment. This has allowed Atlass to keep its costs low while maintaining safety at low altitudes and low air speed where twin engine aircraft were statistically less safe and helicopters too expensive; and

Automated batch processing to allow • data processing to be kept within the tight timeframes

“We entered into an exclusive agreement with German LiDAR specialist Toposys, now owned by Trimble, and purchased a package of equipment and software. In August 2007, we conducted our first laser survey at the Drayton Mine in Hunter Valley.”

The Atlass story so farThe results from the initial surveys were very positive. Accuracies of ±100mm were being achieved and the company developed processing workflows and computing systems that allowed it to easily achieve its target turn-around. Demand for Atlass services however, was initially limited to the smaller mines with tighter budgets and more

innovative mine surveyors.

Atlass utilised this time to develop its systems and procedures. Matt brought a strong safety and systems focus from his time in the mining industry. The company’s commitment to safe operation and their team’s understanding of the safety drivers made dealing with the aviation regulator, CASA, a relatively straight forward process. “I am very proud that during our two years of operations we have had no significant safety incidents” Matt said.

Atlass now conducts several surveys a week from the Torres Strait to Adelaide. Many of their mining clients choose to purchase a package of monthly surveys which includes stockpile volumes and ortho-rectified images of operating areas. The rapid turn-around allows the data to be used for mine planning and monthly reporting. “Getting accuracte images and the data within 3 days of the survey is something that the mining industry has not had before” says Matt. “It is taking the guess work out of planning”.

“It’s the growing demand for our services that is the best measure of our success and the quality of our product” says Matt. Atlass recently purchased a second sensor system and now operates two aircraft, one of which is dedicated to the mining industry, greatly increasing their capacity. The company has also recruited specialist staff to allow it to offer a broader range of products, including environmental survey products.

“Our goal for 2010 is to improve our market position in the coal industry. We are constantly developing new processing workflows and as a result the quality and range of our products is always improving. I am particularly pleased with the quality we have achieved with our ortho-images”

The futureMatt has given more than a passing thought to how his business could operate in the west. “I don’t have quite the depth of knowledge about the Western Australian Mining Industry that I have about the Coal Industry so there is bit of work to do. I can imagine Atlass operating a similar business successfully out of one of the mining centers in WA.”

The immediate focus however is definitely the

QLD and NSW coal industry. Atlass sees a bright future in this business. With new mines and new infrastructure planned there is plenty of scope for filling the spare capacity in the Atlass business.

Atlass is a new and growing name in aerial surveying in Australia. Started in 2007, Atlass (Aerial Topographic Laser Survey Systems) has found its niche in the mining industry. The company uses state of the art “LiDAR” technology to provide high resolution survey information in a quick turnaround. It currently has ongoing contracts with more than a dozen companies and is expanding.

We spoke to Atlass’ Managing Director, Matt McCauley, about why he started the company and what makes their service so attractive to the mining industry.

AtlassA New Paradigm for Aerial Surveying

in the Mining Industry

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Aviation Services to the Mining Industry

So what can Adagold Aviation do to help you choose the right tool for your Charter trip? More importantly make sure that it’s a successful trip as well? Adagold will help to make sure you get competitive pricing, the right aircraft to land at all the airports you are planning on, and ensure that there is contingency planning in place to prepare for any unexpected delays. But most importantly, Adagold will give you peace of mind.

Unfortunately not all Operators are created equal, and not all aircraft are equal. Adagold can help you to make sense of which aircraft is the most appropriate one for you, making sure it is safe, and ideally goes above and beyond ‘just the minimum’ requirements that they are required to meet.

Quite naturally, an Aircraft operator is obliged to offer you their own aircraft. They have a responsibility to their shareholders, and to their staff, to generate revenue for their own aircraft. So how do you know that the aircraft being offered is the right one for you? A good broker like Adagold Aviation, who have implemented a Safety Management System, in line with CASA guidelines, is the best broker to ensure you travel on the safest, and most appropriate aircraft for you.

Adagold Aviation’s long-term relationships with Operators around the country and internationally facilitates access to a range of aircraft that aren’t advertised in the marketplace. Whether for a one-off flight, or a 5 year FIFO contract on a dedicated aircraft, Adagold has the experience and the

knowledge to ensure you get the best package for your operation.

Our attention to detail and high levels of customer service, combined with the right Operator focused on safety and performance, results in a better managed product, with the added bonus of better pricing. Whether it is a single engineer urgently required for machinery breakdown, an Investor-Group from overseas on a site visit, or a short to long term Fly-In-Fly-Out operation, Adagold has the knowledge to make sure the right aircraft is working for you. Adagold works like your own in-house procurement department, making sure you don’t pay too much, but at the same time providing the best level of service.

Adagold are an approved supplier of contract aircraft to the Commonwealth of Australia, the Australian Defence Force and the United Nations. And in Brisbane, Adagold operates the Brisbane Jet Base Terminal, where we make sure your staff or guests are handled efficiently, and the aircraft can depart/arrive separately from the main terminal, without the hassle of commercial check-in facilities, and the delays that come with it.

So don’t tie your staff down searching for the right aircraft at the right price, let Adagold do it for you, on time and on budget. Visit our website www.adagold.com email us at charter@adagold.com or give Adagold a call on 1800 767 747 to see what we can do for you.

Whatever you take on, mak-ing sure you have the right tool for the job is an essential part of making sure you get the job done properly. So who’s looking out for you when you think that a Char-tered aircraft is the best way to get you where you need to be?

With hundreds of companies operating aircraft all around Australia, and thousands of aircraft to choose from; operating in regional and remote communities, almost every small Australian town, right through to every major city, there is no doubt that the Charter Aircraft makes an enormous contribution to the way Australians travel around the country. This is particularly relevant in the Mining and Resources industry.

choosing the right tool for the job…..when chartering planes….. for cargo or People

There are thousands of aircraft available for charter in Australia.

For help selecting the right one for your needs, call us.

PASSENGER, CARGO & EVERYTHING ELSE IN BETWEEN

Tel: 1800 767 747 (24/7/365) www.adagold.com

Jed, a former Navy pilot, flew commercially before forming HART Aviation. He, his wife Sue and family, lived in Australia, Asia and Scotland, with Jed flying principally for the oil and gas industry. Jed joined Shell International in 1982 and worked in Brunei, Peru and in London as an Aviation Advisor. In 1990 the family returned to Australia where Jed became BHP’s Aviation Manager.

The goal of forming a worldwide aviation consulting company to provide specialist aviation advice to global organisations came to fruition in 1995. In the early days as HART Aviation’s sole Adviser, Jed drew on his experience in the Navy, commercial flying and the resource sector, and Sue provided the administrative management. After winning a global support contract to mining giant BHP Billiton in 2001, HART Aviation purchased offices in Carlton, a suburb of Melbourne.

Since then the company has grown to become one of the world’s leading aviation audit firms, providing aviation related services in fifty countries a year. These services include, inter alia, development of safety policies; auditing aircraft operators; investigating incidents and accidents;

advising on geophysical survey flying, helicopter offshore support and other specialist flying.

Staff numbers in 2009 had grown to between 30 and 40, with a specialist workforce of some twenty aviation advisors, on four continents, comprising pilots, aircraft engineers, senior aviation industry managers and former senior regulators. These specialists bring great experience to service delivery.

With many resource sector clients, HART Aviation has acquired deep and broad knowledge of the aviation issues these companies face. HART Aviation also advises companies in food manufacturing, television and a growing number of government bodies worldwide.

In addition to the Melbourne, Australia Head Office, HART Aviation has additional offices in Perth, Canberra and Queensland and permanent global representation in Canada, USA, Venezuela, the UK and South Africa. With this worldwide representation and a focus on hiring, training and retaining high quality professional staff, the company has few peers in its specialist niche in the aviation market.

Founded by Jed Hart, HART Aviation has been advising clients on aviation related matters worldwide since 1995.

hART Aviation

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Aviation Services to the Mining Industry

Mark Davies, NSK Australia’s Mining Manager says, “one of the key factors in the enhanced performance of NSK’s bearing range is the development of

special materials technology: in particular, Hi -TF material”. Bearings manufactured from Hi -TF are designed to provide outstanding toughness under harsh operating conditions. The combination of Hi -TF material and the special heat treatment technology provides a range of bearings that give longer service life under contaminated lubrication conditions than conventional bearings, together with the added benefits of superior resistance to wear, seizure and heat.

Developed specifically for applications with heavy or shock loads, of the type encountered in jaw and cone crushers, NSK’s CA series of double row spherical roller bearings are manufactured with a machined brass cage to combat the effects of vibration, operating fatigue, wear and corrosion. The CA bearings have high load rating superior durability and are resistant to wear.

Extending the CA range into harsh vibrating applications is NSK’s CA-VS series of spherical roller bearings. VS series bearings have been optimised for use in harsh vibrating applications. Their vibratory specification builds upon the extended load and life benefits of the standard CA construction with an optimised design that provides improved fatigue strength against the vibration and shock loads conditions encountered on screens, feeders and compactors.

In addition to addressing the problems of heavy shock loading and vibration, NSK is also providing significant benefits to mining and extraction industries, by reducing maintenance and energy costs, and enabling product downsizing. The new bearing range that provides these benefits is the HPS™ series. HPS bearings offer innovative performance with twice the running life, compared to conventional Spherical Roller Bearings of the same size, and a maximum limiting running speed that has been improved by up to 20%.

Also providing improved performance benefits, this time as a result of extra rollers in their design, is NSK’s EW/EM series of Cylindrical Roller Bearings. In addition to these bearings being used in industrial electric motors, they are also used in the differentials of off-road trucks; the transmissions and torque converters of crawler

dozers; the transmissions of wheel loaders; and the speed reducers and hydraulic pumps used on hydraulic excavators.

The EW/EM series CRB are capable of carrying particularly large radial loads and are also suitable for high-speed applications. The EW series features a pressed steel cage, and the EM series a one-piece machined brass cage. Both of these cage designs offer high-load ratings for standard size bearings, in addition to excellent and longer operating life - approximately twice that of conventional CRB.

Also benefiting from NSK’s focus on improving bearing life in mining and extraction applications is a new range of full- complement cylindrical roller bearings for use in crane sheaves. These bearings offer advanced levels of ingress protection with a new sealing system, which minimises grease leakage and increases resistance to the entry of water and other foreign substances.

Designed to provide maximum reliability and operating life in the difficult environments encountered in mines, quarries, ports and building sites, the new full complement bearings are supplied with phosphate surface treatment to improve their resistance to corrosion.

The ability of the bearings to provide reliable life in arduous environments is also enhanced by specially machined holes, which are provided on the inner and outer rings of the bearings to allow grease replenishment, even with the bearing in situ.

NSK welcomes any communication to discuss how best their bearings can solve or extend bearing life at your site. Contact NSK by telephone or their enquiry email address at aus-nskenquiries@nsk.com.

NSK has worked with the global manufacturers of mining machinery to develop a package of tough, high-performance bearings that offer longer service life under demanding mining conditions. NSK’s new bearing range is designed to cope with the dust, mud, high-loads and extremes of temperature that are encountered in mining and extraction environments. It exceeds the limits of conventional bearings both in terms of longer operating life and limiting speeds, helping to deliver the high levels of reliability required in mining projects all over the world.

What is NSK doing to Extend Bearing Life?

Bearings

[ 58 ]

Bearings, the hidden component that enable continuous operation, the hard working unseen workhorse on the mine site. Not the most fascinating topic for discussion yet such a vital link in the chain of operation. From crushers to screening, mobile plant to draglines, bearings & lubricants exist all over our mine sites. Paying attention to your bearing and lubricant requirements across the board will pay dividends in production uptime. How much does machinery downtime cost you? Each and every bearing you utilize is under genuine pressure to perform and faces conditions on Australian mine sites that are some of the toughest in the world.

Bea

ring

s

harsh and brutal environments where high shock loading, vibration, dust and moisture ingress are continual concerns, are the everyday lot our bearings face. Low maintenance

coupled with the need for round the clock operation is specified as a requirement, hence dedicated bearings and lubricant suppliers are necessary partners in a mine managers arsenal.

The cleanliness of oils and lubricants and the proper use of O rings, the correct greases. These all require expert knowledge. As does filtration and protection from dust and water. Agitator shafts will have different problems such as bearing steadying. Spherical roller bearings are used differently and what about angular contact in bearing usage? Surely we just want the correct bearing for the job so we can forget about it and get on with the successful running of our mine sites.

Finding great suppliers who understand the conditions you operate under can dramatically help improve your workflow. By reducing downtime and cutting maintenance requirements, your bearings wear and seizure resistance, coupled with constantly improving high temperature performance will improve bearing lifespans in such arduous vibratory environments

Bearings are unobtrusive yet they make the constant working of many of today’s machines a reality. Machines would wear out very fast due to excessive friction without them. When surfaces contact each other by rolling rather than sliding then friction issues are decidedly reduced.

In general, bearings reduce friction either by using hard metal smooth balls or rollers. These

are normally coupled with smooth inner and outer surfaces for the balls to roll against.

Some bearing types;

Roller thrust bearings can support very large thrust loads. Often to be found in gearsets and between the housing and the rotating shafts.

Tapered roller bearings are specifically designed in order to support large radial loads as well as large thrust loads. Either constant loads or shock loadings are normal reasons for their usage. Often mounted in pairs which face in opposing directions giving them the ability to take thrust loads in both directions. Angular mounting is what allows dual load ability.

Roller bearings are often used in heavy duty applications. A good example that concerns the mining sector is conveyer belt rollers. Roller bearings here have to cope with very heavy radial loads. In these bearing examples the roller is comprised of a cylinder. This enables the contact between the inner and outer of the bearing to be a line along the cylinder rather than a single point. This obviously aids in spreading the load out over a far larger area. Thus allowing this roller type of bearing to cope with far greater loads than that of a ball bearing. The downside of a roller bearing however is that a roller bearing cannot cope with large thrust loads.

Bearing manufacturers have multitudes of other designs, many of which have specific applications. However, all perform the same basic function. Many though are amalgamations of the characteristics of the above bearing designs and fuse them to make one design.

A great bearing manufacturer will make very careful selections of the component materials required for the application that the bearing is to be used for. They will then administer high levels of machining precision and design to create an advantageous bearing solution. Your relationship with your bearing supplier or manufacturer is a vital link in your ability to keep your mine site rolling smoothly.

Keep your mine site rolling sm

oothly

Bearings

Through their global search for superior quality bearing and power transmission products, CBC has established selective alliances with international icons at the forefront of product development,

including NTN (Bearings), SNR (Bearings), INA (Bearings), Rothe Erde (Slewing Rings), Timken (Bearings), National (Oil Seals), NOK (Oil Seals), InterSeal (Machined hydraulic and pneumatic sealing solutions), Trelleborg-GNL (Duocone face seals and floating seals), TBC (Made to order bearing housings and wire rope sheaves), Falk (Gear Reducers, Backstops and Couplings), Motovario (Gearmotors), Coremo (Manufacturers of mechanical, pneumatic and hydraulic caliper brakes), Wichita (Pneumatic Clutches), ComInTec (Overload protection devices), Martin (Pulleys, Bushes, Sprockets & Couplings), Regina and Iwis (Chain), MAV (Locking Devices), Transfluid (Fluid Couplings and Brakes), Invertek (Electric Motors and Controllers) and Gates (Belts and Hoses), just to name a few.

These suppliers are testimony to CBC’s commitment to house the most comprehensive range of bearing and power transmission products in the southern hemisphere.

CBC’s national team of technical service engineers and factory trained product specialists ensure that customers receive the best possible solutions everytime. CBC’s Technical Services package is designed to optimise the performance of all your rotating shaft assets across the three key phases of asset life RUN IN PHASE, USEFUL LIFE PHASE and WEAROUT PHASE.

Run-In Phase: This phase can help you avoid costly premature failure through recommendations and the implementation of correct fitting tolerances and practices. CBC can design and manufacture specialist solutions, get initial lubrication right and train your staff.

This phase includes:

design centre

The CBC Design Centre is a dedicated information website providing their customers with ready access to key product and operational data associated with the design, selection and specifications for bulk material handling equipment, conveyors and related components.

Engineering design CBC’s team of over 40 qualified Technical Service engineers work closely with customers to develop unique, fit for purpose solutions. Their engineers

have a long history of assisting customers to design solutions with specialised features to meet tough application requirements and solve functional problems.

ManufacturingTransmission Bearing Company (TBC) is CBC’s manufacturing Division. TBC’s total machine shop capability provides customised engineering solutions not available from any other Australian bearing company. From initial evaluation of requirements through to design, manufacturing and installation.

TrainingIn today’s highly competitive environment, businesses are becoming more aware of the need to invest in skills training. Equipment productivity and reliability depends on the skillful accomplishment of maintenance practices and there is a clear relationship between maintenance practices, equipment productivity and bottom-line profit.

Alignment of Shafts, Pulleys & drives Keeping rotating equipment in line is critical to achieve its optimum lifespan. Misaligned machinery will eventually cause bearing, shaft, seal and coupling failures; and has been identified as a cause of increased energy consumption.

Installation & Commissioning of Rotating and Static Equipment Equipment failures are most often caused by contamination of the product before they are installed, or by failure to follow the correct installation techniques essential for larger bearings, seals and power transmission components. Proper installation ensures maximum service life.

Bolt tensioningCBC is an authorised agent of Technofast Industries Pty Ltd - Australian manufacturer of state of the art hydraulic bolt tensioning equipment. The Technofast Industries range of bolt tensioning equipment enhances maintenance programs with solutions for critical bolting applications.

Support Products & Services CBC is the authorised Australian distributor of specialised maintenance products which are available for hire or sale and are backed by local service and repair agencies.

useful Life Phase CBC’s site surveys and software systems help you to identify your site’s major mechanical componentry and parts. Condition monitoring programs can detect early signs of impending failure or damage resulting from unusual operating occurrences and

our expertise will ensure that your equipment is lubricated correctly and efficiently.

This phase includes:

Site Surveys & Mincom Linkone Identifying components of equipment and ensuring they are available when necessary is a critical part of plant uptime. Site surveys are the first step to improving efficiency in maintenance, energy consumption and inventory, and the first step toward achieving the longest possible life of equipment without unexpected breakdowns.

Standardisation Standardisation of equipment and components is one of the most important areas a site needs to consider. Many suppliers use generic numbering systems for the same style items. These items are usually replaceable as a complete unit but can have different components that can affect performance and reliability.

Condition monitoringCBC Technical Services & AzimaDLI reliability services are designed to provide you with all the benefits of a condition based maintenance program without the investment in equipment, software and personnel.

The purpose of our program is to deliver the maximum productivity for the life of your capital asset, through world’s best practice diagnostic expertise.

oil analysisAs part of our condition monitoring service, CBC Technical Services provides a NATA accredited oil analysis program. Maximising plant uptime and efficient operation requires the monitoring of operational factors such as friction, lubrication condition, wear, temperature and erosion using oil analysis techniques.

CBC’s oil analysis program provides you with information on the condition of your oil and the machine from which it came, as well as advice on what to do about it.

Thermography As part of CBC’s condition monitoring service, their Technical Services team provides a thermography program. Thermography uses cameras that measure infrared radiation to create thermal images of objects which show the variations in temperature as brightly colored patterns. These images reveal problems in a vast range of mechanical and electrical applications in a precise, quick and highly effective way. They provide crucial information for many applications.

Lubrication

Effective predictive and preventative maintenance programs rely on scheduled lubrication, oil sampling and analysis programs to provide an accurate indication of equipment and lubricant condition.

Lubrication Systems CBC stocks an extensive range of single and multi-point automatic lubrication systems to suit your every need. Supliers include Grease Max, Tecalemit, Simalube, Perma and Alemite.

Slewing bearings CBC is the Rothe Erde GmbH authorised Foreign Representative for the Australian Sales Territory (with the exception of Rothe Erde GmbH direct Original Equipment Manufacturers worldwide).

The CBC Rothe Erde Division has factory trained engineers who can provide technical services for Rothe Erde bearings.

wear-out Phase: CBC can increase monitoring to detect fatigue (normal wear from use), provide detailed root cause analysis with a view to improving future performance, bearing refurbishment and a comprehensive gearbox design, upgrade and structured maintenance program. Their inventory management programs can help to rationalise your inventory and plan for spare parts.

This phase includes:

Root Cause Analysis Unfortunately, in real-world operations, all conditions rarely will be satisfied and mechanical service life will be threatened regularly by the effects of abrasive wear, corrosion, electrical erosion, fractures or a combination of these or other factors. When bearings and other mechanical items sustain damage and must be replaced, profit loss follows due to equipment downtime and lost productivity.

Bearing refurbishment

CBC Technical Services can refurbish bearings in partnership with experienced providers, whether it’s a bearing with damaged packaging, the re-working of a bearing to keep production going, or a critical spare.

Gearboxes

CBC has extensive experience in gearbox upgrades and has assisted many customers in design upgrades for a variety of applications and in root cause analysis reports on gearbox failures.

For over 55 Years CBC has been servicing mining and heavy industry all over Australia.CBC has a continued enthusiasm and overwhelming desire to be every company’s supplier of choice. They have moved with the trends and continued to grow their product range to meet all facets of industry. With the inclusion of more products and the assistance of the best technical services package available, this has helped CBC become Australia’s largest distributor of Bearing and Power Transmission products.

cBcmore than just bearings

CBC has a Sydney-based workshop where gearboxes can be assembled to specific ratios.

Redesign

OE manufactured equipment can fail prematurely in harsh environments and conditions. CBC Technical Services can provide an application redesign and standardisation service, utilising the depth of product and application knowledge of CBC’s engineers, to provide you with alternative solutions to premature failures.

Inventory management

In order to maintain customer satisfaction at the highest level and ensure that all orders are fulfilled on a timely basis, CBC has a national computerised system of inventory control and product tracking in place. This means that right across their national network of 55 plus distribution centres, CBC can virtually guarantee products and parts are always in stock.

Optimising asset performance through improved uptime availability, extended maintenance cycles and enhanced reliability increases overall cost effectiveness, can dramatically improve returns on investment and improve your company’s energy efficiency.

For more information on CBC Products and technical services contact your local CBC branch, or visit www.conbear.com

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TIM002710 Timken GlobalMiningAdOL.eps 27/1/10 9:54:24 AM

Timken invests heavily in gaining a better understanding of the challenging conditions found in mining so that we can develop solutions that make sense for the industry. With more than 100

years of experience we’ve become a trusted resource for both equipment manufacturers and the people who operate and maintain mining equipment; from longwall shearers and vibrating screens to massive draglines and shovels.

Timken is focused on maximising bearing life and total system performance. Our products, services and knowledge enable our customers’ machinery to perform more efficiently and reliably. With sales of $5.7 billion in 2008 and operations in 26 countries, Timken is Where You Turn™ for better performance.

draglineTimken bearings have been used in draglines for decades – hoist & drag machinery, propel and swing drives, fairleads and boom point sheaves. A relatively new development, the patented design of Timken’s sealed, lower swing shaft bearing offers improved performance and cost savings for dragline operators. It integrates a spherical roller bearing, seals and mounting components into a single unit with special-purpose grease which keeps the top row of rollers lubricated without the need for frequent regreasing. In the past, mines have used open gear lube which would purge onto the lower swing rack causing inadequate lubrication levels and unexpected failures of the bearing and associated gear systems. The new

Timken design overcomes this problem resulting in reduced incidence of failure, lower grease usage and less clean-up costs (by virtually eliminating the amount of grease build-up on the swing rack pan) whilst the unitized design simplifies handling and mounting of the entire swing shaft system.

Timken’s sealed, lower swing shaft bearing offers improved performance and cost savings for dragline operators

Timken’s integrated bearing assembly does not require any modification as its designed to fit into the existing pinion bearing envelope on the lower end of the dragline swing shaft. In addition the design can be easily adapted to draglines of various sizes and there are now versions to suit the most popular models found in Australia.

Timken’s sealed, lower swing shaft bearing was successfully trialled by Kennecott Energy in the USA where it saved thousands of dollars a year in maintenance and clean-up costs and dramatically improved productivity and uptime. The sealed spherical bearing is now Kennecott’s standard for this dragline position. Other miners in the USA and Australia are also trialling the new Timken bearing to realise the benefits for themselves.

Cone CrushersThe cone crusher environment represents a considerable challenge for aggregate producers. Large, uneven loads and high contamination levels continually threaten bearing life. Product reliability and performance is key.

Typically the cone assembly is supported by a set of large, custom designed, Timken radial and thrust bearings

Cone crushers use a range of specialized bearings that are designed to suit each unique model but typically the cone assembly is supported by a set of large Timken radial and thrust bearings. Operating at moderate speeds with heavy loads and the potential for severe shock forces the goal is to maximise the load-carrying capacity. Timken engineers work directly with Original Equipment Manufacturer’s (OEM’s) to design bearings specifically for these conditions. Most designs use a fully machined brass cage for durability and Timken controls key geometric features to provide trouble free operation. We also offer a full line of bearings that provide excellent reliability for the high speed input shaft positions.

Timken engineers work directly with Original Equipment Manufacturer’s (OEM’s) to design bearings specifically for Cone Crusher models

vibrating Screens Vibrating screens are one of the most demanding applications for antifriction roller bearings. Operating conditions result in high radial loads and high rotational speeds. In addition, screens transmit high vibration levels to the bearing cage and rollers which can increase the operating temperature. Complicating this situation, screens operate in a wide range of environmental conditions including extreme ambient temperatures and severe contamination.

Timken offers the W800 modification code specifically for Vibrating Screen duty

Timken offers a complete line of spherical roller bearings including the 23 and 33 series. While the 23 series is more common, the 33 series bearings offer higher load capacity as they maintain the same bearing bore and outside diameter but are wider.

Key to the Timken spherical roller bearing design is the one-piece fully machined brass cage. Apart from being extremely durable, the cage pocket wraps around the roller providing excellent guidance as the rollers travel through the load zone. Furthermore, the roller end and cage pocket geometry is intentionally designed to promote lubrication flow and therefore help to reduce operating temperatures.

In combination with the brass cage design, Timken has created the W800 modification code specifically for vibrating screen duty. W800 incorporates reduced tolerances on the bore and outside diameter to optimise the bearing fit and reduce fret damage along with an internal clearance which is at the high end of tolerance to accommodate the large amounts of thermal expansion experienced during operation.

The success of a vibrating screen is dependent on bearing life. Problems with improper lubrication and/or abrasive wear often reduce the life of screen bearings therefore selecting the proper lubricant and lubrication system is critical for successful operation. For both grease and oil systems, the viscosity of the base oil is one of the most important considerations.

Testing shows the load zone of the bearing can be 16°C higher than the sump temperature and up to 22°C higher than the housing temperature. The bearing operating temperature is important because it directly affects lubricant viscosity and lubricant life. As a general rule, a lubricant should maintain a minimum viscosity of 20 cSt at the bearing operating temperature for adequate lubrication.

Friction can’t be eliminated – but it can be managed and its negative effects (power loss, heat, noise and wear) reduced. In the past Timken primarily sought to reduce friction through improvements to tapered roller bearing materials and designs. Today our focus has widened to a larger view of ‘friction management’ encompassing a much broader range of solutions. These solutions begin with a greatly expanded selection of bearing types in sizes and configurations to meet virtually any need.

Timken Keeps Mining Equipment Online and Running at Top Performance

Right: Timken’s sealed, lower swing shaft bearing offers improved performance and cost savings for dragline operators

Far Left: Typically the cone assembly is supported by a set of large, custom designed, Timken radial and thrust bearings

Left: Timken offers the W800 modification code specifically for Vibrating Screen duty

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Bearings

The most common types of lubrication systems used by vibrating screen manufacturers are manual grease, automatic grease feed, oil splash and circulating oil systems.

Typically mineral oil based greases are used in vibratory applications however synthetic greases may be necessary if operating at elevated temperatures (e.g. 90°C to 120°C). For most vibrating screen applications, NLGI#2 greases with extreme pressure (EP) and anti-corrosive additives are suggested. When initially filling a bearing with grease there should be enough to liberally coat the internal surfaces and exclude contamination. However care should be taken not to over-grease the bearing as this can lead to excessive heat generation from lubricant churning. For vibrating mechanisms the suggested initial fill quantity is 30% to 50% of the free volume inside the bearing and 30% to 50% of the free space in the housing.

Bearings need to be relubricated when grease leaks out through seals, breaks down due to high operating temperatures or when it is contaminated. Mixing greases should be avoided because different types of thickeners are not always compatible. If attempting to mix greases consult your lubricant supplier first. Determining the proper regreasing volume and frequency is difficult because it is application specific. It depends on factors such as the bearing speed, the type and grade of grease, the effectiveness of the seals, the operating temperature and the environment. For these reasons the regreasing cycle is typically determined by vibrating screen OEM’s based on past experience. Ideally, grease should be purged before it exhibits thickening, separation of oil, acid formation or a noticeable degree of hardening. The relubrication intervals should be more frequent if there is significant abrasive contamination.

Oil lubrication systems dissipate heat faster and allow bearings to operate at higher speeds than grease systems. Another benefit of oil systems is

the ability to add a filtration system to remove contamination during operation. There are many additives available to enhance the properties of oils but similar to grease, EP and anti-corrosive additives are suggested. For applications with high operating temperatures or more demanding conditions synthetic oil may be used. The oil viscosity required to generate the proper film thickness during operation depends on the bearing load, speed and operating temperature however oils with an ISO 150 or 220 grade are commonly used in vibrating mechanisms. The life of an oil depends on its oxidation stability and operating temperature. A change in lubricant appearance should be used as a guideline for replacement and the oil should be changed more frequently if significant abrasive contamination is present. OEM recommendations for oil change frequency should be followed.

off-Highway Haul TrucksTimken offers enhanced bearings which are designed to maximize life and reduce downtime for off-highway haul trucks. These trucks can be driven through a multi-staged mechanical transmission or a unitized electric wheel motor. Either way they are always in constant motion pausing only to collect or dump a load of ore.

In addition to the enormous radial loads on the wheel bearings there are also axial loads as the trucks corner; the bearings must support these loads whilst being subjected to shock forces from uneven haul road surfaces and enduring the constant swirl of abrasive dust and grit. Consequently an array of Timken technology comes together to ensure the big wheels are always turning.

Testing has shown standard, case carburized Timken tapered roller bearings provide a level of shock and debris resistance that is superior to most of our competitors’ debris-resistant products. But for the most severe environments, and in applications where downtime is unacceptable, Timken offers a line of enhanced bearings. These bearings start with super-clean, air-melt steel; free from inclusions that could lead to premature bearing failure. The bearing components can be machined with customized geometries which optimize the internal stress profile to combat the effects of misalignment and load induced edge stresses. This is particularly beneficial in mechanical transmission haul trucks where the trend is towards increasing payload and engine power.

Proprietary surface finishing processes are used to enhance performance in thin-lubricant-film environments. Special surface coatings (termed Engineered Surfaces) can also be applied to further deter the most aggressive of abrasive damage - bruising, pitting and grooving – which can lead to component wear, loss of system rigidity, increased system deflections, loss of bearing setting and ultimately reduced bearing life. The most obvious example of Timken’s engineered surfaces technology is our DR2 product range which has distinctive, black colored rollers. Timken DR2 bearings have been used successfully in Australia for many years to maximize wheel bearing life in the largest off-highway haul trucks.

The most obvious example of Timken’s Engineered Surfaces technology is our DR2 product which has distinctive, black colored rollers

In addition to wheel and transmission bearings for off-highway haul trucks, Timken also manufactures Spherical Plain Bearings which can be found in the hoist cylinders, A-frames and suspension struts. Spherical Plain Bearings are designed to carry radial and axial loads in small envelope dimensions and are ideally suited to static or oscillating applications where moderate misalignment may exist.

Timken manufactures Spherical Plain Bearings which can be found in hoist cylinders, A-frames and suspension struts

This bearing design consists of a spherically ground inner ring housed in a mating outer ring without any rollers. Because there are no rollers the rings are phosphate treated and coated in Molybdenum Disulphide to reduce friction between the mating surfaces. The inner and outer rings also feature a groove and holes for lubrication. Many people notice the outer ring has been fractured axially in one place parallel to its axis and incorrectly assume the bearing is faulty. The outer ring fracture is necessary to permit assembly of the rings and is therefore an important part of the manufacturing process. As the suggested applications are either static or oscillating this does not pose any problems. In fact, this design is sometimes supplied with a double fracture outer ring for easier assembly.

ConclusionOur years of experience supporting equipment manufacturers and mine operators, provides unique insights that lead to new technology. Many ideas for innovative products and services develop as a result of working onsite with customers. Mine operators share similar performance goals – to maximize uptime, reduce maintenance and replacement costs, and improve productivity. Timken helps meet these goals by considering your entire system and recommending solutions that keep mining equipment online and running at top performance.

To request your free Mining CD with more detailed product information contact Timken direct.

P | 1800 060 345E | aussales@timken.comW | www.timken.com

Right: The lubricant viscosity required to generate an adequate film thickness is critical for successful Vibrating Screen operation

Left: The most obvious example of Timken’s Engineered Surfaces technol-ogy is our DR2 product which has distinctive, black colored rollers

Bottom Left: Timken manufactures Spherical Plain Bearings which can be found in hoist cylinders, A-frames and suspension struts

Australasian Mining Review 2010: 1st edition

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Bearings

cSE Ex has been at the forefront of design and manufacturing of electrical equipment for Hazardous and Arduous locations in Australia since 1994. CSE was the first

Australian manufacturer in its field to obtain QA Accreditation to ISO 9001.2000 and the first in Australia to obtain product certification to the ICEX scheme which is now recognised worldwide. During this time many changes have evolved within the manufacturing and certification of products for use in Electrical Hazardous location, through which CSE has remained, and continues to be, the leader in its field.

CSE manufactures and supplies a wide product range of electrical equipment covering Lighting, Cables and Glands. All of CSE’s products are designed and manufactured to suit Australian standards for hazardous quality and specification, and are 100% quality control tested at time of

manufacture prior to shipping out to site. CSE understands that quality and reliability are the key to safety in hazardous areas, which is why we diligently maintain 100% quality inspections for our products.

CSE is now proud to announce its new affiliation with Sylvania Lighting Australasia (SLA). SLA’s extensive luminaire range within the SYLVANIA Brand, coupled with its ongoing commitment to quality, innovation and customer service will both complement and enhance CSE’s success in providing customised, complete package solutions for your Hazardous or Arduous environment requirements. SLA and CSE are proud Australian Manufacturers, with all CSE products being manufactured in their fully equipped manufacturing facility in New South Wales. This control allows CSE to ensure the highest quality products are delivered every time, making CSE a brand you can trust for when it comes to your safety.

cSE ExLeaders in electrical equipment for hazardous

and Arduous Areas

Electrical

Climate Smart SolutionS offers a remarkable Heat reflective insulated Coating that utilises revolutionary thermal Protection technology which will reduce the temperature of your building as well as insulating and providing protection from the elements.

When outside temperature increases, so do cooling costs. the emission of harmful uV rays and ultra violet light on a roof or wall, can over time take a tremendous toll. these emissions cause high cooling and air conditioning costs, damage to the roof or wall itself, and even underlying structural damage if left unaddressed.

a hot roof or wall increases a building’s energy consumption. an immediate benefit of using Heat reflective Coatings will be energy cost savings. it also has a guaranteed long lasting attractive appearance.

Heat refleCtiVe CoatingS Can be uSed on:-industrial and Commercial buildings, Shopping Centre’s, Schools, tafes, Clubs, Pubs, mining accommodation, Containers, Caravans, trailers, Plant and equipment, Water/fuel tanks, Storage Solo’s, factories, Workshops and residential.

HoW it WorkSthe nu-technology reduces the amount of sunlight your roof absorbs, dramatically lowering its heat buildup. Conventional zincalume, colourbond roofs and buildings absorb up to approximately 95% of the suns infrared heat.

Heat reflective Coatings reflect up to 90% of the uV rays and 80% of solar rays subject to colour and application. this means that it will be up to 40+°C cooler on the surface of your roof or wall and 10°C – 15+°C cooler inside the building!

Heat reflective Coatings is a highly energy efficient coating that reduces summer cooling costs, reduces peak energy usage and helps reduce pollution, fossil fuel usage, land fill and also extends the building’s lifespan.

tHe benefitS of Heat refleCtiVe CoatingS and HoW it SaVeS you money;

Heat reflective Coatings have a longer lifespan •than traditional paints providing significant

savings both short and long term and offer a 10-15 •year warranty.

reduced cooling costs (up to 40%) conserving •energy and valuable resources.

a cooler building means reduced chemicals and •pollution for healthier cities.

reduced air conditioning maintenance and •replacement costs.

Prevents surface rust, roof deterioration or roof •replacements.

access to government grants/funding and carbon •credits.

the ‘green building fund’ is an element of the Clean businesses australia initiative by the australian government. this aims to reduce the greenhouse gas emissions impact of the built environment by decreasing energy consumed in the operation of commercial office buildings and industrial warehouses.

grants can be obtained from federal, State and territory governments in order to help businesses reduce greenhouse gas emissions with funding available for up to 50% of the total costs, ranging from $50,000 - $500,000.

energy Supply companies are also offering carbon credits and funding to large businesses with high power consumption.

Climate Smart Solutions are fully licensed/insured sustainable builders (australia Wide).

Climate Smart SolutionS Can alSo offer your buSineSS tHe folloWing SerViCeS;

Heat reflective roof and Wall Coatings •

industrial & Commercial retrofit (renovations & fit •outs)

Solar Hot Water/Power •

Water tanks and Water Saving fixtures•

Some of our recent Customers include:

news limited – Chullora (nSW)•

tupperware Warehousing – brisbane (Qld)•

bHP billiton – mt isa (Qld)•

Shoalhaven Heads bowls & rec. Club – Shoalhaven •Heads (nSW)

albion Park rSl – Sydney (nSW)•

Public trust building (Qld govt) – toowoomba •(Qld)

motorama Holden – Springwood (Qld)•

Sunshine ford – Southport (Qld)•

Clarke rubber – Sunshine Coast (Qld)•

ray’s resort – Southport (Qld)•

Peachy Constructions – ormeau (Qld)•

illawarra yacht Club – Woolongong (nSW)•

Help enterprises – brisbane (Qld)•

“goVernment grantS and funding aVailable to aPProVed aPPliCantS”

for further information and an obligation free quote please check out our websites

www.climatesmartsolutions.com.au

www.heatreflectivecoatings.com.au

www.coolpaints.com.au

Email admin@climatesmartsolutions.com.au

Free call 1300 57 58 59

Modern, complex and neat MBR systems present a small footprint size. However, the more traditional larger tank, 25+ days sludge age, sequencing batch reactor (SBR) followed by microfiltration (MF) is a safer, more pragmatic, remote area

solution. Maintenance is lower and any system disturbance is not as critical. Treatwater P/L favour a single tank system incorporating a variable PLC program allowing the SBR to be ramped down from ‘Construction’ to ‘Shuts’ to ‘Operation’ numbers – no need for costly separate systems.

Sludge reduction is enhanced by cell lysis, re-digestion and finally consolidation, reducing desludging to about 20 month frequencies.

System aeration efficiency and cell lysis are carefully controlled by our workshop matched impeller and ejector design. All components are external to the tank and at ground level for HSE reasons.

Disposal may be directly to impact sprinklers or via a separate MF module if required. The SBR system still produces quality effluent even if the MF is out of service, thereby minimizing site environmental exceedences.

The aboveground tanks are ideal for drill and blast sites and can easily be relocated as required.

Wastewater Treatment

After treatment, Groundwater Recharge is a viable disposal option. Our re-Injection valves are designed to control the flow characteristics of water into an aquifer/bore. These can also be used at a minesite where dewatering is required for ore abstraction.

Flow control down the bore is important as any entrained air can block the soil interestices and hinder groundwater re-uptake. Additionally the air can promote acid sulphate soil conditions or can give rise to bacterial growth similar to ‘DeepShaft’ sewage treatment. All of these can cause major permanent damage, contamination and rebore costs. Our pilot-operated modulating valves waft from ‘open’ to ‘closed’ using line hydraulic power alone, to obviate these conditions.

The ‘down hole’ parts are all constructed from selected polymers or 316 stainless steel, while the ‘head works’ companion pipework is hot dip galvanized incorporating isolation valve etc.

The patented, WA made, low maintenance valves supplied - 151 to date – have proved fault free. Typically these are 100mm or 150mm diameter and installed in 200mm or 250mm bores, each passing in excess of 30 L/s to 70L/s.

Reinjection Valves

Treatwater Pty Ltd Tony O’Kelly MSc CEng WEM(uk) Principal

7 B Searle Road, Ardross, Western Australia 6153

Tel: (+61 8) 9315 5225 Mobile: 0419 12 09 09 www.treatwater.com.au

Since sustainability best practice recognises the need to reduce the mine site’s ecological footprint, it is logical to include the mine camp in this equation.

Many mining companies have been embedding sustainability principles into mine camp design for decades and their experience in this area can be shared with other miners new to these concepts.

The application of sustainable development principles can include the selection of location, materials, energy and waste management for the mine village.

In this way, the mine village can be developed using socially and environmentally responsible design principles.

Mining companies that are already taking these issues very seriously implement accommodation solutions that deliver value to the business and improved standards of living for their mine site employees. They are using the approach of Ecologically Sustainable Development (ESD), which considers the short and long-term impact of the mine site accommodation and more importantly advocates establishing a sustainability framework before the site is developed.

Pre-fabricated buildings are the structure of choice in this solution as they can be transported to the next “short-term” accommodation site – taking their sustainability benefits with them.

Early consideration of the impact of these plans on the environment and the people being housed provides a better chance of delivering a sustainable solution and applying the latest technological advances.

Furthermore, while working on a sustainability philosophy for design and site master planning, considering all three sustainability pillars – social, environmental and economic – is vital. The “whole project” perspective ensures sustainability is on the agenda at the start of the project and ecological design concepts are conceived and tested to increase the long-term value of the development.

Areas for early consideration:

Life Cycle Analysis Recommended to include embodied carbon, recyclability and reuse considerations

Water Supply Includes water demand, treatment and disposal but worth noting the impact of remote locations and the affect of drought

Master Planning Influences passive energy efficiency, social impact and consideration for surrounding vegetation

Building Materials Select on basis of thermal performance to maximise energy efficiencies

Building Fabrication The emphasis is on waste generation and environmental management plans for construction

Transport How accessible is the site and what modes of transport are required to access the site?

Energy Management Energy management, in particular, provides tangible results and delivers a quick pay-back.

The choice of building materials has a significant impact on internal thermal conditions and therefore influences air-conditioning demand and operational costs. The use of high thermal mass materials not only provides thermal benefits but also acoustic comforts. Computer modelling is also a useful tool to assess the impact of alternative building materials in relation to thermal conditions.

Equally important are energy supply and demand. Significant improvements are achieved by considering the impact of air-conditioning systems, hot water systems and artificial lighting systems. Alternative energy options of on-site renewable energy generation through solar, wind or geo-thermal sources are also valuable.

Measuring anticipated energy demand supports the decision-making process. Computer modelling using statistical local weather data provides information to optimise design decisions while predicting current and future demands. Computer modelling software can also be implemented to simulate building thermal performance and energy consumption. Sub-meters also provide an economic way to monitor high energy use areas.

Mine site employees have a role to play in minimising energy consumption. Communicating energy efficiencies to employees helps them to understand the role they play in conserving energy and contributing to a better mine site living experience. Real-time energy data can be collected and presented in a graphical format to highlight energy consumptions.

By Jody Finsen of Sinclair Knight Merz

The pulse of sustainability is beating in the mining sector. For mining companies, a long-term licence to operate depends on a capacity to renew existing commitments while seeking new solutions to environmental concerns.

Improving Sustainabilityof Mine camps

About SKM Sinclair Knight Merz (SKM) has a long-term commitment to sustainability. SKM designs and delivers projects with an awareness of environmental, social and economic objectives, to ensure the most efficient, cost-effective and sustainable outcomes are achieved. SKM can also provide a suite of specific tools and tech-niques to clarify, articulate and respond to clients’ sustainability challenges. By de-fining strategic, technical and operational approaches and pragmatic implementa-tion plans the life cycle of a project can be addressed.

SKM can also implement cost-effective, environmental sustainable mine site infra-structure for brownfield and greenfield sites and provide in-depth advice and engineering solutions for water, energy and waste management systems.

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Environment, Water & Air Treatment

Communications is a powerful tool to drive behaviour change.

water Management Like energy, water is an essential service that needs to be used intelligently and is often in short supply. Water efficient fittings and appliances are now commonplace in areas where water has been in short supply for some years. Techniques such as rainwater and stormwater harvesting, grey-water reuse and on-site water treatment are commonly used to boost the available water supply and reduce the reliance on dams and bore water systems. However, most importantly, behaviour change is critical for water conservation. Again, sub-metering is a technique that is used to monitor water consumption trends and compare against set water targets.

The increased productivity level of mineworkers who are accommodated in comfortable, energy efficient environments has been shown to impact on the bottom line.

Learning from successful mine camp developments, a sustainability strategy involving energy-efficient pre-fabricated buildings and water conservation solutions is an achievable goal and should be given early consideration in any mine site development.

Case study Improving environmental design of mining villages With key assets located at Leonora Village, in the north eastern goldfields of Western Australia, mid-tier gold producer and mineral explorer, St Barbara, undertook a Mine Camp Design Study that led to the development of a new mine village. The new village, built within a sustainable framework, illustrates the possibilities that can unfold when companies go beyond compliance to achieve the best possible environmental outcome.

Situation Having acquired an existing mining village as a result of the purchase of new gold assets in 2005, St Barbara set about determining the best possible approach to bringing the accommodation up to world class standards while satisfying, environmental, social and economic concerns.

Working with Sinclair Knight Merz (SKM), a study was commissioned to identify opportunities for water and energy efficiency and environmental performance during the construction and operation phases. The study succeeded in pinpointing a number of environmental opportunities and provided clarity around costs and benefits necessary to judge the project achievable.

Challenge Mine site accommodation development is typically

characterised by a requirement to keep costs to a minimum and requires a fast establishment time. St Barbara however, recognised that accommodation facilities for their workforce should follow the same environmental principles applied to operational areas.

Response St Barbara understood that the approach to success would entail engaging with experts in sustainable mining village design and construction.

The program entailed three steps: • Initial investigation into the feasibility of establishing an environmentally

sustainable mining village – the SKM study examined environmental initiatives and a cost benefit analysis.

• Architect, Ian Hooke, used the study to design the village and implementing the recommendations. After the initial design was complete, Ausco, a temporary accommodation construction company, was invited to custom design the village units. The combined efforts of all those involved resulted in a cost-effective solution incorporating as many of the recommended initiatives as feasible, within budget.

• The final stage involved constructing the village. The units were constructed off-site to reduce waste while on-site installation and preparation works got underway.

Some of the initiatives implemented included:

Results St Barbara’s 222 room sustainable mining village was completed in October 2008. The village was subsequently recognised for its contribution to environmental excellence and awarded a “Certificate of Merit” from the Western Australian Department of Mines and Petroleum at the 2009 Golden Gecko awards.

Results to date indicate a reduction of per head water use of 50 per cent and energy use of 30 per cent.

Initiative Results

Concrete floors Reduces demand for heating and cooling

Parasol roof design and larger verandas

Absorbs and reflects heat as well as cooling air passing through to reduce cooling demand

Solar energy generation Energy generated is fed into the switchboard and provides base-load energy requirements for the village

Greywater reuse system connected to all rooms and water is delivered to gardens

Reduces water consumption associated with gardens

Energy and water efficient washing machines

Reduces water and energy consumption

Low flow shower heads Reduces water consumption

Upgrading of existing facilities, ie gym, recreation room, kitchen

Reduces requirement for new resources

Environment, Water & Air Treatment

http://www.eco2forests.com

http://www.cumminsfiltration.com

Now a flagship brand of the global tools giant, The Stanley Works, Sidchrome has the backing of local and international teams of research and design engineers, who are

also delivering cutting edge technology to some of Stanley’s other major industrial brands, such as Proto, Facom and Mac Tools.

“New product development within the Sidchrome brand is hitting levels we haven’t seen for many years”, says Ben Hall, Sidchrome Brand Manager for Stanley’s Australian and New Zealand division. “While we have seen competitor brands tighten their belts and all but stop R&D spending during the financial slowdown, we saw it as an opportunity to really focus on delivering new, innovative products to the market”.

On the back of this increased R&D focus, Sidchrome is set to launch a swag of innovative tools during 2010.

New Compact RatchetOne such product, which is on shelves from March 2010, is the new Sidchrome compact head ratchet (part number 14910). This ½” drive 72 tooth ratchet features a compact, sealed head, making it highly resistant to dust & grit. This dust resistance is critical when working in dirty environments, as down time is reduced to virtually zero. You can be sure that the tool will last the distance, as it is tested to 40,000 cycles at 300Nm load!

Safety has been a hot button in not only the mining industry, but across all walks of life for many years now, and Sidchrome has prided itself in staying at the forefront of building tools for a safer working environment.

New Ergonomic PliersWith an eye on consumer safety and comfort, Sidchrome is delivering a full range of ergonomic pliers, due to hit the market not long after the compact head ratchet. With specially designed “spatula” shaped handles, and “always ready” springs (tested to >1,000,000 cycles), the new Sidchrome pliers require significantly less operating force than leading competitor products. Manufactured in one of Stanley’s French industrial tool plants, the new formulation chrome molybdenum vanadium and double heat treated cutting edges, mean Sidchrome’s new plier offer is the safest and most rugged on the Australian market.

Safer SpannersOne of the most commonly used tools in the average toolbox is the humble spanner. Its sole purpose in life is to fasten and unfasten nuts and bolts (no, it is not a hammer!) It is the spanner upon which Sidchrome has built its formidable reputation over many years. In 1999, Sidchrome took this most common of tools, and revolutionised the way in which the open end of a spanner works.

Not satisfied with the exclusive Torqueplus™ feature on the ring end of the spanners, which works on the flats of a fastener and delivers 15% more torque, engineers from Stanley set about designing an altogether safer, more efficient open end. The result is Sidchrome’s patented and exclusive “AntiSlip Design™” or “ASD”. Using clever geometry and a small locking groove, all Sidchrome open end spanners, including the open end of combination spanners up to 32mm or 1 ¼” come with ASD.

The ASD works on the flats of a fastener, delivering up to 400% more surface area contact. This reduces the chance of fastener rounding, and also “locks on” to the fastener as torque is applied, meaning significant reduction in knuckle injuries. These injuries are not only painful, but they really impact on workplace productivity.

Worth the investmentManufactured to some of the strictest standards across the globe, you can be sure that the entire range of Sidchrome products will fit the bill in your next mining project. If you would like to get in touch with a Sidchrome representative to discuss your specific industrial needs, then please feel free to contact Joe Mancuso, Stanley’s industrial business manager at jmancuso@stanleyworks.com.au

Be sure to stay up to date with all the latest product releases and offers by visiting the new Sidchrome web site (www.sidchrome.com.au).

Since 1942, Sidchrome has been synonymous with quality, reliability and toughness. As generations of Australian workers can attest, Sidchrome tools are built to stand the test of time – even in the harshest of working environments.

Sidchromean iconic Aussie brand steps it up in 2010

Hand Tools in Mining

[ 84 ]

All I&M Winch Hire products are manufactured on site using the latest engineering, technology and materials ensuring that when the client chooses I&M Winch Hire, their clients are

getting the very best in safe reliable and cost-effective equipement.

Operating out of Henderson, Western Australia means I&M Winch Hire are well placed to take advantage of existing transportation channels to ensure the right equipment arrives on site on time. I&M Winch Hire have grown with the WA Mining Industry by expanding its hire fleet to accommodate the increased demand, and subsequently have an extensive range of top products to meet all its clients winch, power-pack and crane needs on the mine sites.

I&M Winch Hire’s range includes hydraulic winches ranging from 0.5 tonnes to 30 tonnes – with the facility to manufacture specially designed winches to suit your application, as well as an extensive range of the high quality and reliable hydraulic power packs. In addition to a range of cranes available for that bit of extra lift.

I&M Winch Hire Capabilities include:

Supply and installation of Hydraulic drive • winches, 0.5 tonne – 100 tonne capacity;

Supply and installation of Diesel or Electric • driven hydraulic power units, up to 500lts/min;

Compact capstan and winch cable hauling • units, complete with power units skid mounted.

Supply 0.5 tonne – 10 tonne air winches•

Telescopic compact crane, complete electric • or diesel driven hydraulic power unit, housed in an approved lifting enclosure. Crane capacity: 2.4 tonne cranes @ 5m

Fully equipped workshop for in house testing • of winch, cranes and power units;

Technical and practical advice to clients • providing customised solutions;

Supply full back up service with experienced • personnel and spare parts.

I&M Winch Hire can also provide custom built winches and power packs, hydraulic hoses, directional valves as well as fairleads & deflector

sheaves, all adding to their already extensive range of equipment.

They business constantly strives to develop its capabilities and exposure through providing quality equipment with the base foundation of experienced personnel, planning strategies and constantly achieving technical excellence within the organisation. This manifests itself through the quality and reliability of the end product.

The I&M Winch Hire difference is its dedication to being a high quality service provider focusing on supplying safe, reliable and cost effective equipment – exceeding its client’s requirements and expectations.

The business’ occupational Health and Safety Policy is founded on a belief that the well being of staff and people operating its equipment always remains their highest priority, and their safety translates to their client’s safety.

Combining the manufacturing and engineering excellence of Hamilton Engineering, and the superior hydraulic systems designed by Fremantle Hydraulics, the end quality of the winches, power-packs and cranes available through I&M Winch Hire is second to none. With the added ability to provide mining companies and clients unparalleled hire equipment with the highest degree of safety and reliability, with all of its equipment fully tested to absolute measures.

I&M Winch Hire provide winches, power packs, and cranes for every mining need, wherever you are, whatever you need.

For more information on the I&M Winch Hire range or to discuss your project needs contact.

info@imwinchhire.com.au

Jamie Oreb Mb: 0408 067 000Rob Tranchita Mb: 0408 060 047Charlie Tranchita Mb: 0418899214

For more pulling power – pull up our website www.imwinchhire.com.au

Industrial and Marine Winch Hire (I&M Winch Hire) specialises in the hire of winches, power-packs and cranes to local, national and international mining companies. Whether mine sites need heavy duty equipment for a short or long term basis, they are ready to supply any equipment to suit client’s needs, as well as provide technical support 24 hours a day, seven days a week.

Industrial and Marine Winch Hire (I&M Winch Hire)

www.imwinchhire.com.auinfo@imwinchire.com.au 28 Jessie Lee Street, Henderson Perth, WA 6166 08 9494 7207

Top: Range of electric or diesel power packs up to 500 lets/min.

Middle/Bottom: Hydraulic winch drives 0.5 to 100 tonne capacity.

Hire Equipment - Winches & Hydraulic Power Units

[ 86 ]

Two ways to assist in your environmental resource management and cost recovery programmesThe very fact that mine sites are often remote means that supply of water for process, potable use and dust suppression can be expensive.

The old adage of what you can’t measure, you can’t manage rings true in this instance.

With the high level of sophistication associated with systems used to provide water treatment on sites for both potable water and water reuse, the cost of delivering the water begins to show as a significant factor.

Identifying the use is easy with the installation of meters throughout a site, but what if anything is done with the readings, if they are read at all.

Are there opportunities to recover some of the costs by on charging for the water used?

The first thing is to know how much water is used and where.Water meters can be fitted with lithium battery powered wireless radio transponders that interface with a command centre. The use of water through each meter can be logged and recorded and where possible external users can be charged according to their actual use.

Think where water meters are currently used on site. This is often only in one or two locations but to get a full understanding of where the water is used, an extensive metering audit needs to be done. This would include, ablution blocks, refectories, wash down areas, dust suppression fill points, air conditioning make up tanks, processing areas like wash plants etc. Once each area is monitored true costs of water used in the section can be allocated.

The information provided by the logger / transponder will allow identification of peak demands and leakage plus allow informed forecasts of future water use to be made. The information can be logged as often or a little as deemed suitable and uploaded to the command centre at a remote location daily, weekly, monthly, whatever.

How do you charge contractors for their water use?Automated water filling points can be established whereby users are issued with a touch button encrypted with their details. When water is drawn from the filling point, either raw, potable or recycled the amount taken is recorded and sent back through GSM/GPRS to a command point. The user is identified and a bill for the water taken can be immediately raised.

This technology is inexpensive, reliable and not reliant on the honour or booking out system which reduces the human error aspect.

These can be located across a single site or across entire leases. They are tamper proof and weather resistant and can be set up for an unlimited number of users. The information can be downloaded via Bluetooth or sent back to a command centre with GSM / GPRS / 3G for FTP access.

The filling station operates on low voltage 24VDC and is available in both 240V and solar powered models.

Encrypted touch tags can be programmed to work on a single filling station or on multiple filling stations and are available for account customers and re-chargeable pre-paid customers. The touch tags are stainless steel and plastic and are robust enough to handle being run over. Each touch tag has a unique serial number and can be disabled at any time so access to water is removed should the tag become lost or stolen.

Both of the above systems are maintenance free and can be self powered eliminating the need for maintenance programmes or costly connection of electricity.

As the cost to provide water increases, the management will become an area that warrants regular scrutiny. Only by fully understanding where and how it is used will allow the true costs to be allocated and on charged where possible. A coordinated metering and automated dispensing approach can be implemented quickly and cost effectively. A major benefit is that the payback of the costs is often achieved shortterm through the detection of lost / stolen water and leakages.

Water Management Control

Hoses, Valves & Pipes for Mining

[ 88 ]

Product Description

The Waterlord is an ultra tough lay-flat hose for use on mine sites and rugged terrain environments. It is constructed by weaving a tight polyester fabric and covering this material with polyurethane.

The polyurethane cover and liner ensures maximum abrasion, corrosion and chemical resistance. The cover is also UV treated so that the hose can be left outdoors without concern for cracking.

The tight polyester fabric is designed to handle high pumping pressures with minimal friction loss. The manufacturing process of interlocking the textile fibres keeps the hose flexible whilst minimising bulk and weight. This makes it easy to roll up, handle and move around during pumping operations.

Waterlord is made in a range of diameters from 40mm to 200mm.

All hose is fully manufactured at our Australian factory under stringent quality standards. Each length is individually tested thus ensuring many years of trouble free pumping.

Main Uses

Dewatering in mines 9

High pressure wash-down hose 9

Industrial hose for use with certain oils & 9chemicals

Heavy duty farm hose 9

Temporary bypass hose 9

Air hose 9

Waterlord features

Low coil volume for easy handling 9

Long custom lengths up to 300m 9(for certain sizes)

High pressure 9(Extra heavy duty, HD available)

High abrasion resistance 9

Chemical resistant (to many acids) 9

Flexible from -40° C to + 70° C 9

Repairable 9

Potable version available (AS 4020 9

Non-cracking polyurethane cover

Woven polyester fabric

Impregnated polyurethane

bonded to outer cover which eliminates separation

Each Crusader hose is covered by a 10 year pro-rata warranty against faulty materials and workmanship.

WaterlordMine Dewatering Hose

WATERLORDWATERLORDMine Dewatering Hose

Crusader Hose Pty Ltd22 Industry Place Bayswater VIC 3153 AustraliaTelephone: (03) 9720 1100 Facsimile: (03) 9720 5756 www.crusaderhose.com.auHoses, Valves & Pipes for Mining

At Premier in WA, the company’s Flexibore hose range surpassed previous performance during a major project which called for dewatering at depths up to 247 metres. Thirty bores

were required to reduce the ground water at flow rates of 45 litres per second.

Premier Mine’s project manager, Brian Wade, said, “Importantly, the borefield has been achieved with zero lost time injuries and within budget. Flexibore is a zero maintenance product and we look forward to ramping up to a peak of around 100 million litres of pumping per day by 2011.”

Flexibore captures a revolutionary technology of combing tightly woven fibres and extruded polyurethane to give it burst pressures of 50 bar (nearly 1000 psi) and with tensile strengths reaching 14 tonne. Flexibore riser is like flexible steel and combines the high tensile strength and burst pressure of steel with resistance to corrosion and internal scaling.

“Flexibore’s inherent ability to flex and swell slightly under pressure ensured there would not be any flow reduction due to the build-up of iron bacteria”, explains Francois Steverlynck, Managing Director of Crusader Hose. “Because of the flexibility, no iron bacteria or calcium is able to grow on the inside of the hose.

This keeps the pumping costs down due to the low friction loss on the inside of the pipe.”

Flexibore was the right choice for Premier’s project because not only does it not corrode and fall prey to internal scaling, but it is also very easy to install and extract. The water around the coal mine is very acidic with a pH of 4.5 The acidity of the water makes it a high maintenance issue for the mine due to the fact that the screens at the bottom of the bore get blocked thus preventing the flow of water into the well.

In order to maintain a flow of water into the bore, the pumps need to be extracted every 18 months and the bores cleared using a high pressure wash.

Flexibore assisted in making the servicing easy due to the fact that the pumps can be pulled out from 247m deep in less than 3 hours. There are no sections of pipe to unscrew as the hose is made in one continuous length.

Heading up the experienced installation team at Think Water , Bunbury, Manager Mark Sanders commented on the ease of receiving Flexibore in specified continuous lengths. “This was a massive saving in time as each riser was on a single pallet, and was so much easier to handle than columns of steel, stated Mark.

Crusader Hose has been manufacturing Flexibore flexible riser for over 20 years at its Bayswater plant in Melbourne.

This project has been the biggest for the company to date. Francois Steverlynck also believes that it has set a new benchmark for flexible risers in that it is successfully pumping water using 90kW pumps from depths of 199m to 247m .

Every hose was made to exact length as specified by Wesfarmers and the pumps are suspended off the Flexibore hose only, without the use or need of a safety cable. The weight of the pump plus cable, combined with the weight of water in the full column fell well within the tensile load capability of the 125mm Flexibore (14 tonne)

As a quality accredited company, Crusader Hose ensured that every hose was hydrostatically tested prior to despatch.” We are aware of the costs involved to Wesfarmers in case of replacement “said François Steverlynck. “Our company is proud that we are producing world’s best quality. We are also delighted at the support and opportunity that Wesfarmers Coal has given an Australian manufacturer, and we have delivered!”

Loy Yang Power Station provides approximately 40 % of Victoria’s power requirements.

With a large ongoing de-watering program of over 40 bores, they are also a large user of the Flexibore hose. This system gives them the adaptability for “in and out” pumping operations with ease.

Crusader Hose has set a new benchmark in the use of flexible risers at Wesfarmers’ Premier Coal Mine in Western Australia as well as Loy Yang Power Station in Victoria.

A New Benchmark in Waterbores

IF IT IS A BORE THINK

FLEXIBOREFLEXIBORE

Easy to Handle

Crane Installation Easy Installation and RetrievalRoller Installation

NO CorrosionNO Iron Bacteria

Crusader Hose Pty Ltd22 Industry Place Bayswater VIC 3153 AustraliaTelephone: (03) 9720 1100 Facsimile: (03) 9720 5756 www.crusaderhose.com.au

Flexibore Coupling

Flexibore Hose

Power Cable

Power Cable Strap

Borehole Pump

Typical Borehole

Arrangement

Hoses, Valves & Pipes for Mining

Custom Fluidpower, a national hydraulic solutions provider, is in an ideal position to meet this need with the design and build capabilities to improve the safety and efficiency of

underground machinery.

An example of an upgrade conversion is in the case of a customer who had an old air track drill rig, the purpose of which is to complete bolting projects (strata roof control) and repair in underground coal mines.

The existing machine required a large volume of high pressure air, the supply of which could not be guaranteed in the areas where the machine operated. This could cause the machine to be inoperable resulting in costly downtime and safety concerns. The machine also was not up to current safety standards as it had no braking system and unreliable steering systems, amongst other issues.

Custom Fluidpower reduced the air requirements by replacing the pneumatic traction motors with Sai Hydraulic motors. The existing air motor driving the hydraulic pump was replaced with a tandem system, and actuators were fitted to the tramming valves to allow the valves to be operated from a pneumatic pendant. These changes kept the machine simple to repair and service without the use of electrics.

A pneumatic pendant was constructed to operate the tramming function, allowing the machine to be trammed remotely and removing the operator from a dangerous interaction zone behind the

machine. The pendant was fitted with a two-hand control module, reducing the chance of unplanned movement.

Another key area was the addition of hydrostatic braking, through use of a Sai F21 brake and a Custom Fluidpower manifold. The steering of the machine was improved dramatically, again resulting in increased efficiency and safety.

This example gives an indication of the possible improvements which could be made to existing mining equipment. Custom Fluidpower can enhance your mining machine efficiency whilst improving safety, without the need for the costly purchase of new equipment.

For further information regarding Custom Fluidpower’s services and locations please visit www.custom.com.au or phone 1300 781 178.

In these challenging times, the focus of many mining companies is on service and repair of machinery, rather than the upgrade of old equipment.

Improve Safety and Efficiency of Old Mining MachineryWithout the Cost of New Equipment

ADELAIDE | BRISBANE | EMERALD | MACKAY | MELBOURNE | NAVAL BASE | NEWCASTLE | PERTH

Hydraulic & Pneumatic Product Sales •

In-House Testing Facilities•

Lubrication Technology •

Filtration Products & System Maintenance •

Industrial Braking•

Complete System Design •

Hydraulic Manifold Design & Manufacture •

Field Service •

Workshop Repairs •

Installation & Commissioning•

CertifiedFluidPowerTraining•

Complete Hydraulic Solutions

1300 781 178www.custom.com.au

Hydraulics, Lubrication & Solutions

[ 94 ]

The team at Hydraulics Australia have honed their skills working with industry leaders on some of the largest and most technically demanding systems in the field. Their knowledge and experience was developed in the most challenging industries including maritime, aviation, construction, transport, port operations and resources.

Sean Wright, Hydraulics Australia’s Operations Manager, understands his customers needs for quality and cost effective solutions. Sean and his team all come from practical engineering backgrounds and offer tailored solutions for:

Pump And Motor Repairs•

Cylinder Repairs•

Power Units•

Filtration And Cooling •

Technical Services•

Hose And Tube Installations•

Ball and Sag Mill Bearing and Lubrication Systems•

The Company has established strong relationships with a wide network of manufacturers and suppliers, providing Hydraulics Australia customers the quickest turnaround in the industry. Using their global partners, Hydraulics Australia can also source rare and difficult to find components for even the most specialised equipment.

Hydraulics Australia’s technical resources are extensive. They can design and engineer entire hydraulic systems for specific requirements. With their fully equipped workshops and test facilities, the team can manufacture a wide range of equipment and components. They can also undertake both the mechanical and electrical installations of any Hydraulic System, streamlining any project to just one contractor, saving time and money.

Hydraulics Australia also offer an extensive service and exchange programme for a wide range of Hydraulic equipment. All units are fully overhauled and tested, using only genuine components to meet OEM specifications, and have a complete return to base warranty.

Years of experience working with and refurbishing everything from cylinders to the largest compensating piston pumps, affords Hydraulics Australia the confidence to repair and support any hydraulic components currently in the field.

The company has also integrated fully functional Quality and OHS systems ensuring all work is constantly performed to the highest quality and safety best practices.

Hydraulics Australia has the experience, products, expertise and systems to provide its customers the Best Brands, Premium Service and Total Solutions they desire.

Hydraulics Australia is fast growing into the #1 alternative in the Hydraulics industry.

Hydraulics Australia

Hydraulics, Lubrication & Solutions

More than 2,000 Niton XRF analyzers are already deployed in the global mining industry in companies such as Anglo American, Barrick Gold,

COLDECO, CVRD and Grupo Mexico. With the introduction of the Niton XL2, mining companies of any size can access a range of products that are engineered from the ground up to withstand harsh mining environments, reduce laboratory costs and improve efficiency.

Niton also offers users the choice of an out-of-the-box field mapping option or the flexibility of seamless integration with their existing mapping packages. Either way, these analyzers excel at storing results that are matched to GPS coordinates; these results can simply be downloaded to existing GIS and data analysis packages.

A Family of Thermo Scientific Niton XRF Analyzers

Handheld Niton XL2 and award-winning Niton XL3 Series XRF analyzers are purpose-built for taking measurements anywhere, anytime, with accurate results available in seconds, saving significant expense in comparison to traditional laboratory testing. These easy-to-use, nondestructive instruments provide integral storage of all test results, which are completely tamperproof. Multiple communication options are incorporated, including Bluetooth* wireless, USB and RS-232 serial communication ports.

They also come standard with Thermo Scientific Niton Data Transfer (NDT©) software, a suite of data management utilities that allows users to set operator permissions, print certificates of analysis to document results or operate the analyzer remotely from a PC. The NDT file format preserves and protects the data from each sample analysis, ensuring that this data is not unintentionally or intentionally compromised.

Replacing the award-winning Niton • XLt analyzers, Niton XL2 analyzers are lightweight yet ruggedly built to withstand severe environments. Ergonomically designed and featuring daylight readable icons, the Niton XL2 incorporates customizable menus for ease of use, multi-language options and a standard analytical range of more than 25 elements from sulfur to uranium. It is particularly suitable for mine mapping,

development and grade control where accurate elemental composition data is required across a large number of samples.

Niton XL3 GOLDD™ analyzers deliver major • improvements in sensitivity and measurement times, as much as 10 times faster than conventional Si-PIN detectors and up to 3 times more precise than conventional SDD detectors. Easily analyzing elements from magnesium to uranium, without requiring helium or vacuum purging for light elements (Mg, Al, Si, P, S), the Niton XL3 GOLDD delivers fast, accurate analysis for intensive metals exploration, even helping to identify anomalies at or below the earth’s average crustal abundance.

No matter which Thermo Scientific Niton analyzer you choose, you will be choosing today’s intelligent solution for the mining and exploration industry. These instruments provide elemental analysis of soils, cores, rock chips, ores and concentrates, helping you drive your exploration, trading or mining programs with real-time information. You benefit from an instant decision making capability, whether you’re identifying potential exploration targets, directing activity on a drill rig, mapping ore deposits in a mine, or sorting mine waste from ore.

Niton users in Australia are served by Portable Analytical Solutions with offices in Sydney and Perth offering sales, local factory-trained service, rentals, application and technical support to provide the most effective customer service possible.

For more information or to schedule a demonstration, call Portable Analytical Solutions in Sydney: 02 4381 2844 or Perth: 08 9389 4454 or visit www.portableas.com

Thermo Scientific Niton analyzers are available in a range of configurations and with an assortment of optional features and accessories to suit a wide variety of analytical needs.

* Bluetooth is a registered trademark of Bluetooth SIG, Inc.

The Niton XL3 SeriesAnalyzers Deliver Rapid,On-site Geochemical Analysiswhile Maintaining Point andShoot Simplicity Portable x-ray fluorescence (XRF) analysis has become the industry standard for mining and exploration, and mining companies around theworld are choosing ThermoScientific Niton XRF analyzersto cost effectively determinethe elemental compositionof sample data at all stagesof the exploration process.

Now, the Niton XL2 Serieshandheld XRF analyzer joinsas the newest member of theThermo Scientific family ofNiton analyzers for miningand exploration.

Thermo Scientific Niton XRF Analyzers Lead the Way for Mining and Exploration

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Instrumentation

[ 98 ]

Mill relining is key to the success of a maintenance shutdown. Grinding mills require regular relining maintenance and this activity has traditionally defined

the length of the plant shutdown.

Leading the global industry in the niche relining market is Russell Mineral Equipment (RME). RME is a designer, manufacturer and marketer of specialist equipment for the mineral processing and mining sector, also providing after-sales support for it’s suite of Mill Relining Systems products. Founded in 1987, it has grown to become the company which is at the forefront of the industry globally, with installations in 200 mines in over 40 countries.

Company owner and Managing Director, John Russell said “RME now has a global reputation as a designer of specialist equipment which deliver effective solutions. The primary focus of RME’s engineering team is to develop equipment used by mine operators and mineral processing plants to increase plant availability and crew safety.

“There are many unidentified and unmet needs in the mining industry sector. In developing our Mill Relining Machine, our focus was on the process of replacing wear parts within grinding mills. We wanted to make it quicker and safer, and to improve overall plant availability.”

The company now exports 80% of its production. A fully mobile team of 15 Technicians also travels globally to train operators and service machines, and there is a 24h/d, 365 days a year helpline for troubleshooting.

RME has an in-country operation in Chile, and in 201 will establish another in-country operation in the USA.

In identifying and developing the economic potential for mill relining systems, RME’s clients can halve the time for a reline compared with a manual solution.

The Mill Relining Systems suite of complementary products developed and marketed by RME include:

RUSSELL Mill Relining Machines•

RUSSELL and MILLMAST Liner Handlers•

THUNDERBOLT Recoilless Hammers•

O-ZONE Worn Liner Lifting Tools•

RUSSELL Feed Chute Technologies, and •

Service and Support for commissioning, • training, maintenance and spare parts.

“RME is a one-stop-shop for hard-rock metaliferrous mine operators, who know all too well that when the grinding mill stops turning, the mine stops earning. The need to maximise mine and plant productivity is crucial. These products and services combine to produce an extremely beneficial outcome for mine owners, typically an extra 1-3 percent extra production for a relatively small investment” said Mr Russell.

The RUSSELL Twin 8 Mill Relining Machine, suitable for the world’s largest mills is able to save 25% on any previous solution, making up to 10 days extra full plant production per year. With large processing throughputs, the value proposition of the RME Mill Relining System can provide full payback in even the first reline. RME has also developed products for small mills. RME MILLMAST, an in-mill-erected liner handler, solves the common problem of manually lif ting liners inside small mills.

In a world where decisions are usually defined by trade-offs, RME’s Mill Relining System goes against this trend, by greatly enhancing worker safety during the maintenance function. With mechanisation, and the incorporation of safety technologies in it’s equipment, injuries incurred during a shutdown are greatly reduced.

A solution with a Systems approachMill relining efficiency will be achieved most easily by adopting the Mill Relining Systems approach. This includes THUNDERBOLT Recoilless Hammers, for removing worn mill liners and liner bolts. O-ZONE worn liner lif ting tools again improve safety but also speed up the operation, while the efficient extraction, transportation and replacement of mill feed chutes contributes to a fast reline.

Many sites have adopted the Mill Relining Systems approach, including an RME feed chute transporter, a number of THUNDERBOLT recoilless hammers and associated suspension systems; O-ZONE worn liner lif ting tools and an RME on-site technical services team for training, preventative maintenance, and repair work.

“The provision of on-site and off-site services, in a sector that has traditionally been ‘self-contained’ has been welcomed by our clients. Mill operators want to make the best investment decisions for their business, and then make that investment work most effectively at their site. The service component of our business is a growing area, due to the developing demand from our customers” said Mr Russell.

FutureRME continues to design, develop and add new technologies to the Mill Relining System, whilst ensuring that current elements of the System remain at the leading edge of development. RME’s attention is firmly on the future, and on continued growth for the company. This strategy ensures the long term sustainability of the business. John Russell commented ‘”RME strives to be a

model Australian technology company, and an example to others. It is possible to be a successful vertically integrated technology company in Australia.”

Mill maintenance key part of process

Russell Mineral Equipment, recently installed into the Australian Export Awards Hall of Fame, is leading the development of Mill Relining Systems technologies throughout the world

Russell Mineral Equipment the Technology Company

Image opposite: RME Eight (8) Axis Liner Placefment Mill Relining Machine of 6000kg rated capacity.

Australasian Mining Review 2010: 1st edition

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Milling - Mill Maintenance & Operating Efficiency

Originally established, as a provider of trade engineering services to the greater Brisbane region, by Andy Igo, in the early 1990’s ADE diversified into the design,

manufacture and installation of hydraulic services for mobile mining equipment (belly dump coal haulers). By the mid 1990’s, Andy had expanded this capacity to include the hydraulic services for belly dump bauxite haulers and water tankers (for both rigid truck and tractor arrangements). At the turn of the century, ADE commenced its machine assembly division with the contract to assemble Euclid Off-Highway Rear Dump Trucks for Hitachi Construction Machinery Australia (HCMA). Some 10 years later, ADE continues to support HCMA in this capacity.

In 2004 Clive Gray joined ADE to fill the position of General Manager with a goal to rationalise the rapidly expanding machine assembly and fabrication divisions. This acquisition was followed soon after in 2005 by the addition of Danny Irvine, who assumed the newly created role of Engineering Manager, and was presented with a scope to build a team of professional engineers and mechanical draftspersons. With a combined experience in excess of 30 years in the mining and earthmoving industries, and supported by resumés heavily endowed with skills in contracts management, machine assembly, machine design, and machine modification, ADE was certainly about to open a new and exciting chapter in its already successful history.

In 2007 ADE was contracted by Rio Tinto Weipa to design and manufacture a comprehensive access system arrangement for a Grove GMK-5220 All-Terrain Crane to manage operational and maintenance “working at heights” issues. The design methodologies & concepts (cultivated in accordance with the applicable standards and codes of practice), and manufacturing techniques developed during that project have since spawned an impressive range of access solutions for a variety of mobile equipment and workshop maintenance tasks. Engineering design tools such as 3-Dimensional Computer-Aided-Design (3D CAD) software and Finite Element Analysis (FEA) has further enhanced their team of highly qualified and experienced engineers and draftspersons.

In only three years since the Grove GMK-5220 access system, ADE has built a remarkable

catalogue of mobile equipment access solutions. There are products for off-highway trucks and

tractors (Caterpillar, Hitachi & Komatsu), bulldozers/track type tractors (Caterpillar & Komatsu), motor graders (Caterpillar), wheel loaders/dozers (Caterpillar, Komatsu & Le Tourneau), mobile cranes (Grove & Terex), as well as specialised equipment such as low loaders. This diverse range of access products for mobile equipment has required ADE to undertake a large amount of research and development activity, ensuring that they maintained a high level of creativity and innovation, which in turn has become their trademark.

Great pride is taken by ADE in providing the best product documentation and product support to the market. To make sure that their customers have easy access to the “latest and greatest” product documentation, such as Operation and Maintenance Manuals and Parts Books, the information is readily available for viewing and download (pdf format) from their website (www.ade.net.au). The daily running of the business by the directors allows their clients direct contact to them, giving them surety of ADE’s support and commitment.

Over the past two decades ADE has developed relationships with many of Australia’s leading miners (including Anglo Coal, BHP Billiton, Rio Tinto & Xstrata) and contractors (including EDI Downer, Emeco, & Leighton ), as well as mining equipment manufacturers and their dealers (including Caterpillar – Hastings Deering (Aust) & Westrac (NSW, WA & China), Hitachi (HCMA), Komatsu and Le Tourneau) operating both within Australia and overseas. As ADE’s business profile increased, so did demand for the company’s products and services, and by January 2010 their workforce had grown to over 50 people.

With ADE having now achieved a strong market presence in Australia’s mining sector as a supplier of solutions for “working at height” issues on mobile equipment, they are looking to the future to not only strengthen their position, but to expand further into the overseas markets.

Their goal is simple; to be the best in the business.

Founded in Brisbane 21 years ago, Australian Diversified Engineering (ADE) was the creation of Andy Igo, a mechanical engineer by trade. Fast forward to 2010 and ADE, now managed by Clive Gray and Danny Irvine, continues to live up to its name.

Australian Diversified Engineering…

ADE has a proven track record of designing and manufacturing products for the mining industry, including hydraulic services for off-highway mining trucks, water tankers, belly dump haulers (coal & bauxite), as well as access systems for both mobile equipment and for the workshop environment.

ADE provides a one-stop shop for taking a concept from design through to manufacture, be it for new products or enhancements to existing products. The latest 3D CAD and FEA technology is utilised in conjunction with the relevant standards and regulations to develop designs that meet the customer’s requirements.

This expertise in providing product solutions is backed up by a team of highly qualified and experienced engineers and tradespeople, who have built a reputation for their diverse activities within the mining industry.

www.ade.net.au T +61 7 3865 2660F +61 7 3265 4519

Australian Diversified Engineering Pty Ltd516 Bilsen RoadGeebung QLD 4034Mining Machinery Engineering & Attachments

[ 102 ]

From modest beginnings as a steel foundry in the 1920s, today Bradken services the mining, freight rail, steel making, smelting, transport, cement, oil & gas, power generation and sugar

industries and is a major supplier to some of the world’s largest companies in these sectors.

For the mining sector, Bradken understands the importance for customers to have ready access to expertise of the highest calibre. Our experienced sales and service teams have been established in regional centres in Australia and around the world. Manufacturing and refurbishment facilities are also conveniently located for our Australian-based customers at Karrabin, Mackay and Mt Isa in Queensland, the Hunter Valley in New South Wales and Bassendean in Western Australia.

The focus of both sales and service staff is to provide mining operators with high quality products, prompt service and technical support, on the spot. Bradken’s account managers are customer advocates, working closely with our highly skilled in-house product development teams to produce innovative solutions to industry challenges.

Continuous improvement is one of the company’s core values, which translates into constantly looking for ways to help customers achieve productivity improvements and profitability growth.

One-stop-shop for mining products and services

Bradken’s Mining Products Division supplies an extensive range of mineral processing, wear

plate and block, and crawler systems. These products are augmented by dedicated

refurbishment and maintenance services. Customers need only deal with one

specialist supplier throughout the entire product life cycle, from product selection, customising or design, through to manufacture, monitoring, refurbishment and finally, scrap removal.

But while Bradken offers a ‘one-stop-shop’ in terms of product

range and after sales service, when it comes to providing customer

service, the company certainly does not have a ‘one-size-fits-all’ attitude. Local

account managers and sales staff assigned

to help with customers’ daily needs have years of relevant industry experience and are well qualified to solve those needs across the wide variety of mining conditions.

Crawler Systems

Bradken’s strong global reputation in design and manufacture of crawler shoes derives from superior performance of these components in the most rigorous mining conditions. Four of the six major OEMs choose Bradken as their preferred supplier.

The range now includes full undercarriage components for mining excavators and hydraulic face shovels. Our product portfolio includes the world class Evolution® and Opti-Trak® series and we also offer a track remanufacturing service. We can supply case-hardened and through-hardened parts tailored to suit every mining application and budget, combining the latest design techniques with high quality manufacturing.

Product Development

Bradken’s design goal is to develop products which provide superior performance, thereby delivering tangible economic benefits to customers. In this context, the company’s in-house design capability is a cornerstone of the philosophy of supplying all components of a full product life cycle.

Harnessing advanced computer technology, such as Unigraphics CAD/CAE/CAM, Ansys Finite Element Analysis and AFS Solidification Analysis, Bradken links engineering with manufacture, ensuring strong synergy between our customers’ needs as determined by their particular operations, the product design process and its practical application.

Bradken’s investment in new technology and focus on product development reinforces the company’s commitment to provide our customers with precise, world competitive solutions to their individual needs.

Providing the “Total Solution”

From consultation with customers to determine specific needs, through the sophisticated design process, to manufacture, supply, refurbishment, and down to scrap removal, Bradken concentrates on providing the total solution to our customers, customised to suit their specific situation and unique challenges.

With 4,200 employees and 26 manufacturing and service facilities throughout Australasia, China, United Kingdom and the Americas, Bradken® is a global powerhouse in the design, manufacture, supply and service of differentiated consumables and capital products.

Bradken delivers the goods to the mining world

Mining Machinery Engineering & Attachments

Any mineral processing plant optimisation study must first consider the material entering the mineral processing plant and how it will react within the plant. Geometallurgy aims to understand and quantify the variability of fundamental rock properties that critically impact ore processing performance and production rates, in terms of ore types and spatial distribution within the orebody. This knowledge then allows for mineral processing performance modelling (such as comminution and flotation) throughout the orebody providing the ability to facilitate more effective process design, mine planning, optimisation and hence the potential for improved economic returns, forecasts and risk management. Geometallurgy can be applied at greenfield sites, existing operations and expansion projects and at many scales from bench to orebody. JKTech has expertise across all areas of geometallurgy, including Mine-to-Mill® studies, linking mining operations to the mineral processing stages.

Comminution Circuit StudiesJKSimMet is the world-standard for analysing and optimising comminution circuits. This software simulation package includes mathematical models of various comminution and classification devices used in minerals and coal beneficiation, resulting from more than four decades of research at the JK Centre in Brisbane, Australia. More than 350 JKSimMet packages have been sold around the world.

To make use of the models in JKSimMet, the general form of the model must be tailored to match the specific application required. This is achieved by fitting or adapting the model parameters. The model parameters are either a characteristic of the ore being processed or of the specific mineral processing machine.

In general, the ore specific parameters are determined by laboratory tests.

For an optimisation study, real plant survey data is used to derive the machine specific parameters applicable to that particular process. A typical optimisation study involves conducting detailed surveys followed by mass balancing and model fitting of the survey data to create a simulation model of the comminution plant in JKSimMet. The model is then used to assess and compare options for optimising plant operation.

For a design study in which the plant does not yet exist, machine specific parameters must be ‘borrowed’ from other operations. JKTech has

established a large database of these parameters suitable for use in most design situations. The model is then used to predict equipment size requirements, recirculating loads and other key operating parameters for the circuit.

Flotation Circuit StudiesSimilar to the comminution methodology, the general form of the flotation model must be tailored to match the specific application required. The model parameters are again split into characteristics of the ore and the machine. The methodology to obtain the model parameters was developed from over 15 years of research conducted by the JK Centre and is constantly updated in light of new findings in flotation research.

For optimisation of existing plants, a survey campaign including sampling, flotation cell characteristic measurements and batch flotation tests is undertaken to determine the floatability of the ore being processed at that time. Using these parameters, the flotation simulation software package JKSimFloat can be used to simulate changes in circuit configuration and operating conditions, ultimately determining the optimal performance of the flotation process stage. The JK Floatability Index test can determine the floatability parameters for different ore types and blends, which can then be used in JKSimFloat for benchmarking and optimisation studies.

For a design study, JKTech has developed a database containing typical cell characteristics for a wide range of flotation cell types and sizes. The database can be used in conjunction with the JK Floatability Index test to predict the optimum circuit configuration and operating parameters for the ore types in question.

Once a model has been developed of the circuit, JKTech’s state-of-the-art software solutions enable users to assess and improve performance with confidence, without the high risk and cost of the ‘trial and error’ approach. This approach has been used with great success in many and various operations around the world.

JKTech is the technology transfer company for the Sustainable Minerals Institute (SMI) at The University of Queensland, taking viable research outcomes and developing them as high technology solutions for application in the global mining industry. See www.jktech.com.au for more details.

Optimising Mineral Processing Plants – the JKTech way

Delivering World Class Solutions to the Minerals IndustryJKTech is the world leader in ore characterisation and process improvement, resulting from technology developed by the Centres of the Sustainable Minerals Institute (SMI) at The University of Queensland.

JKTech provides the global minerals industry with a range of technology, software and consulting solutions, proven to increase mine site profitability via increased plant throughput, mineral recovery and grades.

www.jktech.com.au

Consulting Comminution, Flotation, Applied & Process Mineralogy, Mining and Geometallurgy and Sustainability Consulting

Metallurgical Laboratory ServicesComminution Testing, Flotation Testing,Sizing, Geometallurgical and other Laboratory Services

SMI Knowledge Transfer Training Courses, Professional Development, Workshops

Specialist SoftwareJKSimBlast, JKSimMet, JKSimFloat, JKMultiBal

Specialist EquipmentJK Batch Flotation Cell, JK Drop Weight Tester, JK Rotary Breakage Tester + more

JKTech’s innovative expertise includes:

JKTech Pty Ltd40 Isles Road, Indooroopilly QLD 4068 AUSTRALIATel: +61 7 3365 5842 | Fax: +61 7 3365 5900 Email: info@jktech.com.au

Optimising Minerals Processing Performance

[ 106 ]

From inception, Belminco’s principal focus was mineral processing, and the company offered services from pre-feasibility studies to complete project management.

In recent years, the company has expanded its services to include engineering design, EPCM and structural steel fabrication.

It is now a one-stop-shop offering a wide range of services including everything from basic scoping, metallurgical and feasibility studies to project engineering, fabrication, installation, commissioning and complete management.

Illustrating its skill across the sector, Belminco’s list of recent projects over a variety of tasks: optimization of iron ore beneficiation plant performance, gold project feasibility, metallurgical and engineering studies, diamond recovery plant construction, commissioning and operation, and processing plant commissioning.

Other services Belminco provides include decommissioning and rehabilitation of closed mining operations, and, in the past few years, Belminco has successfully decommissioned and rehabilitated five closed mining operations.

Belminco has now emerged as a major provider of closure and rehabilitation cost estimates, which are a statutory requirement for inclusion in operating budgets.

In recent years, Belminco has become a major structural steel fabrication outlet through its acquisition of West End Steelworks. It now provides structural steel design, fabrication and installation for the mining and commercial building sectors.

The companys client base includes small to major mining and exploration companies as well as engineering and structural building companies.

Specifically, Belminco has enjoyed a long relationship with Dominion Mining. The partnership goes back for than 15 years, with Belminco providing services to a number of Dominion’s operations.

At Dominion’s Challenger site, Belminco operates the gold processing plant and provides technical support, laboratory management and operations, metallurgical support, mechanical and electrical maintenance and supply, and operation of ore handling machinery.

Established in 1992 as a service provider to the mining industry, Belminco has grown substantially and now has the ability to handle varied mineral processing projects across all stages of development

Belminco

Mineral industry consultants | engineers | Project Managers

Phone: 08 9446 1129

Fax: 08 9446 6288

Email: info@belminco.com.au

Website: www.belminco.com.au

Process Engineering •Metallurgical Services•Metallurgical Testwork •ManagementScoping & Feasability Studies•Process Flowsheet Development•

EPCM•Project Costing and Financials•Processing plant contract •managementOnsite Laboratory Services•Technical costing estimate•

Closure costing estimate •Decommissioning & •Rehabilitation Management Contract Crushing•Recruitment•Operator Training•

Optimising Minerals Processing Performance

D otmar Engineering Plastics’ high performance thermoplastics have been proven to replace and outperform traditional metal counterparts such as bronze bushes, bronze bearings, phosporous bronze, stainless

steel sheet & rod and cast iron in a wide range of applications. Thermoplastics such as Ertalyte TX, Uniboard and HPV PPS are chosen for their value added features such as cost reduction, weight, machinability and with the focus on the environment, the argument of recyclability adds to the appeal of using plastics.

Plastics are not only lightweight, they are easy to machine into complex shapes and allow for integration of different materials such as titanium and stainless to create better quality end products. Compared with metals, plastics have the ability to increase part life in un-lubricated conditions, eliminate corrosion and keep heat in or out due to its low thermal conductivity. Dotmar’s high impact strength plastics are cost effective and significantly decrease noise levels and vibration therefore reducing the need for sound insulation and dampening.

Here are a few examples of the Dotmar product range and the benefits of these products over metals:

PEEK outperforms steel in high temperature steam applications •

PTFE performs better in corrosive chemical environments •

PE and lubricated grades of Ertalon offer exceptionally low • co-efficient of friction and are the ideal alternative in high wear and sliding abrasion environments

Machined Nylatron GSM sheaves offer an ideal replacement • to traditional steel sheaves. Weight is reduced, rope and sheave life is extended and the need for lubrication eliminated. The long term cost savings allow the maintenance budget to be stretched further

Bushes and gears machined from Ertalon require no lubrication, • have excellent wear resistance and smooth operation whilst reducing overall noise within the plant

For more information, please visit the Dotmar website, www.dotmar.com.au.

Material Weight

Bronze ø100mm 62.94kg

Stainless Steel ø100 62.80kg

Ertalyte ø100mm 11.85kg

Ertalon 6PLA ø100mm 8.95kg

Make your next engineering

decision a light one.

Plastics do replace metalsPLASTICS DO REPLACE

METAL

BEnEfITS Of PLASTICS OvER METALS:• Lightweight

• Low Density & High Impact Strength • Easily Shaped

• Corrosion & Chemical Resistant• Electrical & Thermal Insulation

• No Lubrication Required• Lower Co-Efficient of Friction

• Longer Wear Life• Cost Effective

• Decreased Noise Reduction

for more information, please visit www.dotmar.com.au/solutions/ and click on Metal Replacement

www.dotmar.com.au • 1800 170 001 sales@dotmar.com.au

www.dotmar.co.nz • 0800 650 750 sales@dotmar.co.nz

Dotmar halfpage vertical ad.indd 1 13/01/2010 4:42:12 PM

While some corrosion problems are so serious they can render operations ineffective, others can be easily remedied. The use of composite materials for the

construction of walkways and other structures, leaves accessways safe and with need for very little maintenance. This means companies can concentrate their time and budget investing in high-risk corrosion issues that have a direct impact on their core business.

To meet this need, engineers are turning to products such as Fibreglass Reinforced Plastic (FRP), as a viable, safer alternative to steel. The replacement of corroded, unsafe flooring has become a huge market for FRP manufacturers.

Perth-based FRP Engineering supplies a large number of these products to the mining sector, including walkway grating, handrails, ladders, access ways, cable ladders, trays and fixings. Their clients are impressed by both the cost effectiveness of the product during its lifecycle and the increased safety factor that it provides.

The strength and corrosion resistance of FRP is related to its glass content, resin content, resin type and method of construction. This unmatched protection is ensured by the manufacturing process in which fibreglass is thoroughly wetted providing continued structural integrity, even in tough environments.

This is, of course, not a new technology. FRP products have been used for over 40 years and have already met the challenges brought by the harsh environmental conditions of mining in Australia. However, in the past, the final decision often came down to a matter of budget which saw steel being selected as a cheaper alternative. More recently, the cost of installing composite materials has reduced dramatically and although metallic components may appear more economical initially, they often end up costing more due to high maintenance and replacement costs.

“Our clients come from all sectors of the industry. Many of them who followed the traditional metallic route in the past are now coming back to us to make the switch to FRP because traditional metals often deteriorate in a few years or less, requiring numerous replacements within the facility life.” says Dirk Bevilaqua, Director of FRP Engineering. “Chemical treatment, washdown and

water treatment areas benefit greatly from the use of our products. Problems where weight is an issue, or there’s an increased risk of corrosion, can be solved by installing FRP componants.”

The use of composite materials is already very popular within the oil and gas industry where they offer superior resistance to corrosive saltwater, drilling fluids and other chemical compounds. The lighter weight of the composites, one-third the weight of steel, provides substantial savings for floating offshore facilities and significantly reduces the lifting requirements during installation.

So it’s not just their corrosion resistance that makes composite products an attractive prospect for the mining industry. There are a number of benefits associated with choosing FRP over traditional metals such as;

Slip resistance - provided by a meniscus top • or permanent grit on FRP flooring products, provides a safer walking surface whether wet, oily or dry.

Flame retardant – most products engineered • to have a low flame spread rating and self-extinguishing properties.

Non-conductivity – composite products • are both electrically and thermally non-conductive, as well as not affecting electromagnetic or radio wave frequencies.

Impact absorption – they can withstand • major impacts with negligible damage.

Low maintenance – corrosion resistant and • do not require scraping, sandblasting or repainting.

Overall, the result is a product that has minimal maintenance requirements, a long service life and a lower life cycle cost than ferrous metals and aluminium.

So, if you are looking to prevent corrosion, improve the safety of your operation, as well as finding a cost effective and versatile solution , maybe now is a good time to consider looking at the benefits of installing high performance composite products?

If you are interested in learning more you can contact the team at FRP Engineering on (0) 8 9455 4343 or at www.frpengineering.net

Corrosion presents a huge problem for mining companies the world over, but in Australia, where extreme environmental conditions play a role, it’s a critical consideration. Reviews carried out by the Western Australian Corrosion Research Group suggest that corrosion creates a significant cost burden to the mining industry, with estimated costs as high as 3% of GDP. In monetary terms several billion dollars per year.

Is Corrosion Eating Away at Your Budget?

Australasian Mining Review 2010: 1st edition

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Plastic & Composites V’s Metal

Belt drive systems are no exception to the technology development process, but how often are they given more than a cursory thought in the design stage of a new process plant? The

motors driving them have to comply with minimum efficiency ratings, the machines they supply power to have to be as efficient in their performance as possible, and on both these fronts the latest and most up to date technology is used. So why is it do we find “design engineers” specifying belt drive systems to power these state of the art machines, that are based on products with 1960’s and older technology? Why will design engineers specify a belt drive that has the potential to be the most inefficient point in the drive system, and not employ simple preventive measures? The answer is mostly cost, but it is also a lack of comprehension of what the drive system has as a total lifecycle cost and what contributes to it. This, let’s say status quo in design of drive systems, is also born from the lack of feedback from plant operators and end users to these design engineers which is a key in causing change in design practices and the development of new products.

Product development is a function of feedback. Successes can be replicated and adapted to enhance designs whilst failures or problems can be ironed out of future designs. Without the feedback there is no catalyst for change. In most cases the designers don’t receive feedback on things as “basic” as belt drives and hence continue to employ the same methods as they have always done.

Take for example a coal handling and preparation plant in the Newcastle region of NSW, serviced by the local Gates distributor CBC Bearings & Power Transmission. The site operates approximately 50 pump drives of various sizes in the plant. The three largest are the Cyclone Feed Pumps. They are 280 kW in capacity and were being driven by 8 x SPC section V-belts. As a set up it is a very common drive, not only in a coal plant but in just about every pumping application in the mining industry. Using a quality belt manufacturer, a planned maintenance program for tension and alignment, it is possible a reliable and 93-95% efficient belt drive can be maintained to run these pumps. This sounds great unless you are the one providing the maintenance. Refer to Image 1 – Belt Drive Tension Adjustment to get a glimpse of the process to tension the belts on one of these pumps. The process is lengthy in time and requires the full effort of at least two maintenance

personnel and the shutdown of the pump and down the line processes.

Even using a set of Gates SPC belts there would be need to tension the belts to maintain efficiency. Due to the nature of the task of tensioning, it sometimes gets ignored and drives are left to run to failure causing unplanned downtime and a rushed change which also leads to more maintenance and more unplanned downtime. To maintain efficiency they need to maintain tension (as the belts stretch over their lives and lose tension) and the drive configuration means it is an awkward task at best.

Are there other means to have set this drive up when designed? Yes, different motor mounts exist but all have their price and add to the total capital cost. This set up is serviceable and will yield the results needed to maintain tension, but with considerable effort and time. Imagine having to adjust tension on this drive 2- 3 or even up to 4-6 times a year depending on the quality of belt you use and how much attention you pay to installation practices. Now magnify that by more than 50 pumps and you’ll understand why tensioning could easily be ignored, or rushed. However this site does follow a proper installation program with their belts and hence the overall lifecycle cost to the plant operator has to take this into account, where the capital cost and design did not.

Lifecycle System Costs in Designing Belt Drive Systems

Image 1 – Belt Drive Tension Adjustment.

PREYS ON MAINTENANCE & DEVOURS DOWNTIME!

Dual Drive 150 kW Cone CrusherOriginal Drive Twin 150 kW MotorsDriver Pulleys 560 mm 6 Groove 8V Section (100 kg)Driven Pulley 630 mm 12 Groove 8V Section (245 kg)Belts 12 x 8V1600 (30 kg)Monthly Tension Adjustments

Predator DriveTwin 150 kW MotorsDriver Pulleys 560 mm 4 Groove SPC Section (58 kg)Driven Pulley 630 mm 8 Groove SPC Section (102 kG)Belts 8 x SPC4000P Gates Predator Belts (19 kg)Yearly Tension Adjustments

Mechanical Savings• 55% Reduction in Drive Weight• 40% Reduction in Drive Width• 5% Increase in Power Capacity• Elimination of Monthly Tension Adjustments

NSW 3 The Crescent, KINGSGROVE 2208 PH: (02) 9150 0206NSW 4/585 Maitland Road, MAYFIELD WEST 2304 PH: (02) 4968 4000WA 789 Marshall Road, MALAGA 6090 PH: (08) 6363 8200QLD 865 Kingsford Smith Drive, EAGLE FARM 4009 PH: (07) 3866 2111SA 479-481 South Road, REGENCY PARK 5010 PH: (08) 8348 2100VIC 174 Fairbairn Road, SUNSHINE WEST 3020 PH: (03) 9313 2000NT Unit 4/Lot 1554 Stuart H’Way, DARWIN 820 PH: (08) 8984 3558

For more information on Gates products call your nearest CBC branch for details:

G AT E S P O LY C H A I N ® G T ® C A R B O N ™

280 kW MeDiuM DenSity Slurry PuMP – COal WaSh Plant

*Based on 24 hours per day, running time for 300 days in a year and NSW carbon emission calculations.

energy Savings*10 amp drop in power consumption29880 kWh* saved per year31.3* tonnes of Green House gasses savedMechanical Savings• No Maintenance• 59% Reduction in weight• 48% Reduction in width• 22% Reduction in diameter

The mainTenance free energy reducing drive sysTem for The mining indusTry.

Enquiries: cbcsales@conbear.comwww.conbear.com

Australasian Mining Review 2010: 1st edition

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Australasian Mining Review 2010: 1st edition

113

and with only a 22% reduction in diameter shaft loads were kept to a comparable level. This significantly reduces the efforts required to install the drive. Also the sprockets will have a much slower wear time and hence have longer lives than the v-pulleys and thus require less often replacement. This leaves the only manual labour in replacing the belt which is only 2kg in weight. However the real success of the system, and the use of this technology, is in the energy savings and associated benefits with it.

Generally the pump will run 24 hours a day and seven days a week. There are scheduled down days for the plant but for simplicity we will assume 300 days a year running time. CBC obtained running data on the v-belt drive (power consumption information from the plant control room) and this was compared to that of the Poly Chain Carbon drive after the change. The manager of the coal handling plant conveyed that an approximate 10 amp reduction was noted in the Poly Chain Carbon drive system when delivering the same amount of output as the v-belt drive. This 10 amp reduction in power draw equated to 4.15 kW of power (approximately 5% of the total power draw of the v-belt drive under the same conditions). For 24 hours a day, 300 days a year, this equates to 29,880 kWh of power saved per year. This power saving generates financial savings in the cost of power (just over $2000 at $0.07 per kWh), and when using the NSW calculation for green house gasses for energy generation it saves 31.3 tonnes of green house gasses being released into the atmosphere. That is one pump and is only being measured at a third of its rated capacity. At full capacity and if all three of these pumps were converted the numbers would be 302,400 kWh of energy savings and 316.8 tonnes of green house gasses. Obviously the more drives that the site converts the more they will save, remember they have approximately fifty pump drives on site.

So, going back to the original proposition of this article, why are design engineers still specifying belt drives using old technology, it is because they do not hear this feedback from the end users of their systems. They require plant operators and end users to say they want more energy efficient drives. They need to hear that the people using their systems want less maintenance requirements to hold drive efficiency at its peak, and they need to hear that their end users want drive systems that last. Ultimately they need to hear about what

has worked in the market so they can adopt it in their designs.

Gates has the belt drive technology to offer drive systems to design engineers that not only eliminate maintenance and give the most efficient drive options, but they can also rate these belt drives to specified hours of operation. They can also set up drive monitoring systems for these drives that warn in advance that the drive is approaching its rated service life and should be scheduled for replacement at the next opportunity. In the case of these pump drives the life of the belt drive could be designed to replicate the life of the pump and when the pump is removed from service and replaced with a refurbished pump, the belt drive can also be replaced at the same time and put back into maintenance free operation and scheduled to be replaced again with the next pump change. A 100% fully reliable pumping system, with maximum drive efficiency and zero drive system maintenance over the life of the pump.

Of course these systems will come at a cost, but when viewed as a total lifecycle cost of the system and not just from the capital expense in designing the system, the advantages and cost benefits will be self evident, along with the lower carbon footprint of the drive system. As energy reductions and carbon trading schemes start to become reality the overall lifecycle costs of a process plant must be considered in the design phase. Plant operators who start demanding that design engineers and project development teams begin to look at all aspects of the overall lifecycle cost of systems and equipment, instead of the capital cost and all too short warranty periods, will be the ones who reap the rewards of those changed design practices. Those that do not will have to retrofit and modify their plants after commissioning and delay the benefits of the use of the latest technologies.

100% maintenance free belt drive systems, guaranteed and monitored service life intervals at 98-99% drive efficiency is a reality. You just have to ask for it.

For more information on Gates Predator and PolyChain Carbon products contact your local CBC branch, or visit www.conbear.com

Article is written by Rob Taranto a Mechanical Engineer with Gates Australia, with over 12 years of belt drive system experience in the Australian market.

> Lifecycle System Costs - Continued

Original V-belt drive

8 x SPC3550 V-belts (15kg)

Driver 315 mm Diameter (40 kg)

Driven 800 mm Diameter (145 kg)

Total width 213 mm

Total weight (200kg)

2.54 speed reduction

New Poly Chain GT Carbon Drive14MGT-3136-90 (90mm wide) (2 kg)

Driver 250 mm Diameter (20 kg)

Driven 625 mm Diameter (61 kg)

Total width 110 mm

Total Weight (83 kg)

Gates have a new construction v-belt called Predator that reduces the need to adjust tension due to stretch. Predator still is functionally a V-belt, however making use of the latest v-belt construction technology; the advanced Predator design means half the stretch over standard Gates belts and the realistic possibility of having to adjust tension only once perhaps a maximum of twice a year on this drive. Predator will reduce the amount of maintenance and downtime associated with trying to maintain peak efficiency from the belt drive and hence the energy consumption of the plant operator. CBC Bearings & Power Transmission use Predator very successfully in helping to lower the costs associated with maintaining v-belt drive efficiency in many mining applications.

However the technology exists today that this pump could be driven using the latest synchronous drive system that would maintain a 98-99% transmission efficiency over its life, have absolutely no need for tension adjustment (as it doesn’t stretch) and will actually reduce the amount of power consumption and green house gas emissions associated with that power consumption as well as the costs of supply of that power. Gates Poly Chain GT Carbon synchronous belt drive systems are the latest in belt drive technology and can be designed in to existing systems and just as importantly “new design projects”.

However unless end users start demanding low or zero maintenance drive systems from their plant suppliers and their project design and management teams, Gates Predator and Poly Chain GT Carbon drive systems, which will lower the overall lifecycle cost to the plant operator and end user, will get overlooked in favour of lower capital cost products like the one on the pump drive above. Your feedback as operators and consumers in the mining market will have the ability to force change in design practices and is essential for change to happen.

To give you real life ammunition for your feedback, read now what happened when CBC Bearings & Power Transmission used Gates Poly Chain GT Carbon in place of the v-belt drive on this feed pump. By only changing the drive system and leaving the drive structure as is, there was no infrastructure change required.

The first thing CBC achieved with the conversion is the massive reduction in drive size. A 59% reduction in weight, a 48% reduction in width

Australasian Mining Review 2010: 1st edition

115

Power Transmissions

T he Australasian Institute of Mining and Metallurgy (The AusIMM) has served the needs of professionals in the minerals industry since 1893. Over time, The

AusIMM has seen its membership grow from several hundred members in Australia and New Zealand to 10,000 members working across the globe. This global network and 117 years of retained knowledge and professional service provides a significant and continuing benefit to AusIMM members and has ensured its status as the leading organisation for professionals in the minerals industry.

Similarly, the backgrounds of AusIMM members have also evolved and diversified as the industry has grown. The AusIMM now represents professionals in all parts of the supply chain, from education to exploration and on through mining, minerals processing, research, remediation, and operational and corporate management. This diversity reflects the industry itself and is a core strength of The AusIMM, making it unique among professional bodies.

In addition to being a source and disseminator of information for professionals in the Minerals Industry, The AusIMM, like other professional bodies, contributes to the maintenance of professional standards within the minerals industry. Through The AusIMM Code of Ethics, members are bound to uphold the highest standards of professionalism and ethical behaviour in all of their activities, thus providing increased certainty for the industry and credibility with the wider community.

The AusIMM assists professionals in developing their skills and competencies through four main means:

• Publications The AusIMM produces a range of publications including monographs, conference proceedings, spectrum series, the bi-monthly Bulletin and the technical journal International Transactions. These publications are produced by industry experts with a focus on technical topics of interest to members. Members receive discounts on all publications, with an increasing number of published papers being made available online.

• Conferences and Events The AusIMM provides a wide range of events, including national and international conferences,

seminars, workshops, site visits, exhibitions and networking functions. Each event is coordinated by a committee consisting of AusIMM members and staff to ensure that the proceedings are of a high technical standard and that the conference meets the expectations of delegates and sponsors. Members receive discounted registration to all AusIMM conferences.

• Networking The core strength of The AusIMM is its ability to facilitate networking and information exchange amongst its members. This occurs on a geographical basis through its Branches and Overseas Correspondents, who conduct at the local level a variety of activities, including technical talks, networking evenings, workshops and mentoring sessions.

Over time, The AusIMM has fostered the development of industry specific groups and eminent societies operating within the broader AusIMM network. Through these professional societies and interest groups, members draw on the knowledge of others to the benefit of their own group and the industry as a whole. Members interact across disciplines and within specific groups.

These networking opportunities and relationships begin at the tertiary student level through the activities of Student Chapters and are nurtured throughout diverse career paths as young professionals achieve Member and then Fellow status.

• Continuing Professional Development Continuing Professional Development is both encouraged and facilitated by The AusIMM. The AusIMM’s Chartered Professional (CP) Program provides opportunity for members to enhance their knowledge, remain up to date and demonstrate their skills and experience by achieving and maintaining accreditation as a CP. This program works in conjunction with the activities above to provide formal recognition for those members who are actively engaged in CPD and education.

As the leading organisation for minerals industry professionals, The AusIMM serves members in a global industry, providing diverse opportunities for professional development and at the same time fostering discipline-specific networks and information exchange. This is the mark of an effective professional body.

By Ashley Van Krieken MAusIMMDirector, Member and Branch ServicesThe AusIMM

The minerals industry is skills intensive, and experienced, motivated professionals are critical to its operation. The ability of a professional to fully meet the industry’s needs depends on several factors – formal education/training, professional experience and Continuing Professional Development (CPD). These factors have a significant impact on the personal success and professional status of the individual and the organisation for which they work.

Getting the best from your professional body

Professional Mining Associations - Education Training & Development

[ 116 ]

Exceeding our customer’s expectation on a daily basis by providing you with superior products and services is the Webforge Philosophy. With faster lead-times, quality controlled

products, engineering and drafting solutions, delivered to you with a friendly and professional manner; it is no wonder why Webforge is seen to be the market leader in providing access products throughout Australasia.

The Webforge Group has in excess of 60 years experience as a specialist manufacturer of metal flooring and allied products to various national and international standards. The company’s origins trace back to Western Australia when William Edward Bradshaw (WEB) commenced hand welded grating in Perth in the 1940’s. In 1968 Web Grating as it was then known purchased a grating welder and began providing the current range of forge welded style gratings we see today. Expansion throughout the next 3 decades saw the company opening up operations in China, Indonesia, Philippines, Thailand, Malaysia, Singapore and New Zealand as well as sales offices in the Middle East and Vietnam. The core business remains Grating and Handrail systems, and is now complimented by Drainage Products, Architectural Sunscreens, Safety Barrier,

Engineering and Galvanizing Divisions. Webforge offers an engineering service in support of its product range, including designs of economically appropriate systems for a particular application. Today Webforge manufactures in New South Wales, Victoria, Queensland, North Queensland (Townsville) and Western Australia as well as having operations in South Australia and 10 other countries with over 500 employees. Throughout its network of operations the company has the resources and experience to service a complete range of projects whatever the complexity or size.

Webforge manufactures and supplies grating and handrail products in steel, stainless steel and aluminium as well as fabrication and supply of FRP (Fibre Reinforced Plastic) grating and handrail. The metal grating products are manufactured in numerous combinations of load bar depth and thickness, load bar pitch and cross rod pitch to meet any application requirements, specification or standards.

Webforge can also assist with your safety concerns by providing a large range of options that will provide a safer working environment. This can be achieved by increasing the slip resistance of the grating with products such as serrated load bars, cleats and abrasive strips added to the grating or just choosing a pattern with 100mm cross rod centres.

Safety Barrier Handrail is another specialist range manufactured by Webforge which enhances work place safety and is also economical, strong and simple to install. Specifically manufactured to suit Australian Standards and conditions it is highly suited to any industrial environments and because of its unique design, the Webforge Monowills Safety Barrier System can be transported and quickly erected. Webforge can supply complete systems comprising stanchions, rails, bends, kickplates, grating and stair treads, galvanised and or painted to any specification for any order. Webforge Monowills Handrail Systems can be used in a multitude of applications including stairways, bridges, parking stations, schools, commercial premises, fire escapes, gangways, power stations, sewage treatment works and marinas. They also meet the requirements of government departments and instrumentalities.

Webforge aluminium grating has grown from what was an option to mild steel products catering to different environment requirements, to a product

that offers a distinctive and versatile design element now featured on a number of leading edge projects. It provides access to a building while being integrated into the overall design of the building.

Webforge Fibre Reinforced Plastic (FRP) grating is a moulded, one-piece fibreglass reinforced plastic grating, available in standard panels or fabricated into panels of the shape you require to fit your floor. The square pattern design with interwoven construction allows the load to be transferred to the adjoining bars providing a superior load-carrying capacity. The high resin-to-glass ratio provides maximum corrosion resistance to a wide range of chemicals frequently encountered in many industries.

The full range of Grating and Handrail Systems are shown on the Webforge website www.webforge.com.au . These ranges should cover the requirements of any customer; however, if other combinations are required, please contact your local Sales Office.

Contacts

Webforge (NSW)73-75 Bassett StMona Vale NSW 2103Phone: 02 9998 1300Email: nsw_sales@webforge.com.au

Webforge (VIC)142-146 Fairbank RdClayton South VIC 3169Phone: 03 8551 2414Email: vic_sales@webforge.com.au

Webforge (QLD)1149 Kingsford Smith DrvPinkenba QLD 4008Phone: 07 3859 8300Email: qld_sales@webforge.com.au

Webforge (NTH QLD)68 Crocodile CresMt St John QLD 4818Phone: 07 4753 1666Email: tville_sales@webforge.com.au

Webforge (WA)24 Tennant StWelshpool WA 6106Phone: 08 9373 5100Email: wa_sales@webforge.com.au

News Flash “SA Branch Now Open”Webforge (SA)7 Senna RdWingfield SA 5013Phone: 08 8169 2350 Email: sa_sales@webforge.com.au

Where Safety and Quality counts for Handrails, Walkways and Metal Flooring

Australasian Mining Review 2010: 1st edition

119

Ramps, Walkways & Metal Flooring

Corrosion Eating Away Your Budget?

2-28 Baile Road, Canningvale Perth, Western Australia 6155Ph: +61 8 9455 4343 Fax: +61 8 9455 4373www.frpengineering.net

walkway grating | handrails | ladders | access ways | cable ladders | trays and fixings

What is FRP?FRP (Fibreglass Reinforced Polymer) are composite mate-rials made of a polymer matrix reinforced with glass fibres.

►Using FRP products the first time around saves time, money and constant repairs.

► FRP products will improve the safety of your operation

► FRP products have superior resistance to cor-rosive process water, fluids and other chemical compounds

Improve the profitability of your operation

FRP products are also:

• Slip resistant • Flame retardant • Non-conductive• Impact resistant • Low maintenance

Structural materials manufactured from FRP have minimal maintenance requirements, a long service life, easier installation and a lower life cycle cost than ferrous metals, alu-minium and other traditional materials.

Safe Flooring Screening Media

Over the last 50 years, Locker Group has developed an intimate knowledge of the Mining and Quarry market, through its involvement in materials handling machinery, screening media and walkway and access products.

Locker Group can offer a number of solutions for walkways, ramps or flooring applications depending on the individual requirements of the site.

GridforgeTM Welded Grating is available in a large range of load bar and cross bar combinations to meet the varying requirements of load and traffic; in either standard panel sizes or fabricated to suit the exact requirements of the installation. Suitable for a multitude of installations, GridforgeTM can be supplied in stair treads with handrail stanchions to suit, and can be hot dip galvanized or bitumen dipped if the environment necessitates.

Locker Group can provide a complete handrail stanchion system to suit your installation; using a combination of standard ball & tube stanchions and custom manufactured angles /bends. Locker Group’s manufacturing facility in Townsville has

extensive experience with handrail systems and will fabricate to your exact requirements, including self-closing gates, kick plates and so on.

Gridforge welded grating and Locker Group’s handrail system are both compliant with AS1657; Fixed Platforms, Walkways, Stairwells and Ladders, offering you peace of mind.

Environments with higher risk of chemical corrosion can take advantage of Locker Group’s FRP (Fibre Reinforced Plastic) grating. Supplied in two alternative resin systems, depending on the particulars of the exposure, FRP Grating is available in either panels or stair treads and can be combined with Locker Group handrails for a total solution.

GridwalkTM expanded metal walkway sheets are ideal for quick and easy installation by a small maintenance team. Available in steel or aluminium, the range offers high open area and strength to weight ratio. The raised profile is also advantageous on small inclines, especially when combined with the appropriate handrail solution.

When searching for ramps, walkways or metal flooring for your site, there are two major considerations; the product & the company.

1. The product you choose must meet the relevant safety standards (AS/NZ1657) so that you can rest assured your OH&S requirements are met and your people are safe.

The product must be the right choice for your environment; exposure to high levels of moisture or salt necessitates different materials or coatings. If the installation has a high incline gradient or high potential for slippage; a product with strong grip underfoot is a minimum.

You want to choose a product you can install and forget, confident it will stand the test of time.

2. The company you choose must understand your business, your objectives and what you value, and be able to provide a total solution; walkway and handrail, pre-fabricated and ready for installation.

Locker Group

The raised profile in either plain or serrated versions of Gripspan® make it ideal for even the steepest inclines. Combining two 300mm wide planks is an easy way to meet the AS/NZ1657 width requirements, while the six metre lengths make installation fast and easy, ensuring minimal down time. Gripspan® is not only ideal on ramps and walkways beside machinery, but is often used to access A/C platforms on building roofs.

Locker Group’s Safe-T-Perf® range is a perforated flooring product, offering a fantastic combination of raised flanges, which provide grip and anti-slip properties and drainage holes ideal for areas with a high propensity for spillage. The combination ensures that even if a large spill occurs, the safe walking surface isn’t compromised. The range has built in flexibility, available in 3 profile sizes, depending on requirements; sheets, planks and stair treads.

In addition, Locker Group can offer a number of screening media solutions, including

Woven wire screens• (hooked or flat); with a very fast turnaround from three strategically located manufacturing facilities around the country

Wire ripple & Poly ripple screens• ; a combination of high open area and increased vibration ensure these screens are ideal for almost any screening environment

Piano Wire or Harp wire screens• ; for high productivity

Wedge Wire• ; a static robust screen, ideal for dewatering

Rubber Cross tension screens• ; ensuring superior impact and abrasion resistance and increased flexibility to reduce pegging and blinding

Moulded Rubber screens• ; for heavy duty applications incurring high impact and heavy load conditions

Polyurethane cross tension and modular • panels; for high wear and corrosion resistance

Full range of complimentary • accessories and fixing systems

Locker Group’s nationwide footprint is unmatched in the industry with sales offices in every major capital city plus locations designed to support the mining and quarry industry, including Townsville and Newcastle. Three

major manufacturing facilities in Australia, supported by company owned international manufacturing operations and external suppliers, ensures Locker Group can provide your site with the ideal product to suit your requirements; while combining delivery and local product knowledge at the right price.

Above: Locker Group woven wire screening

Right: Gridforge grating and handrail solution

Australasian Mining Review 2010: 1st edition

123

Ramps, Walkways & Metal Flooring

2 PROJECTS GUIDE www.outdoordesign.com.au 2www.outdoordesign.com.au

FROM: ODS PHONE: 02 9887 0351 FAX: 02 9805 0748

Dataspec to be placed in ODS#12

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PLEASE EMAIL YOUR CONSENT TO ods@universalmagazines.com.auOR FAX THIS DOCUMENT BACK TO 02 9805 0748

All dataspecs, listings and advertising are to be viewed and checked thoroughly by client prior to press. All care is taken by Universal Magazines, however, the respon-sibility for correct details remains with you, our valued client. Please pay special attention to ensure that your contact details and chapter location are correct. The attached proof is for reference only - it is for you to use as a rough guide. As such the colour depicted on this proof may vary to what will appear in the actual publica-tion due to all computer screens being different. Pics will print as supplied.

RHINO GRATINGCOMMERCIAL WALKWAY MANUFACTURERS AND SUPPLIERS

COMPANY PROFILE:Rhino Grating has been in operation for seven years. We supply a unique product that meets Australian Standard AS1657-1992 and our walkways are both bicycle and wheelchair safe. Rhino Grating is the only Australian supplier of this walkway grating.

PRODUCTS AND SERVICES:Rhino Grating designs, manufactures and supplies:• Heelguard Walkway SystemsWe custom manufacture to your requirements and specifications.

COMPOSITION AND MANUFACTURE:• Galvanised Steel Grating• FRP Grating• Stainless Steel Platforms

RECENT PROJECTS:• Woolwich Dock, Sydney Harbour, NSW• Waverton Observation Deck, Sydney, NSW• Centrepoint Tower, Sydney, NSW• Kirribilli Walkway, Sydney, NSW• North Head Walkway, Sydney, NSW • Sky Tower, Auckland, NZ

SERVICEABLE AREAS:Australia-wide, New Zealand and Asia

CONTACT:Rhino GratingKen Williams21-23 Marshall Court, Altona VIC 3018Ph: 03 9360 3444Fax: 03 9360 3400Email: ken@rhino-grating.com.au Web: www.rhino-grating.com.au

COMPANY PROFILE:

Rhino grating has been in operation for over 7 years, we have offices in three countries and our own manufacturing facilities in Australia and overseas, we are also 100% Australian owned and operated. We meet or exceed Australian standards AS1657-1992 for elevated walkways and Galvanizing standard AS4680 for Hot Dip Galvanizing.

PRODUCTS AND SERVICES:

Rhino Grate will design and manufacture your walkway to your unique specification in CAD by our highly qualified engineers.Whether it be:

Forge welded galvanized steel •

FRP panels•

Aluminum platforms•

Full range of galvanized stanchions•

We will cut, band and deliver to meet your requirements anywhere in the world.

COMPOSITION AND MANUFACTURE:

Galvanised Steel Grating•

FRP Grating•

Stainless Steel Platforms•

RECENT PROJECTS:

Lihir Gold mine Papua New Guinea •(For RIO TINTO)Pohokura oil platform•

ESSO Bass Strait Off Shore platforms•

Sydney tower Tourist platform•

Melbourne international Airport•

Townsville coal conveyers and bulk •loaders

SERVICEABLE AREAS:

Rhino Grating can supply and deliver throughout Australia, New Zealand and the Asian region.

CONTACT US:

Rhino gratingKen Williams1300763745+61 3 93603444www. Rhino-grating.com.au

RHINO GRATINGCOMMERCIAL WALKWAY MANUFACTURERS AND SUPPLIERS

100% Australian owned

and operated

When threatened with fire, the heat and smoke builds fast. The fire often takes hold very quickly and with little notice. Occupants need to feel safe before a fire

ever happens. They need to know that they have methods for escaping safely and by having these methods in place and by being properly trained in how to use them, occupants can comfortably go about their business in high situations whether in buildings or on large machines. With any egress system the main issue therefore is the fight against time. Those who find themselves suddenly trapped in a building or machine will as often or not, have much time to spare. This could be due to fire, bomb threats, earthquakes or indeed any life threatening emergency.

The need for The Ingström Escape Chute in these situations is paramount. The Ingström Escape Chute is a highly versatile system that specialises in the safe evacuation of people from high situations during emergencies. No matter what their physical capabilities, the Ingström Escape Chute can allow safe passage away from the ensuing emergency, safely to the ground. It will provide the fastest and most efficient means of controlled, safe exit from any hazardous environment.

The Ingström Escape Chute has the remarkable capability of conveying up to 30 persons per minute from any storey to safety. The system allows children and handicapped people, aged, infirm and even people strapped to stretchers to escape quickly and safely from a hazardous environment.

What makes the Ingström Escape Chute so versatile and functional is that the Chute comprises of three separate layers. The outer layer provides a shield from heat and fire to the occupant egressing away from the dangerous situation. The middle layer is comprised of an elastic material that ensures a safe and as far as is possible in these situations, a comfortable, controlled descent. The inner layer is made from a Para-Aramid material for tensile strength which makes our chute capable of handling multiple evacuees.

The Escape Chute is extremely flexible and is individually tailored to suit the specific need.

The three main installation applications of the Ingström Escape Chute are :

Internal - multi-storey chute systems provide an • entrance on each floor of a tall building.

External - stored in an external container fitted • with quick release mechanisms.

Portable -; mounted on a cherry picker, • hydraulic ladder, boom or similar extension device

Why mine managers are increasingly deciding to install a chutesThe first unit specifically designed to cope with the rigours within the mining industry was installed on a P&H 4100 shovel at the then Lemington Mine, now part of Hunter Valley Operations, Coal and Allied.

Since that first installation, the mining industry in New South Wales has continued to recognize the benefits of the system and now we estimate that 80% of open cut mining operations in the Hunter Valley area have installed an Ingström Escape Chute on their diggers.

We have made promising inroads into the mining industry in Queensland where, to date, our system has once again recently proved itself in the safe evacuation of an operator in an emergency situation that involved a fire on a machine. Knowing our emergency evacuation chutes constantly help save lives and make mine sites safer is a great source of inspiration for us as we continually strive to improve our products.

How the escape chute works.Below is a case study of how the application of an Ingström Emergency Escape Chute, which was originally designed for evacuation from buildings in Scandinavia twenty years ago, has proven itself recently in a mining equipment fire;

In 1998 an Ingström Escape Chute was installed of onto a 540 tonne Hydraulic Shovel. This chute proved its’ effectiveness to the mining industry in Australia when at a Hunter Valley (NSW) mine in October 2000 there was a loud explosion on board the large shovel. This had occurred not long after the shovel had been fuelled and greased. Immediately following the explosion a fire started which very quickly took hold and burnt through the two engine compartments as well as the operator’s cabin.

The operator had no chance of exiting the vehicle as he soon realized that the fire blocked his escape route via the cabin door. The operator was able to kick out the cabin window so he could simply step out onto the side platform where the Escape Chute had been fitted in the handrail.

By activating the chute container and entering the chute, the operator was safely on the ground in less than 20 seconds. With a height of 5 metres from the cabin (and therefore the chute) to the

ground his only other option had a chute not been fitted would have been to attempt an uncontrolled and hasty jump! The operator made a statement after having evacuated through the chute, away from the burning machine. He said, ” I could feel the heat of the fire as I travelled down the chute but felt very comfortable and safe.”

One of the major components used in the construction of the chute material is PARA-ARAMID. This gives the chute it’s strength and durability and has proven to be a tough, reliable fibre combined with the other components of the chute material in fire affected environments.

Incidentally the explosion and fire were so fierce that it took the rescue crew 6 hours to extinguish the fire on the shovel. After examination it was found that the chute material had withstood the extreme heat of the diesel fire exceptionally well, even though it was used well before the fire had fully reached it as is normally the case in these circumstances.

It is a credit to the mine management, who had the foresight to have the escape system installed, that the operator was not killed or badly injured had it been necessary for him to jump the 5 metres from the platform to the ground.

The Ingström escape chuteThe world’s most efficient emergency evacuation system

Australasian Mining Review 2010: 1st edition

127

Safety in general

Our range of Class 5 protectors:

VARIPHONE HEARING PROTECTOR

Ear-O-Tec is the licensee for the unique Variphone adjustable hearing protection device which offers comfort, durability, affordability and adjustable attenuation levels. The unique two-canal design of the Variphone allows for fast and effective quality controls and regular check-ups. The adjustable valve allows the attenuation to be set to reduce the noise load to a safe level within 1dB accuracy.

After an ear inspection an ear impression can be made for the manufacturing of an individual Variphone® hearing protector. A second visit by a technician is necessary for the fitting procedure and fulfilling the standard quality controls. Each device will be leak tested and fitted in the ear of the wearer. Attenuation is then adjusted according the each individual’s exposure levels as indicated by safety staff.

AccessoriesEvery Variphone® hearing protector will be • delivered in a durable storage pouch together with a detailed instruction leaflet, cleaning cloth and earwax remover.

Adjustable attenuation valve (1dB increments to • allow communication)

Durable acrylic•

Comfortable: custom made•

Various comfort and colour options•

On-site impression taking, fitting and training with • limited down-time

Easy maintenance•

Environmentally friendly•

Verified in the wearer’s ear•

Adaptable to communication system (Varilink)•

Australian made•

Annual monitoring $ 73.00 •

Access to central database•

Cost: $320.00 (volume discounts apply)•

Complies with AS/NZ 1270:2002 standards•

Noise-ClipperEar-O-Tec is the licensee for this unique product • that offers extreme durability, accountability and

accuracy. This design allows the device to be leak tested and have the advantage of calibrated filtering options.

Fixed attenuation ranges between 20 to 35dB • filters

Durable acrylic•

Comfortable: custom made•

Various comfort and colour options•

On-site impression taking, fitting and training with • limited down-time

Easy maintenance•

Environmentally friendly•

Annual monitoring suggested for leak tight checks•

Cost: $270.00 (volume discounts apply)•

Accessories

Every Noise Clipper hearing protector will be • delivered in a durable storage pouch together with a detailed instruction leaflet, cleaning cloth and earwax remover.

Complies with AS/NZ 1270:2002 standards•

Insta-Mold Product (made on the spot!)Ear-O-Tec can also provide Insta-Mould product • which can be made on the spot and clients can take their finished custom earplug with them on the same day which saves the client time and money.

The products are hypo-allergenic, non-toxic and non-shrinkable with a proven protection according to AS/NZ1270:2002 standards.

HYPO-ALLERGENIC • NON-TOXIC • NON-SHRINKABLE • PROVEN PROTECTION

V-Sil soft hearing protectors

For those clients where hard acrylic devices are contra-indicated, we offer the V-Sil with calibrated, fixed filters. This is a high-quality silicon product which offers high durability.

Transparent or blue•

Optional cord•

Selective Filter•

Comfortable (custom fit)•

Durable, quality silicon•

Cost: $ 310.00•

More people within noisy industry sectors recognize that merely providing a baseline hearing test and disposable hearing protection is perhaps not the best solution to the prevention of noise-induced hearing loss in the work place.

Therefore Ear-O-Tec has a range of custom made, verifiable products available to suit all industrial workplaces. We now have names such as Variphone, Noise Clipper, Sensear, Insta-Mold and Varicom in our selected range of products. Our network of qualified technicians deliver all services on-site to guarantee minimum down time.

Ear-O-Tec Pty Ltd:

info@earotec.com.auSafety in general

Each of our clients has unique needs and is operating in unique environments. In order to provide health services that meet the needs of both, JTA undertakes initial

assessments of the following: client requirements; operating environments; existing services; and the disease burden of the area. Based on this evaluation, we provide a range of health services options for discussion with the client. This range of services extends from hospital management, clinical service delivery, community health program design and implementation, baseline health studies and health impact assessments and occupational health and safety.

Many resource operations in the Australasian region are located in remote and challenging environments where the capacity of existing health services can be low and unable to meet the expectations of international companies. JTA is experienced in negotiating partnerships between the local health service providers, often the relevant nation or local level government, and resource companies.

These public private partnerships increase the chances of sustaining improvements to existing services while ensuring the resource company

has access to the standard of health services it requires. We have successfully negotiated partnerships in difficult environments, such as Papua New Guinea, where relationships between mining operations and the government and local communities can be challenging.

Reduced risk from epidemics and communicable disease in the workforce, improved sustainable social and economic development in mine-affected communities and enhanced social licence to operate are all objectives of JTA’s approach to supporting the health needs of our resource sector clients. This approach has proven beneficial to all involved – it supports the public sector in improving health service delivery, the private sector can know it has contributed to sustainable health development within the communities in which it operations.

JTA International (JTA) has been providing specialist health services support to resource operations throughout the Australasian region for a number of years. A health consulting and project management firm, JTA has been supporting mining operations to ensure the health of their workforce and the communities in which they operate through the provision of clinical services and sustainable community health solutions.

JTA Mining and Industry an Overview

Our Consultants have the skills to critically examine your safety management systems (SMS) and identify gaps within SMS and provide practical, cost effective

solutions to overcome these shortfalls.

MACSS advisors will work with your current staff through coaching and mentoring and guide them to improve upon your safety performance to a level that not only meets your legal and moral obligations but one that far exceeds your expectations which will ultimately improve your business bottom line.

We will identify your relevant legislative requirements and ensure your systems are developed to allow compliance can be achieved within your organisation from a safety management perspective. Provision of legislative and specialist auditing services

We are confident we can work within any environment in any country in the world while still providing the same high level excellence of service that MACSS are renowned for in Australia.

Our strategy is simple:

We identify what your organisation wants to • achieve through your engagement;

We examine your organisations current safety • management systems;

We identify gaps and opportunities for • improvement; then

We work with your people to develop a • practical and cost effective solution to lift your safety systems to a level that far exceeds your expectations.

MACSS consultants are hand picked specialists from various industry sectors and have expertise in all areas of safety and environment management systems including but not limited to:

Underground Mining•

Open Pit Mining•

Processing•

Construction (Major Projects)•

Electrical•

Environmental•

Critical Incident Investigation•

Project Mobilisation•

Risk Management•

Legislative Systems Mapping•

Web Based Safety Management System • development

MACSS Consultants are dedicated safety professionals who have experience and knowledge in all aspects of Mining, Construction and Petroleum safety system development as well as specialist advice in metalliferous and coal industries in open cut, underground and offshore environments.

M.A.C.S.S.Consultants

Australasian Mining Review 2010: 1st edition

131

Safety in general

Access Environmental Systems design, manufacture, install, commission and service Coolfog™ systems, ensuring airborne dust particles are dramatically reduced on your site.

Whether it’s Unloading Hoppers, Impact Crushers, Jaw Crushers, Cone Crushers, Conveyor Transfer Points, Vibrating Screens or Finished Stockpile Chutes, Coolfog™ will manage and suppress dust better than any other system on the market.

Coolfog™ systems are able to be designed with up to 8 individual fog zones in mind per control module. These zones are then all operated by a remote control system. The transmitter is installed in the main operator control room of the crushing plant, while the receiver is installed at the interface and zone solenoid valves enclosure to give the customer complete control of the fogging system. This means the customer can operate any combination of the zones independently of each other or all the zones together.

How does Coolfog™ work?

Coolfog™ pressurises water to 1000 PSI, through uniquely designed nozzles, producing minute

water droplet particles (fog) that evaporate into the atmosphere, thus reducing temperatures by up to 7 – 15 degrees Celsius in working environments like foundries, waste transfer stations, factories, workshops and other building enclosures.

Similarly, this output of water fog when installed on quarry sites encapsulates the dust particles making them too heavy to remain airborne, thus suppressing the dust particles safely downwards with the product or to the ground when installed in unloading hoppers. The crushing equipment and conveyor belts do not become over wet as with conventional methods causing belt slippage and excessive stockpiles forming under the conveyors from the scrapers.

The system is installed using high pressure nylon tubing and push fit fittings. There is no need for any crimping tools.

Coolfog™ reduces the risk of dust particulates entering adjoining industrial and residential properties creating a healthier environment for all employees and neighbours.

Access Environmental Sys-tems offers new technology with solutions for dust control. Coolfog™ provides answers to managing dust on site. It has been installed extensively throughout Australia and overseas and adopted by Australia’s largest Municipal Authority, Brisbane City Council.

Providing dust suppression solutions for the Quarry and Mining industry

…The New Safe Alternative to Suppressing Dust in Quarries and Mining Environments..

• Dust Suppression• Odour Control• Temperature Control• Humidification• Special Effects

Access Environmental SystemsPhone: +61 7 3881 3262

Fax: +61 7 3881 3265

Free call: 1800 FOGGING (Aust only)

sales@coolfog.com.au www.coolfog.com.au

The DrugWipe Drug Detection System is a rapid, efficient and reliable test for the detection of drugs in saliva. This enables the detection of current and very recent drug use “that is the drugs

that are in the system now”. The DrugWipe device can be used for random, on suspicion and/or for cause testing as is outlined in a company Drug and Alcohol policy.

Saliva testing reduces testing time, is user friendly, sampling is less intrusive. The technology uses a lateral immunoassay approach. Sampling is achieved by a single wipe of the tongue (only 10µl of saliva required) and a result is read within ten minutes. A control line validates the procedure has occurred correctly. No instrumentation is required, providing flexibility to perform drug testing at any location. DrugWipe may also be used to detect drugs on surfaces and sweat, offering you versatility of sampling and detection.

Single-, Twin- or 5-drug devices are available for Cocaine, Opiates, Cannabis, Amphetamines, Methamphetamines (including Ecstasy) and Benzodiazepines.

Pathtech offers support and training in the use of the DrugWipe devices. We follow the Australian Standard Procedures for Speciment Collection and the Detection and Quantitation of Drugs in Oral Fluid (AS4760-2006).

Pathtech Drug Detection Systems specializes in drug detection and are the Australian and New Zealand supplier of Securetec Detektions Systeme AG.

Contact us today, so we may share our experience with the application of drug screening within your workplace.

Pathtech Pty Ltd Drug Detection Systems

Phone. 03 98480 3500 or Toll Free: 1800 069 161

Email: drugwipe@pathtech.com.au

Web Page: www.pathtech.com.au

Workplaces across Australia are using the DrugWipe® device to detect the presence of drugs as part of OH&S procedures. With the advent of saliva testing for drugs, testing is now simplified and made it less invasive to screen for the presence of drugs within the workplace. In implementing drug screening within a workplace, employers are looking to create and provide a safe workplace for all employees, focusing on encouraging a “fit for work” environment.

With just one swipe you can detect the silent, unseen presence of drugs

in your workplace

we

det

ect

to p

rote

ct

Introducing the New Improved DrugWipe® 5+ DeviceThe image above shows a Cannabis positive result (CA line) and the control lines (CL) respectively

DrugWipe® 5+ from Securetec

For the detection of✓ Cannabis (delta9-THC)

✓ Amphetamines

✓ Methamphetamines

✓ Cocaine

✓ Opiates

Detect Drugs in Saliva• Easy To Use Rapid Test

• Detects Current and Recent Drug Use

• Suitable for Random and/or Point of Incident Screening

• Simply Wipe Down the Tongue, Minimum Sample Volume, Less Than One Drip, No Handling of Saliva

• Results in 10 Minutes

• Visual Reading, No Instrument or Computer Required

• Flexibility For On-Site and Off-Site Screening

Pathtech Drug Detection Systems • phone 03 8480 3500 • e-mail drugwipe@pathtech.com.au • www.pathtech.com.au

Australasian Mining Review 2010: 1st edition

133

Safety in general

Prior to inception Integrity Sampling researched various methodologies for alcohol and other drug testing. They established, following their extensive review, that the Cozart drug detection

systems were the worlds leading onsite testing technology to establish recent use of drugs.

Whilst Integrity Sampling’s independent review clearly establish their chosen systems as being the worlds leading technology it has been most pleasing for them in more recent years to have their review vindicated by all mainland Australian Police Services and other safety orientated regulatory authorities. In their independent evaluations these agencies were assisted by State Forensic Science Laboratories and other expert consultants.

Being independent Integrity Sampling are able to effectively implement and manage Drug and Alcohol Management Programs (DAMP) in any workplace ensuring privacy and confidentiality for staff and others in accordance with the requirements of National Privacy Legislation.

Integrity Sampling’s services usually commence with assisting clients develop a workable “Fit For Work” (Drug and Alcohol) Policy and/or Procedure. They can then assist with education in respect to the clients policy and procedure and the health implications of alcohol and other drug misuse to staff and/or contractors if required.

Following this phase Integrity Sampling provide a 24 hour, 365 days per year testing and advice service nationally. This includes testing following a safety or other significant incident (incident testing), if an employee or contractor is suspected of mis-using alcohol or other drugs (cause testing) and to ensure a deterrent is maintained within the workplace regular random testing (random testing).

There are numerous benefits to be gained from using Independent Accredited Technicians for workplace drug and alcohol testing. The main benefit is that privacy and confidentiality can be maintained. It also removes any perception of employer bias towards an individual employee or contractor. The random selection process, establishing those to be tested, can be undertaken using a variety of methods which meet employer and workplace representative satisfaction. The important safety net is that the employer should not play any part in the selection process. It is strongly recommended the selection process be

undertaken by the independent Integrity Sampling Accredited Technicians.

Integrity Sampling believes, as do their customers, ranging from government business enterprises and multi nationals to small or family owned businesses, that they offer professional, cost effective, accountable and fair Drug and Alcohol Management Programs particularly so far as the workplace is concerned

Integrity Sampling is Australia’s most experienced independent oral fluid (saliva) based “alcohol and other drug” testing agency. Integrity Sampling commenced operation in 2002 after an approach from one of Australia’s leading transport and logistics companies. They provide the complete solution for Drug and Alcohol Management Programs (DAMP) within the workplace which existing clients and feasibility studies suggest actually save money.

Integrity Sampling “…because recent is relevant!!!”

Advice

Safety - Drug & Alcohol Testing

The Australian-owned, pan-international Freightplus group is enjoying remarkably robust year-upon-year growth, despite a reported 90% plunge in the movement of mining machinery into Australia during

the global economic meltdown. John Gleeson, Australian CEO and founding partner, attributes this in part to a growing number of mining companies shifting the care of their machinery movements to smaller, very specialised service providers. “Over the last decade, we have regularly bumped heads with local logistics giants and foreign-owned multinationals in our efforts to gain business within the Australian mining sector. There had long been a perception that a company employing 20,000 people in 30 countries was the best option for managing challenging movements of very valuable machinery, despite their core business often being far removed from this, be it high volume container shipping, express parcel deliveries, port management or some other focus. Conversely, every Freightplus employee is 100% focused on moving mining and construction machinery.”

Ironically, during the same period, overseas mines from the Far East, Africa and Central Asia were moving away from the giant ‘one-stop shops’ and engaging niche operators like Freightplus to move their heavy equipment from all over the world. What this has meant for Freightplus is profitable business across multiple continents, exponential growth and a healthy balance sheet. For Australia, it means a steady flow of foreign dollars coming into the local economy.

“Although we have always enjoyed a strong following from heavy machinery importers in Australasia, we have often missed out on opportunities within the mining sector because of a somewhat understandable perception that a small Aussie-owned company couldn’t match the capabilities of a company ten or twenty or a hundred times our size”, Gleeson continues. “Fortunately, this perception is slowly changing and those responsible for getting the right machinery to the right place at the right time are beginning to recognise the value of partnering a tight-knit, dedicated and experienced team”.

Right from its inception as a two-man operation in Sydney a little over ten years ago, Freightplus has focused exclusively on the international movement of heavy machinery. The company now has offices in Sydney, Brisbane, Fremantle, Osaka, Yokohama,

Atlanta and Bremen and an extensive network of exclusive agents all over the world. Every Freightplus office is manned jointly by local and Australian expat personnel, a winning combination according to Gleeson, whose founding partner, Steve Townsend, now heads Freightplus’ operations in the U.S., the organisation’s largest market. The company’s founders take great pride in the fact that profits from their offshore ventures are being returned to Australia, where Freightplus donates a minimum of 10% of its profits to local community groups and charities.

Freightplus originally established an offshore presence to satisfy a need for cost-effective, pre-shipment AQIS quarantine compliance for the large volume of used machinery coming into Australia. It was logical, therefore, that the organisation set up bases in the locations where most mining machines originate – USA, Europe and Japan. Local demand for the company’s forwarding services in these markets grew as it earned a reputation for its expertise, reliability and integrity. With multilingual crews managing an extensive range of door-to-door services, from pre-purchase machinery assessments and pre-shipment AQIS compliance inspections, right through to delivery at Australian mine sites, the company’s international capabilities have grown from strength to strength, as has its ability to compete against the largest of competitors.

“It’s a common misconception that the largest companies will offer the most competitive pricing”, Gleeson continues. “Freightplus has top tier shipping contracts with the major carriers serving the Australasian market. By managing ancillary services like trucking and lifting with carefully selected and closely scrutinised service providers, each expert in their respective fields, rather than owning a fleet of expensive trucks and cranes and buildings, we enjoy the economic efficiencies of a variable cost structure without cumbersome fixed overheads.”

To learn more about Freightplus, please visit www.freightplus.com or call John Gleeson personally, on 0414 980 380.

Moving resources for mining resources

Freightplus

www.freightplus.com

International Freight for Heavy Machinery

Brisbane + Sydney + Fremantle + Kobe-Osaka + Yokohama + Atlanta + Bremen

Transport

[ 136 ]

Whether it’s providing specialized service vehicles and accredited personnel on long term hire to build 300km railway lines in the Pilbara for new mining ventures,

overseeing and supplying large quantities of tyres for national extractive contracts, assisting with sales or service on infrastructure projects in the coalfields of QLD; or simply managing customers supply and service requirements for small civil construction projects in Victoria, Giant Tyres has the capability and experience to ensure customer satisfaction in all aspects of OTR (Off The Road) tyre supply and management.

From humble beginnings many years ago working with a single vehicle servicing a small number of customers, Giant Tyres has expanded to a size where they currently manage Goodyear’s warehousing and distribution requirements for South Australia, Victoria and Tasmania, operate a fleet of modern service vehicles throughout Australia and are strong contenders for large national supply and service contracts.

Whilst Giant Tyres has obviously developed an extensive sales division, emphasis was placed during the formative years on providing unparalleled service to their growing number of customers, irrespective of the size of the company. Their philosophy has not changed since those early days. As such, they now pride themselves on offering what they believe to be one of the most complete, knowledgeable, cost effective and diverse range of supply options and on-site services in Australia.

Owner and Managing Director, David Judd states “it has taken many years to learn the assorted range of skills required to operate successfully in our industry. Work ethic certainly brought many unsatisfied customers from other organizations to our company. I recognized however, that I needed to learn as many of the tricks of the trade as I could to give me an increased edge against the more established companies. As we continued to grow, I also realized that our company needed an experienced operations manager who complemented my own skill base. We were obviously excited when David Danskin; formally of Tyre Lug Services and with approximately 20 years experience, finally agreed to join our team as that manager. We’ve now reached a level where it gives all of us a high degree of satisfaction when opposition tyre companies

request our advice or services to complete their duties. I am also personally delighted when mining companies request independent advice on resolving operational issues, or appeal for assistance on purchasing the most appropriate tyre. Shows we’re taken seriously! We probably punch above our weight when competing with the huge multi-national corporations, but we’ve been doing that for years. We’re consistently gaining market share, so I guess we’re on the right track.”

To continually improve efficiencies within their service division, they are constantly exploring, monitoring and informing customers on an on-going basis of new or innovative technologies to assist in lowering their operating costs. “I don’t care what industry you’re in, you still have to prove your worth to the customer on a regular basis. Otherwise they’ll go elsewhere. Customers will keep on coming back if they know you’re always trying to do the right thing” says David.

Whether it’s fitting or adjusting tyre chains on huge front-end loaders, supplying cutting-edge product in recycling yards, advising site personnel around the country of the increased benefits of tyre additives and nitrogen inflation, managing rim registers for customers machines to adhere to existing OH+S regulations, analyzing potentially-effective new product or simply liaising with customers to organize routine maintenance; all of these tasks fall into the normal sphere of daily operations for Giant Tyres. They maintain that all facets of the OTR industry need to be constantly monitored, addressed and serviced for complete customer satisfaction.

However David warns, “Our industry has seen some pretty amazing and sometimes worrying developments over the last few years during the previous mining boom. Extreme tyre shortages, the explosion into our marketplace–sometimes literally--of cheaper Chinese, Indian or Russian tyres, the ridiculous prices customers were forced to pay for product from a small number of extremely greedy suppliers; all of these factors impacted on our core business. Now that the mining industry is on the rebound, many customers will face similar issues. I urge all mining, extractive and civil construction companies to closely review their relationships with their tyre suppliers. If they were happy with their performance during the last mining boom/ tyre shortage, let them know in advance of potentially increasing requirements, inform them of projected new machinery so that

the correct tyres for their application can be ordered, supplied and fitted, and build a stronger relationship with them. If they weren’t, find another one. Don’t wait or it could be too late!”

Giant Tyres is taking their own advice and reviewing many of their own supply agreements with core manufacturers to cater for the expected increase in sales over the next few months. “We are looking at many of the same issues with our own suppliers. We constantly do.” says David. “Fortunately, we have excellent support in both supply and pricing from most of the premier suppliers in the industry including Goodyear, Yokohama and Michelin for new tyres; Titan Australia for wheels and Tyre-Lug Services for relugs and repairs. For a competitive edge, it’s pretty hard to beat that combination! We’re extremely happy having these companies on board fulltime. We also have arrangements around the country with other like-minded companies so that wherever our customers are working, we can organize safe and effective repair and servicing of their equipment.”

In conjunction with supplying “name brand” tyres, Giant Tyres is constantly exploring and analyzing alternative options. “It’s a fact of life that many customers in a depressed market haven’t been able to afford purchasing premium quality tyres. In the past, we have been extremely cautious about the flood of supposedly cheaper product that’s been introduced into our market. We’ve certainly experimented with small quantities of various Chinese-manufactured tyres at selected sites over the years. Almost all have failed miserably, either from tyre failure or poor tyre wear. Tyre warranty was non-existent, manufacturer support was pathetic,” says David. “Realistically, the only concern these manufacturers had was selling as

much product as possible. They didn’t really care if it worked or not. Many distributors in Australia were left with egg on their face. It also cost us a lot of money to compensate our customers for this under-performing product.”

“As such, our view has been that until somebody could prove that their product worked reasonably effectively, or provided realistic value-for-money, we wouldn’t be involved. We didn’t want our reputation tarnished by being involved with rubbish. Recently however, we have found what we believe to be a good performing, price-effective tyre that is a viable alternative for customers looking to achieve savings on medium usage machinery. Whilst I still believe that customers should purchase premium quality product for machines that are being aggressively used, consistently over-loaded or working in extremely harsh conditions, this alternative cheaper product is a viable option for many customers. It’s taken 18 months for us to be convinced, but we now have good site data, have independent analysis and we have the photos showing machines fitted with this product working in a “real” environment to show to prospective customers. Significantly more important from our perspective, we’ve known the parent company for a while, trust them and are looking forward to being involved with further development of this product.”

“There are also some innovative new products coming on-line for specialized applications in the near future. Excellent savings can be achieved for the customer in these markets. We’re enthusiastic about this potential and are also looking forward to assisting with further development of these products with the manufacturers. I don’t think it’s an understatement to say that the next couple of years are going to very exciting for our company”.

Giant Tyres

Above: working in the Pilbara --westren australia

Above: routine tyre chain inspection in Victoria

Left: crossing the nullabor en-route to a mine site

Contact details: Office Ph: 03 8761 6444 Fax: 03 8761 6555

David Judd - Managing Director 0418 334 886

David Danskin - Operations Manager 0417 152 333

Scott Cromb - Business Development Manager 0418 382 229

Australasian Mining Review 2010: 1st edition

139

Tyres, Wheels & Valve Systems

Jewell Tyres trade in the off-the-road (OTR) tyre industry, mainly in mid size earthmover, mining, logging, industrial and agricultural tyres.

My business is providing a search, purchase & sales distribution network for OTR Tyre businesses & users in new

& second-hand tyres & service provision.

I source tyres, buyers or service providers using an extensive email address book & real-time communication network, linked to a custom built data base, multiple websites & OTR distributors.

Service, reliability, backup & price are the guidelines for operating the business. The business is small, specialist & discrete, where your business information, confidentiality & time matters.

If you have a current list of “tyres for sale” or a list of “tyres wanted to purchase” I would appreciate the opportunity to use my system to try to assist you.

I try hard to provide personnel service & satisfactory results.

Company Details:Keelangie Nominees Pty Ltd, trading as Jewell Tyres

Call 02 60241910 or 0419 358439 and speak with me directly.

Fax 0260 568 039

tyres@jewelltyres.com.au www.jewelltyres.com.au

Thanks for your interest & attention,

David (DG) JewellManaging Director – Jewell Tyres

Jewell Tyres

TyresJewellP : 02 6024 1910

M : 0419 358 439

www. jewel l ty res .com.au

As an ISO 9001/2000 certified company, Haltec’s Quality Policy is to lead the tyre valve systems industry by meeting or exceeding industry standards and customer requirements.

Haltec’s on-site engineering and custom design is complemented with a state of the art machine shop, soldering, fabrication, custom-bending and product assembly services.

Haltec has refined a global network of distribution channels and continues to grow sales to its target markets. Quite simply, any size, shape, quantity and design of valve required is the Haltec Corporation daily charge.

Haltec has added a new mega bore valve with core housing to be used with the IN-95 Inflator. The IN-95 maximizes the air flow by removing the housing during inflation and deflation, similar to the Super Large Bore and Z-Bore.

Haltec has also added to their product line, the “89XTC” temperature compensating tyre Inflator and “TYRECHECK”, the most extensive, integrated vehicle data management system.

Vehicle inspection data is uploaded electronically to your system through the use of Bluetooth Technology for maximum accuracy and timeliness. “TYRECHECK” gives you the information you need when you need it so you can make the best decisions possible to protect your investment. Call us for more information.

Estry Trading Company (established in 1974) has been associated with Haltec Corporation since 1977. As an authorized Distributor for Haltec products, Estry Trading Company services Australia and all South East Asian-Pacific countries including China, with quality guaranteed Haltec products. We work closely with Haltec to provide our customer base with only the best service and support.

See our website www.haltec.com.au and our links to Haltec Corporation USA www.haltec.com for access to the Haltec Product Catalogue. We can also mail out the Haltec Catalogue, just give us a call on PH: 61-7-33764155.

Email: estryadmin@westnet.com.au

Haltec Corporation is recognized worldwide as a leading manufacturer of specialty tyre valve systems and hardware.

Haltec was established in 1970 and maintains its corporate headquarters, manufacturing and distribution services in Salem, Ohio, USA.

Haltec Corporation

AustrAliAn & south eAst AsiA pAcific distributors

ESTRY TRADING COMPANY haltec.com.au 1300 HALTEC (425 832)

looking for hAltec

tyre equipment? trust estry to deliver.

Haltec tyre valve systems and equipment is known worldwide for its quality and reliability.

At Estry, we have been supplying genuine Haltec parts to Australia and South East Asia Pacific for over 30 years.

We stock a complete range of tyre valves and accessories to suit every application, plus we’re trusted experts

in producing customised equipment for your machinery. We pride ourselves on our unbeatable personal service and after-sales support, which means we can help you

reduce downtime and increase your bottom line.

So if you’re after quality tyre equipment, think Haltec, and talk to Estry.

ETC0010_AMJ_half_page.indd 1 25/1/10 10:06:53 AM

Australasian Mining Review 2010: 1st edition

141

Tyres, Wheels & Valve Systems

RIMEX is the leading custom manufacturer of all off road wheel and rim assemblies. RIMEX’s primary markets include mining and industrial equipment, specializing in haul trucks

and loaders. Established in 1976, RIMEX has over 30 years experience in engineering and custom manufacturing wheels and rims for some of the world’s largest and most demanding vehicles.

By focusing on the individual requirements of its customers, RIMEX designs, specifically the double gutter/integrated lock ring technology have become the preferred choice in the replacement of standard rims. The DGS/IGLR is designed to allow all tyre changes to be carried out without ever having the need to remove the rim from the machine. Rimex’s design has been used on more machine types than any other manufacturer in both open cut and underground applications.With time-tested performance, RIMEX customers are now demanding our MES and TSR Series wheels/rims on all new trucks.

In addition to wheels and rims designed to meet various off-highway applications, RIMEX offers a full range of complementary products to match their wheel counterparts. A tyre pressure monitoring system, portable tyre press, and defuzer (fusible link) valves are just a sample of the many RIMEX products that will save you time and money and improve worksite safety.

In Australia, Rimex has full repair facilities in Perth WA, Mackay Qld and Muswellbrook NSW, these locations being specifically chosen to ensure full coverage to our major mining regions. The facilities are equipped to carry out all blast, test, paint and repair procedures to AS4457 and AS1554.5.

RimexBuilding better wheels

Tyres, Wheels & Valve Systems

Background This bulletin is prompted by concern relating to a series of accidents involving heavy earth moving equipment tyres and the operation of tyre handling machinery. Seven fatalities involving the handling of tyres have occurred at a various mines in the Australasian region in the past few years, including one in Western Australian in 2008.

An independent study of some 82 tyre accident events in the period 1987 to 2008 revealed: • 33 per cent resulted in a

fatality; • 50 per cent clearly had the

potential to result in a fatality; • nine per cent resulted in a

serious injury; and • the remainder caused

significant damage.

Clearly, earth-moving equipment tyres, rims and wheel assemblies must be regarded as safety critical items that need to be maintained by competent persons in accordance with documented systems of work addressing all of the risks involved.

Previous safety alerts issued by Resources Safety on this topic include Mines Safety Bulletin 9 (1993) and Mines Safety Significant Incident Report 124 (2003). This bulletin serves as a reminder for responsible persons at mines to review current work practices and ensure they are adequate.

Earth-moving equipment tyres and use of tyre handling machinery

Contributory factors and consequences The independent report also confirmed that many employers, supervisors, operators and contractors were not sufficiently aware of all the hazards involved with the changing and inflating of earth moving tyres or the use of tyre handling machines, and existing safety procedures were not always followed.

Common identified causes included: • employee induction and training processes

did not effectively evaluate the trainee’s understanding of the tyre changing process;

• operator competence was not re-assessed periodically or when tasks, procedures or the work environment changed;

• failure to plan tyre fitting tasks and ensure available employees had the necessary skills;

• failure to establish appropriate systems of work and workplace arrangements;

• operators were unaware of operational safety limits of equipment being used;

• defective or incorrectly assembled components and incompatibility of rims and tyre sizes; and

• inflation of tyres while being held in the ‘grab’ arms of the tyre handling machine.

Possible consequences of incorrect tyre inflation practices include: • complete failure of any tyre handling machinery

being used at the time; • uncontrolled movement of the tyre or equipment

being used to restrain the tyre; and • wheel and rim components projected with

explosive force.

In these circumstances, serious or fatal injuries to employees or bystanders are foreseeable.

Recommendations • Employees carrying out tyre fitting work must

undertake formal training and assessment prior to commencing work and when any changes to the task equipment or environment occur. Training of workshop supervisors is also necessary to ensure effective supervision.

• Tyre fitting workshop facilities should be constructed and arranged to minimise risk to both the operator involved and other persons that may be in the vicinity. Facilities should be periodically audited and expert advice sought as required.

• Comprehensive tyre fitting procedures must be established and adhered to. For further

information, refer manufacturer’s instructions and Australian Standard AS 4457.1:2007 Earth-moving machinery – Off-the-road wheels, rims and tyres – Maintenance and repair – Wheel assemblies and rim assemblies.

• Ensure tyre handling machines are inspected and tested regularly by a competent person. Maintain records of equipment component change-outs, repairs, testing and inspection.

• Tyre handling machines must only be used for the purpose for which they were designed, and information provided by the manufacturer should be kept readily available. All necessary safety warning decals (Figure 1) should be prominently displayed on the equipment and maintained.

• During inflation, tyre pressure should be continuously monitored via a suitably scaled gauge from a safe distance, which avoids any need to stand in front of the tyre or between the arms of a tyre handling machine.

• Inflation of a tyre held in the clamping arms of a tyre handling machine can produce extreme forces capable of causing the machine to catastrophically collapse. Hydraulic pressure limiting devices to safeguard against such a high potential event are strongly recommended. Any loose bolts securing sections of a machine’s “grab” arm are an indicator of previous overload conditions and should be monitored during maintenance and pre-start checks.

Further information Department of Industry and Resources, Western Australia, 2003, Significant Incident Report No. 124 – Tyre inflation fatal accident [available at www.dmp.wa.gov.au/6713.aspx#7002]

Department of Minerals and Energy, Western Australia, 1993, Safety Bulletin No. 9 – Off-highway mobile earthmoving equipment – tyre maintenance practices [available at www.dmp.wa.gov.au/6713.aspx#7061]

Department of Minerals and Energy, Western Australia, 1998, Safety Bulletin No. 40 – Induction, training and assessment of the competency of employees in the mining industry [available at www.dmp.wa.gov.au/6713.aspx#7061]

Department of Minerals and Energy, Western Australia, 1997, Significant Incident Report No. 72 – Tyre inflation – fatal accident [available at www.dmp.wa.gov.au/6713.aspx#7002]

Earth Moving Equipment Safety Round Table (EMESRT), Design Philosophy 12 – Tires and rims [available at www.mirmgate.com/tires_and_rims.asp]

MIRMGate, Causal factors database - TYREgate: Tyres & rims risk management decision support tool [available at www.mirmgate.com/tyregate/index.php]

Natural Resources and Mines, Queensland, 2005, Mines Safety Alert No. 138, Tyre handler clamping fork failure [available at www.dme.qld.gov.au/mines/mines_safety_alerts.cfm]

Otraco, 2004, Otraco incident notice update, 23 July 2004 incident, 2 September 2004 update: Fatal haultruck tire and rim disassembly during a tire change [available at www.otraco.com/techcentre/index.asp]

Otraco, 2004, Otracom incident notice, 9 February 2004: Catastrophic haultruck tire and rim disassembly during tire change [available at www.otraco.com/techcentre/index.asp]

By Simon Ridge STATE MINING ENGINEER

Mines Safety Bulletin Date: 13 November 2009

Left: Figure 1 Example of tyre handler operating restriction decal. Courtesy of Austin Engineering

Australasian Mining Review 2010: 1st edition

BREEZE CLAMPING PRODUCTS ThE qUALITY ChOICE OF DEMANDINg PROFESSIONALS

BREEZE designs and manufactures one of the most comprehensive lines of perforated worm-drive and T-Bolt/V-Band hose clamps available in the world. BREEZE offers a complete coverage for all heavy Duty equipment applications and BREEZE clamping products are performance engineered for long term durability and reliability.

OEM Approved & Fleet Specified- Mining and Construction Equipment- Trucks and Excavators- Diesel and gas Engines

BREEZE hI-TORqUEhighest strength worm-gear clamps made ›Four times stronger than other clamps, eliminates double ›and triple clampingAvailable with inner liner to protect soft silicone hose ›

BREEZE T-BOLTS high strength clamp design for industrial, marine and vehicle ›applicationsAvailable with spring designs for constant tension performance ›Full range of sizes and materials and custom OEM designs ›available

BREEZE CONSTANT TORqUEInnovative clamp that dynamically increases or decreases ›its diameterIdeal for turbo exhaust sleeves, heater/coolant hoses or ›intake systemsCustom designed stainless steel Belleville springs ›

For further information on the BREEZE product range please contact the NORMA Customer Service on (03) 9761 4416 or send an e-mail to: sales.au@normagroup.com

- Exceeds SAE J1508 Specifications- High destruction torque- High clamping force- Low idle torque

BREEZE a NORMA Group brand

Norma Pacific Pty. Ltd.85 Merrindale DriveCroydon South VIC 3136T: +61 3 9761 4416F: +61 3 9761 4030E: sales.au@normagroup.comW: www.normagroup.com www.normapacific.com

Australasian Mining Review 2010: 1st edition

145

Tyres, Wheels & Valve Systems

HOW DOES IT WORK? WHERE CAN I USE IT?Remember the chill after swimming on a hot, dry day, from the wind hitting your wet skin? That’s evaporative cooling.

Evaporative cooling creates this natural process providing a constant flow of cool, refreshing air into hot environments.

Modern evaporative coolers, like Port-A-Cool® portable evaporative cooling products, are simply updated, highly efficient applications of this ancient principle.

Water is distributed across cooling pads keeping the entire air contact surface thoroughly wetted. Fans draw air through the pads where the evaporation process occurs. Control systems operate the water pump while the fan distributes refreshing air an average of 15 to 25 degrees F cooler than the ambient temperature.

The heart of evaporative cooling is the pad. Quality evaporative cooling pads, like Küül® pads manufactured by Port-A-Cool, LLC, utilize fluted paper sheets chemically impregnated to prevent deterioration and to ensure a long service life, bonded at precise angles for maximum efficiency and cooling.

Evaporative cooling works anywhere that affordable, practical cooling is needed to tame the heat offering cooler environments in business and industry hot spots, or at home on the patio or poolside.

EVAPORATIVE COOLING VS. TRADITIONAL AIR CONDITIONINGEvaporative coolers cool air by filtering it through water, thus lowering the air’s temperature. They work best when a small amount of outside air circulates into the space where the evaporative cooler is employed. This also introduces fresh air into the environment reducing the risk of poor indoor air quality.

Traditional air conditioners work by taking humidity out of the air. They produce cold, dry air and work best in an airtight environment, recirculating stale, dry air.

Evaporative cooler operating costs are typically one-third of air conditioning costs, plus the initial equipment cost is also lower making them the perfect, ozone-friendly alternative to traditional air conditioning. Evaporative cooling is also the

solution for heat in business and industrial settings where traditional air conditioning is unavailable, is not practical, or is cost prohibitive.

GOOD FOR THE ENVIRONMENTRefrigerated cooling makes the air dry and uses refrigerants, which can harm the environment. Evaporative cooling is a totally natural process. It won’t dry out the air, irritate skin, throat or eyes, or affect the environment.

Evaporative cooling is the healthiest way to cool replacing stale air with clean, fresh air many times an hour. Operating in an environment with a supply of fresh means smells and airborne germs are expelled.

WILL IT SAVE ME MONEY?Evaporative cooling equipment is up to 50 percent cheaper, and installation is simple. Port-A-Cool® portable evaporative cooling units come ready to operate out of the box. No assembly is required. Just plug it in, connect to a water source and switch it on.

Evaporative cooling is up to three times cheaper to run than refrigerated cooling. Typically, the cost for water and electricity for a 36” Port-A-Cool® portable evaporative cooling unit for eight hours of operation is about $1.52, depending on local utility costs.

HEAT STRESS ON THE JOBHeat stress can occur in people, animals and even equipment. According to the Occupational Safety and Health Administration (OSHA) and other U.S. government agencies, employees required to work in high temperature environments should be allowed frequent breaks in a cool place to avoid symptoms of heat stress including nausea, dizziness, cramps, confusion, unconsciousness, seizure and even death. High temperature environments are generally referred to as those over 87˚F for light work, over 82˚F for moderate work and over 78˚F for heavy work.

Evaporative cooling units, like Port-A-Cool®, can lower the ambient temperature 15 to 25˚F, turning a restrictive 90˚F area into a comfortable 70˚F area.

For further information regarding Port-A-Cool, LLC products, contact a distributor in the Eastern States at # 03 9357 5121, or on the West Coast at # 08 9408 0801.

With temperatures on the rise, the daunting challenge for business becomes keeping employees and the work environment cool while meeting strict budgets, and striving to protect the environment.

One solution does all three with ease. Evaporative cooling lowers ambient temperatures, is inexpensive to operate, and performs on nothing more than tap water and standard household current.

This simple solution is nothing new. The technology is centuries old. Ancient Egyptians used water-saturated cloth hung in window openings to cool night breezes.

An Ancient Solution for a Modern Challenge

• Servicing to O.E.M. specifications.

• Re-builds – Centrifugal & Axial Flow

• Upgrades

• New fan installations & Relocations

• Fan shaft bearing changeouts

• Shaft journal reclaimation

• Dedicated & experienced mobile work crew

• Over 37 years experience in fan maintenance

Fan Ventillation Specialists

Norval Mako Pty LtdTel: 02 65791064 • Fax: 02 65791159Email: ian@norvalmako.com.au

THE FANMANNorval – Mako Pty. Ltd. was created over twenty years ago by

Ian Poole when it was noted that there was a definite need for a

quality Service Provider to the mining industry dedicated to Draft

System Maintenance.

Ian has a sound background in fan assembly,trouble shooting &

maintenance procedures dating back to 1967, having worked in

the Power Generation Industry for a considerable length of time.

Norval-Mako has been involved in fan assembly and trouble

shooting of draft fans in both Japan ( Nippon Steel ) and

Singapore ( Senoko Gas Works ) as well as every state of the

Australian Mining Industry.

Norval-Mako has built and maintained both Axial Flow and

Centrifugal Fans for both of the major fan companies, Howden

Australia and FlaktWoods.

Our company has built up a good reputation for attention to

detail , problem solving and quality servicing procedures.

Ventilation

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