2005_12

December 2005www.im-mining.com Athabasca oil sands tough machines in arduous mines CVRD - Growth at the world’s largest iron ore miner Loading tools the new models News from underground trackless technology Editor and Publisher John Chadwick Email: [email protected] Publishing Assistant Emma Joseph Email: [email protected] Consulting Editor Alan Kennedy Editorial Board Professor Malcolm Scoble Head of the Mining Dept., University of BC, Vancouver Don East Consultant, Denver, USA. Peter Knights Principal Research Fellow, The University of Queensland. Tuula Puhakka Senior Advisor, Mining Business, Sandvik Tamrock, Finland Pieter du Plessis CEO, Minerals & Metals Div., Bateman, South Africa. Paul Mitchell Secretary General International Council on Mining and Metals (ICMM), UK. Ed McCord Project Consultant Caterpillar Global Mining, USA Hans Fernberg Senior Advisor Atlas Copco Rock Drills, Sweden. Dr Kuntala Lahiri-Dutt Community specialist in natural resource management The Australian National University Simon Tarbutt Consultant, Santiago, Chile Design and Production Consultant Trevor Sheldon Email: [email protected] Publishing Consultant Robin Peach Editorial enquiries: Tel: +44 (0)1442 870 829 Fax +44 (0)1442 870 617 Website: www.im-mining.com Advertising Sales Phil Playle email: [email protected] +44 1442 87 77 77 Advertising Production Emma Joseph Email: [email protected] Annual Subscription enquiries: Angela O’Reilly email: [email protected] Annual Subscription UK and Europe £160, €230 Rest of the world US$270 International Mining is published monthly by Team Publishing Ltd, 2 Claridge Court, Lower Kings Road Berkhamsted, Herts. HP4 2AF, UK Periodicals Postage Paid at Rahway NJ and at additional mailing offices POSTMASTER: send address changes to International Mining, c/o Mercury Int’l. , 365 Blair Road, Avenel, New Jersey, NJ 07001. Printed by Friary Press, Dorset, UK © Team Publishing Ltd 2005 IM uses, as preference, SI units throughout, so all tonnes are metric unless otherwise stated. All dollars are US unless otherwise stated th at - Grow CVRD rld’s the wo ore t iron l a rg e s miner sg tool Loadin models w the ne ound n d e rg r y from u News ss technolog trackle www.i CONTENTS Volume 1 • Number 4 • December 2005 24 CANADA’S VAST OIL SANDS RESOURCE 8 CVRD IRON ORE The company aims to increase annual iron ore output to 300 Mt by the end of 2007 18 LOADING TOOLS How to choose between electric and hydraulic shovels, or backhoes, or wheel loaders; examination of electric drive systems; consideration of bucket wear and more 18 & 24 Times have never been better for Canada’s oil sands mines, as John Chadwick discovered. Many new projects are underway, being permitted or under consideration. Manufacturers continue to break down size barriers to provide these miners with bigger shovels and trucks 33 INNOVATION UNDERGROUND New equipment to ensure the highest quality haul roads; different ideas for truck haulage; the latest in drilling and loading; and automation in all areas, including shotcreting AROUND THE WORLD 4 World Prospects 15 Licence to Operate 16 Innovation Intelligence 32 Milestones 41 Mining and Metallurgical Technology (MMT) 46 Coal News 47 Tails 48 Diary 33 5 ber 200 Decem m-minin g.com FRONT COVER: sil sand in asca o Athab h machines s toug uous mine ard Innovations in exploration – Atlas Copco’s new range of impregnated diamond core drilling bits – Golden JET Bits – are of unique design (Patents Pending), based on an extremely high, yet strong, cutting matrix, making it the most productive diamond core bit in the industry. The impregnation height of the JET bit matrix has been substantially raised, to 16 mm, making it the highest matrix on the market. This has been achieved without compromising bit cooling capacity, impairing the water flow in the flushing channels or weakening the fixture of the cast segments. The wider cutting segments and their seatings give maximum strength and stability. There are also fewer flushing channels that, together with the inner and outer grooves, produce a highly efficient flushing system around the whole face of the bit. All this makes the JET bit a true time saver, cost-cutter and productivity booster, especially involving deep holes where heavy pipe handling procedures in order to change bits can create serious downtime. December 2005 International Mining 1 Courtesy of Atlas Copco The Leader with John Chadwick Mines for the world I n the few years we have spent in this century, London has very firmly re-established itself as a global centre for the mining industry. Financiers, promoters, lawyers, consultants, engineers have flocked to the British capital and now, more than ever, are building (in every sense of the word) mines around the world. To provide closer examination of this phenomenon and bring even greater activity to this burgeoning market, International Mining, a London institution itself, is proud and pleased to announce the birth of International Mining Conferences and its first conference in London – Mining Capital focussing on the provision of finance to the world mining industry. International Mining Conferences has an excellent pedigree, bringing together a wealth of London’s mining expertise under its Managing Director, Peter Jacobs, the architect of global mining conferences in London. While London’s influence is felt all round the world, recent events have seen it extend its traditional power base of Australian and African developments to wider interest in South America and, in particular, to them east – ranging from Eastern Europe, through Central Asia to the Far East. There are strong parallels with 150200 years ago when London and the UK was building some of the world’s vital mining industries. Mining has seen a spectacular boom on London’s AIM Market in recent years, and there is no sign yet of an end to its appetite. In the year to September there have been 51 new companies listed in the mining sector this year. The only sector showing more activity is ‘Speciality & Other Finance’ with 88 new companies. High tech ‘Software & Computer Services’ came third with 39 new companies, behind the ‘sunset’ mining industry! Mining is a leader on AIM not just in numbers, but also in value. In September six of the AIM Top 20 (by market capitalization) were mining companies – First Quantum, Bema Gold, Peter Hambro Mining, Consolidated Minerals, Highland Gold and Yamana Gold. There were 136 mining companies listed on AIM, with a total market capitalization of £7,706 million. There were slightly more in ‘Software & Computer Services’ and 200 in ‘Speciality & Other Finance’, but their respective market caps together totaled just £9,005 million. Only the 75 oil and gases companies listed on AIM in September had a higher total market cap than the mining sector, of £8,987 million. Indeed, mining’s performance throughout this decade has been as a leader. At the end of 2000, there were 523 companies listed on AIM, with a total market cap of £14,935 million. Just 3.25% were mining companies, and those 17 represented just 3.9% of the total market cap. In 2001, 14 new mining companies were listed, out of a total of 177, and the amount of money they raised, at £21.35 million, represented 3.6% of the total. In 2002 it was 13 new mining companies raising £47.44 million, representing 9.7% of the total. 2003 saw 17 new mining companies raise £44.66 million and then last year things really started to heat up. New mining company listings were 10% of all new listings in 2004, 36 new companies raising £229.29 million. Today’s top AIM miners are working in Argentina, Australia, Bangladesh, Brazil, Canada, Chile, China, the DRC, Kazakhstan, Mauritania, Russia, South Africa, Tajikistan and Zambia, with a particular strength in Russia. Of course, AIM activity is but a snapshot of what is going on in London. The London Stock Exchange has in total, some 170 mining companies listed – truly providing mining capital for the world. Mining Capital will be held June 13 to 14, Central Hall, Westminster, across the road from Westminster Abbey and the Houses of Parliament. [email protected] December 2005 International Mining 3 Andina wants to expand WA lead mine set to reach world’s top five.000t/d.6 Moz silver. Minera Puren will mine a total of 12.2 Mt during the operation that will last just over four years. with initial production forecast to begin in the fourth quarter of calendar year 2007.100 t/d. W Ranger lives longer Rio Tinto's 68. Energy Resources of Australia has increased total reserves at its Ranger mine by 6. Puren’s expenditure to build an open pit will reach some $23 million. The expansion will allow Cerro Verde to mine a primary sulphide orebody beneath the oxide reserves currently in production. would produce close to 3% of global mine lead production. producing an estimated 100. The Phase 2 . Ore throughput rate will be 1. Andina’s mineable reserves amount to 5. Officially opening the Magellan project. Recovery is expected to average 80%. Angel Alvarez & far right – Peru Copper Founder.200 and 4. Much of the investment required will be in underground crushing and conveying facilities. CEO and President. PD is the majority owner and operator of Cerro Verde and has guaranteed a pro rata share of the project financing debt until completion of construction. The additional reserves will be processed between 2011 and 2014. In 2004 it produced 175. The name change reflects the wider geographical asset base achieved by its acquisition of Minera México (MM). It is a shallow open pit operation with a strip ratio averaging 2. is around 17. or 4.” Carpenter said. yielding a concentrate grade of about 70% Pb.5:1. Atacama region.800 m above sea level and 160 km northeast of Copiapo. controlled by Grupo Mexico. The agreements permit Cerro Verde to borrow as much as $450 million to finance the $850 million expansion.000 t/d in 2012 and 290. a company owned by Minera Mantos de Oro (MDO) (Placer Dome and Kinross 50% each) 65% and Codelco 35%. Processing involves conventional SAG milling. Yandicoogina was commissioned in 1998 at an initial rated capacity of 15 Mt/y.77% Cu. It will be mixed with ore from La Coipa. BHP Billiton announced approval for the Rapid Growth Project 3 (RGP3) which will increase capacity at its Area C iron ore mine in Western Australia by 20 Mt to 42Mt/y. The ore will be transported in 150-t trucks to a Merril Crowe plant at La Coipa.08% uranium oxide. completed in August this year.500 t/d of ore.12 to 0. Some 60. This results from reducing the cut-off grade from 0.4 Mt/y. adding three years to the predicted operational life of Ranger. once the plant is fully commissioned. This project is just 8 km from La Coipa gold and silver mine owned by MDO.800t of copper and 3. The capital expenditure fully reflects Minera Purén in second half 2006 Chile’s Soc Contractual Minera Puren. David Lowell 4 International Mining December 2005 . Hamersley and RGP will expand more Rio Tinto is to spend $1. Andina produced 239.World prospects PD to expand Cerro Verde Phelps Dodge (PD) has executed agreements for debt financing facilities totaling $450 million in connection with the expansion of the Soc Minera Cerro Verde copper mine in Peru. near Arequipa. from 72. The mineralization is lead carbonate and minor lead sulphate with traces of other metals in a property of 260 km2.000 t/d in 2024. Mining of the primary sulphides is scheduled to begin in late 2006 and will increase copper production from 91. We estimate that the study should be completDrilling IMC Orebody – Second from the left Peru Copper Exploration Manager – Mr.000 t/y when full production is achieved. reaches full production in 2006. The first phase is programmed to come onstream in 2008.730 Mt grading 0.4% owned subsidiary.35 billion on further expansion of wholly owned Hamersley Iron’s Yandicoogina mine and Dampier port in the Pilbara region of Western Australia.3 billion for BHP Billiton’s 85% share of the project.000 t to 272. State Development Minister Alan Carpenter said it was WA’s only pure lead mine and when fully operating. which will include data from several other already completed independent technical studies where appropriate. said. SNC-Lavalin for Toromocho prefeasibility P eru Copper has commissioned SNC-Lavalin of Montreal. plans to start gold and silver production from its Puren project located between 4.000 t should be produced in 2005 as the mine builds up to full production levels. The new operations will add two additional years to La Coipa operations. Yandicoogina mine will increase its capacity from 36 to 52 Mt/y at an estimated cost of $530 million.000t/d. Refining will produce a 99. Codelco’s Andina division has presented Chile's environmental regulator Conama with a $250 million investment plan to increase throughput to 92. The Board has approved capital of $1. due for completion in 2007.000 oz gold and 7.000 t of lead in concentrate in 2006. In the same week. Canada to conduct a prefeasibility study for its Toromocho project in Peru.refinery stage . BNamericas says this is the first phase of a long-term threephase investment plan that aims to expand Andina to 230.000t of molybdenum in 2004.923 t contained uranium oxide. “Our hiring of SNC-Lavalin represents another important step in the development of our world class Toromocho copper project. J. with the most recent expansion. PD’s partners in Cerro Verde are Cia de Minas Buenaventura and Sumitomo Metal Mining and Sumitomo Corp. comprising mining leases and exploration licenses. The processing capacity of the leach operation and the Merril Crowe plant at La Coipa. from 24 to 36 Mt/y. fuelled by the rapid growth of China’s vehicle fleet and the subsequent demand for electrical-storage batteries. Total resources increased by 14. in the second quarter of 2006. This includes approximately $235 million of capital required to replace ageing port and rail infrastructure. 40 km west of Wiluna. flotation and concentrate drying by filter press. Charles Preble. Work on the project has commenced. “There is a strong and increasing global demand for lead. The aim is to offset lower grades and maintain current production levels. Since 1999 Hamersley has progressively increased its capacity.285 t of contained uranium oxide. The deposits are friable rock requiring minimal drilling and blasting. Director and Executive Chairman Mr. estern Australia is set to become one of the top five lead producers in the world when Ivernia’s Magellan lead mine.of the Magellan development. is set to further boost economic benefits to the State.95% Pb product. Southern Copper is born Southern Peru Copper has changed its name to Southern Copper. We have been working on the project on a fast track basis and we are excited about hiring an independent firm to complete a prefeasibility study. . This has led to a firming of ilmenite prices. Industry analysts forecast tightness in the ilmenite market to continue for the coming years.000 oz/y platinum group metals (PGM) project. Bulk earthworks are complete and civil works are progressing well. ARM’s CEO. with the balance being contributed by the two partners in their respective shareholding ratios (ARM R330 million and Implats R270 million). The RGP3 scope includes the development of a new pit at the Area C ‘E Deposit’ and the construction of new crushing and screening facilities at the mine’s ‘C Deposit’. The first concrete pour took place in June as foundations were prepared for the arrival of the ex-Beenup plant from Western Australia.World prospects recent cost increases that have been experienced in the resources sector in Western Australia. which is equivalent to 16. It is a porphyry copper. using a Cu equivalent cutoff of 0.65%. which is set to continue as limited new supplies are scheduled to enter the market and Moma is well placed to capitalize on the positive demand outlook. The expansion will include a new stockyard. The UG2 reserve totals 40 Mt at a 6E mill grade of 4.45% Cu equivalent. some six weeks earlier than the contractual programme.27% to 0.” said Inco Chairman and CEO Scott Hand. Big Moma and Malagasy ilmenite C onstruction of Kenmare’s Moma titanium mineral sands project in Mozambique is currently anticipated for completion in late September 2006. Toromocho is estimated to have a life of over 33 years at an average production rate of 221.” said Mr. BHP Billiton’s Western Australian iron ore operations will be examined in depth in IM’s March 2006 issue.000 t/y of zircon and 17. Mining and stockpiling of nearly 240 000 tons of UG2 ore.000 t/y of ilmenite as well as 60. Demand for zircon continues to be very strong and prices have increased to circa $700/t for premium grade. “The demonstration plant at Argentia will build on the successes we’ve already achieved with our hydromet R&D program at the mini-pilot plant in our Sheridan Park research facility. Negotiations are ongoing with a number of customers for the balance of Moma’s ilmenite production. The underground mining operations will be fully mechanised. Project finance of R600 million has been secured through ABSA and Nedbank. The Toromocho project is situated in Morococha. Both the Merensky and UG2 reefs are found on the property.93% Cu equivalent. while Implats will undertake the processing and refining through its subsidiary Impala Refining Services (IRS).000 t of copper in concentrate.” Keith Rumble. The proven and probable reserves within the dredge path design for the project are 469 Mt grading 4.32% Cu and 0.000 oz palladium and about 20.600-m long airstrip has been completed and is in use transporting staff between Moma and Johannesburg. based on a copper cut-off ranging from 0. a US mining company that owned a majority of the mineral concessions contained within the Cerro de Pasco mining district prior to their being nationalized in 1974. The outlook is for zircon supply to remain tight for the foreseeable future. The current expansions at our refinery complex are proceeding well. Main metal sales are planned at an average annual production over the life of the mine of 120. The mine. Two Rivers will flow African Rainbow Minerals (ARM) and Impala Platinum Holdings are proceeding with the 220. an historical mining district in central Peru.800 Mt and an estimated annual mill throughput of 54 Mt. ensuring that we benefit from the continuing strong market conditions. Hand. Total Resources at Moma are 2. André Wilkens said: “The decision to proceed with Two Rivers is aligned with the company’s growth strategy.2 Mt/y (ROM). central part of the eastern limb of the Bushveld Complex in Mpumalanga province.” With the financial support of C$60 million from Technology Partnerships Canada. Using a slightly higher Cu equivalent cut off of 0. Chile office. The PGM sector is one of ARM’s key commodity focus areas. from 1966 to 1976 Cerro de Pasco. “Hydromet technology offers a cost-effective and environmentally friendly alternative to conventional smelting and refining which will help place the Canadian mining industry at the forefront of the development of this processing technology. The molybdenum grade is 0.4 Mt ilmenite. The mine will be accessed via a decline shaft system comprising a footwall conveyor decline and two on-reef declines: one for vehicle access and the other a chairlift installation for personnel transport. driven by strong pigment demand most notably in China. Two Rivers’ capital expenditure is estimated to be in the region of R1. and Centromin conducted a total of 42. We are also optimistic about the upside potential that exists at Two Rivers as additional resources exist in the Merensky Reef that will be mineable in the future.” The Toromocho study will be managed from SNC Lavalin’s Santiago. as well as additional rolling stock and rail sidings. CEO of Implats said: “Two Rivers is an integral part of ed early in 2006. Inco achieved another significant milestone with the start-up of the demonstration plant in Argentia. “Our hydromet research and development represents one of the most significant R&D investments in Canada. and the successful trial mining phase has reduced risk considerably.” Voisey’s Bay On October 20. André Wilkens continued: “All project assumptions indicate that Two Rivers will be one of the lowest cost PGM producers at less than R200/t.000 oz platinum. Managing Director Michael Carvill has said the capital cost of the mine is expected to be $235 million. Peru Copper will immediately begin work on a full feasibility study.18g/t. A 1. potentially open pittable.5% is ilmenite).59% Cu.3% Total Heavy Minerals (of which 3. Inco launched an approximately US$150 million research and development programme in 2002 aimed at confirming the commercial application of hydrometallurgy. as well as extensive access development has substantively validated geological and mining feasibility parameters.88% Cu equivalent. upgraded car dumper and ship loading facilities. Two Rivers Platinum on the Eastern Limb of South Africa’s Bushveld Complex. totals 867 Mt at 0.60% Cu and 0.1 g/t Ag. but UG2 will be the initial focus of the mine.3 Moz platinum by 2010. and the necessary capacity will be available well ahead of the planned commissioning date.000 oz rhodium. Within the newly reported resource is a central core of measured and indicated material of 967 Mt at a grade of 0. mineral deposit. Peru Copper says.3 Mt of ore containing 72 Mt of ilmenite.60%. based on a measured and indicated resource of 1. all of which will be stockpiled for leaching or other processing.000 t/y of rutile. Most of the capital items have already been ordered. The joint venture is held 55% by ARM and 45% by Implats and has contracted ARM to manage the project. Port and rail facilities will also be expanded to facilitate this capacity increase and to accommodate further staged growth. located on the coast in the north of the country. Prior to Peru Copper’s involvement in Toromocho. The go-ahead decision followed successful trial mining to test all critical project assumptions. Kenmare has contracted a significant volume of its zircon to date at market-based prices.023% and there are 8." The life is forecast for 20 years at an underground production rate of 2.2 billion to commissioning. Two Rivers lies in the southern. will have the capacity to produce 700. Measured and indicated material.” 6 International Mining December 2005 . the project has an exciting return which comfortably meets the company’s required return rates. the central core of measured and indicated material is 826 Mt at a grade of 0. Once [it] has been completed.394 m of diamond drilling on the deposit.” Inco is developing hydromet technologies for Voisey’s Bay MOMA Dredge Pond construction Kenmare says the “market outlook for titanium minerals continues to be positive. Full production is forecast during the second half of 2006.63% Cu and 0. 68. “We believe hydromet technology can play an important part in the future of the Voisey’s Bay project and will help to position Canada and Newfoundland and Labrador at the forefront of mineral processing technology worldwide. A platinum to palladium ratio of 5:3 adds to the attractiveness of this project. Implats growth strategy and is a building block in our plans to reach 2. Newfoundland to test hydrometallurgical processing technologies to treat Voisey’s Bay nickel concentrates. This compares to our financing which was based on approximately $500/t. it will be a model of the contribution mining can make through the successful integration of financial.000 t/y of molybdenum contained in moly concentrate. the orebody is the largest known undeveloped highgrade ilmenite deposit. more energy efficient. This was expected to generate revenue in excess of $400. commissioned its molybdenum plant on September 27.” Measured and Indicated resources are estimated at 233 Mt grading 2. It will allow OneSteel to build a distinctive iron ore product brand in global markets. environmental and community objectives. Construction of the commercial processing plant would begin in 2009 and be completed by the end of 2011. The mineralization is hosted in a sequence of sedimentary host rocks with a cumulative strike length greater than 82 km. We are very proud to have the opportunity to represent OneSteel in this venture.3-0. The zone is located 300 m from the edge of the current Rosario open pit and. “The marketing services we will provide will combine the flexibility of a niche producer with the customer base. The enormous deposits at Tenke Fungurume are within a concession area totaling more than 1. at which time Inco will complete its assessment of the technical and economic feasibility of using hydromet to treat Voisey’s Bay concentrates at the commercial processing plant. Production of ore will continue at the rate of 60 t/d with the concurrent development of the lower levels of the mine for future production.5% Cu and 0.700 Mt grading 0. as currently defined. has initiated commercial production at its high grade gold/silver Diablito project located in the State of Nayarit. and more environmentally friendly. The ilmenite will be smelted at Rio Tinto’s facilities at Sorel in Quebec. BHP Billiton President Iron Ore. with recoveries currently running at an average 36%. Chairman of VANE.in four stages: bench-scale laboratory testing.300 t/d of copper-molybdenum concentrate and it is initially forecast to produce 4. both in lump and fines. an aerial view of the primary crusher C PD takes up Tenke option Phelps Dodge.000 t/y but will increase to 180.” Vismedia Collahusai copper More moly for Chile mine. Chairman and CEO of Phelps Dodge commended the country’s leaders for their “visionary efforts to bring progress to the DRC.500 km2 in the rich and prolific Katanga copper belt. Copper outcrops have been mapped over a 300 km2 area to date.” will receive asset transfer payments totalling $50 million during a period of approximately five years as specified project milestones are reached.000 scale mini-pilot plant which began in 2003 and was completed in June 2005. excavation at the Falconbridge (44%) and a Japanese consortium. said: “With a grade of 60% titanium dioxide.000 t/y of iron ore pellets. representing some 50% of the total prospective area. Exploration indicates the zone contains an inferred resource estimated at 248 Mt grading 1.75% Tenke Mining. It has an expected mine life of 40 years and will supply a new. remains open to the north. would be built in Newfoundland and Labrador. eliminating the sulphur dioxide and dust emissions associated with a conventional smelter. It is being developed by QIT Madagascar Minerals (QMM). Agreements with Minera Real de Cosala and Nexxtrade (both Mexican companies) are in place. He estimated that capital costs could range from $70 to 80 million given that the Collahuasi plant had cost $38 to 40 million. December 2005 International Mining 7 . This plant will treat ROM low-grade ore from Escondida's two open pits by bioleaching. The demonstration plant phase of the hydromet R&D programme is scheduled to conclude in late 2007. the operation of a 1/10.000 t/y of molybdenum in concentrate. a joint venture between Anglo American (44%). 3. Chief Executive of Rio Tinto’s Industrial Minerals product group. BHP-Billiton’s Escondida copper mine is conducting scoping studies for the possible construction of a molybdenum plant. The copper is expected to cost $0. according to Villouta. The project comprises a $585 million mineral sands operation and port in Madagascar and a $190 million upgrade of its ilmenite facilities in Canada. A Phelps Dodge subsidiary will be the operator of the project as it is developed and put into production. Mitsui and Co (12%). Production begins at Diablito VANE Minerals’ wholly owned subsidiary. which we consider to be the largest and highestgrade undeveloped copper/cobalt project in the world today. 17. Michael Spriggs. Leigh Clifford. We are now set to produce solid cash flows. In August and September 2005.40/lb. thereby assuring the availability of milling time for the processing of the high-grade precious metal ore and a trading platform for the sale of the resulting concentrates. Further north. a Malagasy subsidiary of Rio Tinto (80%) and the government (20%). BHP Billiton expects to develop markets for approximately 3 Mt/y of hematite ore. Hydromet has several key advantages over a conventional smelting and refining process. rising to up to 8. More than 1. Its design capacity is to process 4. Initial production will be 90.” As the world’s largest producer of copper. Chief Executive of Rio Tinto. In the transaction. south and at depth. high quality chloride slag with 91% titanium dioxide content. The known deposits contain inferred resources of 547 Mt grading 3. two months ahead of schedule and under budget. The commercial plant.000 t/y in year 2. and its final application.27% Co. This stockpile underwent flotation concentration at the mill and the concentrates produced an estimated 100 t . said. told BNamericas in October: “I think we will have the scoping studies complete within six months. Andrew Mackenzie.000 t in later years. and approximately 220.4% Cu cut-off. Minerales VANE.9% Cu and 0. said: “We have already demonstrated that we are committed to developing the project in a manner consistent with the principles of sustainable development. Marcelo Villouta. which is already completed. Rio Tinto is to go ahead with development of a $775 million titanium dioxide project.54% Cu at a 0. freight and back office capabilities of the leading mining house. The project area remains extensively under explored. Escondida VP Processes. This resource comprises only a limited block.30% Co.5%. OneSteel’s Project Magnet is scheduled to begin in the second half of the 2006 financial year.” Escondida’s ore contains 70 ppm Mo in comparison to other Chilean operations that range from 100 to 400 ppm Mo. Indeed.7% Cu has been outlined. It is more economical in terms both of capital and operating expenses. west-central Mexico. located in the central part of the zone.200 t of ore were mined at Diablito and stockpiled at the Cosala mill. Steven Whisler. The action came after the government of the DRC and Gecamines executed amended agreements for developing the project and after approval by presidential decree. the operation of a 1/100 scale demonstration plant.000 t/y of ilmenite. This is anticipated to increase grade and therefore revenues. It was expected that development of the upper level would be completed in November and then only ore would be mined from that level. lead by Rosario pit. 57. This establishes the ownership positions in Tenke Fungurume as Phelps Dodge. using this technology to treat Voisey’s Bay concentrates. and the revenues generated from Diablito will offset the majority of the company’s exploration expenditures which will reduce the cash burn to minimal levels. Meanwhile. Gecamines ollahuasi. Meanwhile. First production from the operation in the Fort-Dauphin region is expected in late 2008 and the initial capacity will be 750.” The development is the largest project in the country’s history and should be the catalyst for broader economic development of the country. has exercised an option giving the company controlling interest of the Tenke Fungurume copper/cobalt project in the Democratic Republic of the Congo. We look forward to working with our partners in developing Tenke Fungurume.” Graeme Hunt.75% and Gecamines. “We could be talking about 4. the first stage of the resource estimate of Collahuasi’s Rosario Oeste zone has been completed. J. Escondida’[s low moly grades would be offset by the large volume of ore processed. 24. through a subsidiary.000 for the two production months of August and September. he said.were scheduled to be sold before the end of November. Project Magnet BHP Billiton is to be OneSteel’s exclusive agent to market iron ores and pellets generated from its Project Magnet. commented: “This commercial production is an important step in VANE’s development as it differentiates us from other junior exploration companies. Escondida should produce the first cathode from its $870 million sulphide leach project next June 2006. technical marketing. 386 Mt. With a total annual capacity of 36 Mt. beating the previous record of 62. Gross revenues of $3. in the State of Maranhão. in the State of Rio de Janeiro. a new record.500 Mt and resources of 15. The CVRD iron ore mines are Alegria. are the heart of the Northern System.000 Mt and resources of 39. examined by John Chadwick C ia Vale do Rio Doce (CVRD) is a global diversified metals and mining company. above all. The Southern System produces lump ore. alumina and aluminium. Brucutu. the largest in the Americas. Fabrica/ Segredo.500 Mt of high-grade hematite. Morro Agudo/Agua Limpa and Timbopeba. Products of the Northern System are Carajás lump and Carajás fines. Just one of those mines. standard sinter feed. Capanema. Records are currently tumbling. potash. In the first nine months of 2005 production totalled 187. the Carajás orebodies. With reserves of 1. Caue. Ore is carried by the Carajás railroad to the Ponta da Madeira Maritime Terminal. kaolin. it is the largest logistics operator in Brazil. Carajás direct reduction pellets and Carajás blast furnace pellets. in the State of Pará. CVRD groups its iron ore operations into two ‘Systems’. It is also growing into nickel. The capacity of these mines is 90 Mt/y of iron ore.26 Mt of 8 International Mining December 2005 C iron ore and pellets were shipped. Gongo Soco. Conceicao. In the third quarter. . copper concentrate. 65. It is also a world-class producer of manganese. in the State of Espírito Santo. direct reduction lump. Ore is carried from these mines by the Vitória-Minas railroad that runs 905 km to the Port of Tubarão. Carajás. Fazendao. Alegria/Germano. However. pellet feed. Tubarão direct reduction pellets and Tubarão blast furnace pellets. Iron ore and other ferrous metals account for about 80% of CVRD’s revenue. CVRD is the world’s number one producer and exporter of iron ore and pellets. Carajás pellet feed. the mines of the Southern System are located in Minas Gerais. São Luis and Minas Gerais consist of nine plants.61 billion were 57.44 Mt of iron ore. and the Port of Sepetiba. Headquartered in the city of Rio de Janeiro.000 Mt.8% higher than in 2004. With reserves of 3. Feijao. ferro-alloys. bauxite. CVRD’s pelletizing complexes in Tubarão.Operation focus CVRD’s iron fist The world’s biggest producer has big plans. . Carajás exploration . 22. a further $17. Complex Carajás Carajás is an integrated mine-railroad-port system. Itabira. is being expanded to increase the speed of handling iron ore in order to reduce demurrage costs. with a total estimated value of $559 million. 1967. One of the important projects concluded in 2004 was the expansion of iron ore production capacity at Carajás to 70 Mt/y. Some $7. Expansion of the conveyor and dockside machinery. a team of Brazilian geologists from Cia Meridional de Minerações .221 billion to be invested in projects and $375 million in research and development. at an average altitude of 650 m. manganese. and 280 km from Marabá.1% – $736 million – was allocated to ‘stay-in-business capex’. gold.596 billion – to growth capex. The final 2005 is sure to be higher still. CVRD’s mining and processing activities there embrace iron ore. to 30 Mt/y is currently under study. an increase of 53% over 2003.332 billion.160 billion – is partly for new investments in 2005 (iron ore. The company aims to increase annual iron ore output to 300 Mt by the end of 2007. these projects will increase capacity by 76 Mt/y. Capex figures are based on actual disbursements.9% – $2. bauxite and. The expansion will be completed by January 2006. A further expansion. copper and nickel).B. Ukraine is the world’s 7th largest steel producer and CVRD stated: “This shipment represents the conquest of a new frontier of the iron ore seaborne market. The Port of Tubarão. 10 International Mining December 2005 The Fábrica Nova iron ore mine. for completion and startup in 2006. Production this year is estimated at 6. The considerable increase in the 2005 budget allocated for projects – $1. Andrade is an additional source of iron ore for the Southern System.CMM (a subsidiary of U. CVRD was already producing iron ore. and uses the Timbopeba beneficiation plant. this will add 15 Mt to CVRD’s annual capacity. in line with the world best practices in environmental protection. In fact. where the ground had a visible overlay of iron ore. It is exploiting the Mariana deposit. Phase II is to be completed in 2007. southern Pará State. for completion and operational startup in 2007. to bring production capacity to 24 Mt/y. CVRD took over the operations of the Andrade mine under a lease contract with the Brazilian steel maker Cia Siderúrgica Belgo-Mineira that extends for a period of 40 years. Expansion of capacity from 6 to 7 Mt/y. Some $3 million was invested in environmental recovery and protection of the areas affected by Fabrica Nova operations.7 Mt/y. started up in April.39 billion in capital spending in the first half of 2005 and earmarked almost $1. the largest town in the region. copper. purchase of small-scale equipment and new access for crushing facilities. the company signed contracts for the supply of 750 Mt of iron ore and pellets with 40 clients in the Americas. soon.606 wagons and 123 locos. This compares with 2004 capital expenditure of $1. in the state of Espírito Santo. the company started exploration to determine the volume of reserves that will support the capacity expansion plan for Andrade. will expand to 100 Mt/y in 2007. for capital expenditure totalling $1.251 Mt. In April 1970. raising nominal capacity to 15 Mt/y.169 billion. CVRD reported $1. Total investment in logistics should attain $760 million in 2005. Works began in second half 2005. Startup scheduled for 2007. made up of $2. On July 31. Fábrica Nova. CVRD generated an all-time revenue high of $8. When completed. and construction of new dockside storage facilities. Main CVRD ferrous metals projects currently in progress Project Budgeted 2005 ($ million) Expansion of the Carajás 140 iron ore mines by 85 Mt/y ship Brucutu iron ore mine – Southern System 205 Status For completion in 2006. and 77.956 billion. in the state of Minas Gerais. much thanks to iron ore. Carajás is served by its own airport.6 million will go on rolling stock for EFVM railroad. and production for 2005 is estimated at 10 Mt. During 2004. The total investment in this project was $106 million. Modernization and expansion. Iron ore projects Five iron ore mining projects are underway in the ‘Southern System’ – Brucutu. It has a nominal production capacity of 15 Mt/y of iron ore. pellets. built and operated by CVRD. Of the total. Asia and Europe. had been since 1942. Steel) landed in a clearing in Serra dos Carajás. nickel. But that now has further to grow. The Serra dos Carajás Range lies in Eastern Amazonia.Operation focus Carajás.S. iron ore demand was so high that CVRD had to expand its general cargo business four times above Brazil’s GDP growth rate. mostly for new projects but not all in iron ore. coal. CVRD Executive Director Finances Fabio Barbosa has predicted that iron ore output will reach 275 Mt in 2007. Extension of mine life to 2008. At the beginning of this year.94 billion more in the second half. in CVRD’s Southern System. Fazendão and Fábrica – as well as the increase in production capacity at Carajás. from Southern System 12 to 17 Mt/y. some 680 km southwest of the State capital of Belém. raising capacity to 46 mt/y. CVRD concluded its first iron ore shipment to Ukraine. The capacity of the pelletizing plant at São Luís will be expanded from 6 to 7 Mt/y.5 billion. with an estimated capacity of 2.” For 2005.8 million will be invested in development. Itabira iron ore mines – Southern System 16 Fazendão iron ore mine – Southern System 52 Fábrica iron ore mine – 38 Timbopeba iron ore mine – Southern System 25 Tubarão Port expansion – Southern System 22 Expansion of São Luis pelletizing plant 18 N. from the Itabira mines in southern Brazil. The fleet of railroad equipment will be expanded to meet demand for both iron ore haulage and general cargo for clients: 5. The second loading system of Pier III in test phase. Phase I should be completed in 2006. In August this year. Project to produce 14 Mt/y (ROM) iron ore. In 2004. CVRD approved capital expenditure of $3. Today it is the backbone of the economic and social development of a huge area of north/northeast Brazil. CMM and CVRD became associated. Project to expand capacity by 5 Mt. to sustain existing operations. At the same time. . 000 Mt (a useful life of about 50 years. compared with conventional mining. Iron ore concentrate is pumped from Germano to Ponta Ubu in a 396-km pipeline. the rich iron-ore region of Minas Gerais. The transport velocity ranges from 1. Over recent years.S. ROM ore is reduced from 150 mm to a 12. concerned about the high investment and poor international market for iron ore at the time. It will use two types of ITT valves. 20% for the mine and beneficiation plant. patented elastomer perimeter seat. capacity 16. it is currently estimated that it can be double that. The principles of belt mining are shown in the diagram. Prior to flotation. Middle East and the Americas. Reserves of high-grade iron ore at Carajás are sufficient to guarantee production for another 400 years. improved operational control and lower corrosion and erosion rates. 14% for the marine terminal. and it involves fewer pieces of equipment and lower consumption of diesel oil per tonne of transported ore. concentrate production was 15. 346 km have a diameter of 508 mm and 50 km a diameter of 457 mm. in the municipality of Anchieta. which reaffirmed its buy rating recommendation for CVRD. June 1978 saw the start of track laying for the 890-km Carajás railroad. which was built 28 years ago! Samarco is an open-pit mine with 4. Innovative Samarco Samarco Mineração is a 50:50 joint venture between CVRD and BHP Billiton .5% in 2008.5 Mt came from Samarco itself and 2 Mt were acquired from CVRD. Almost all of the pipeline is buried at a depth of about 1. and gate support rings that reduce the stress on the seats resulting in remarkable service life. Caemi said the investment will expand operations at its Mineracoes Brasileiras Reunidas (MBR) subsidiary. a new 7 Mt/y pipeline adjacent to the current pipeline and the third pellet plant (7. ranging in size from 51 to 1. linking Ponta da Madeira on the Maranhão coastline to the Carajás resource. in Minas Diagram of ‘belt mining’ .5 to 1. The wall thickness varies between 8 and 19 mm. when U. a low-grade iron ore and now is the second largest seaborne exporter of pellets. raising it from the current 14 Mt/y to 21. and 10% for infrastructure. The Ported Slide Gate Valve is designed specifically for difficult slurry processes. Start-up of Brucutu is scheduled for 2007.. The first orebody selected for mining was N4 (eastern area N4E) due to ease of access to the railroad. and then the final concentrate is pumped to the pipeline. Ranging in size from 51 mm to 914 mm. The Bi-directional Knife-Gate Valve is a full port valve used in water reclamation. the desliming process (three cycloning stages) removes ultra fine particles (<0. because of the lower operating costs. The Ponta Ubu unit (pelletizing plant and port facilities) is in Espírito Santo. which was to cost CVRD $3 billion in direct investments: 56% for the railroad. protected against corrosion by a PVC lining and a system of forced flow cathode protection.183 billion will be required to build a new concentrator in Germano. Some 62 hours after leaving there. pelletizing and a port to export pellets and pellet feed. the concentrate arrives at the Ponta Ubu terminal next to the pelletizing plant. In 2004. It was the first to exploit itabirite. Samarco has optimized production and raised capacity at its pelletizing plants to some 14 Mt/y of pellets. Samarco’s Germano unit (mining and beneficiation plant. at an elevation of 1. The fines recovery plant (cycloning and column flotation) recovers the fines discarded by desliming. . Steel. More than 350 Fabri-Valve products for CVRD C VRD’s new Brucutu mine has chosen the Engineered Valves Group of ITT Industries to supply more than 350 valves. It is expected that an investment of $1. Slurry is thickened to 70% solids.6 Mt/y capacity). Multiple faces are extracted and wheel loaders dump on to the 8-km mine belt system that feeds the beneficiation facilities.mining beneficiating. is going ahead with a $760 million expansion of the Itabaritos iron ore project over the next three years. The company has just received Board approval for its Third Pellet Plant project. 2 iron ore producer and exporter.001 mm) that are detrimental to flotation. Africa. The pipeline is made of API 5 LX-60 steel plates. with a flow rate between 1.011 m.5 m.37 m. Samarco’s iron ore reserves are located in the Alegria Complex.5 Mt (dry). And CAEMI makes $2 billion Caemi Mineracao e Metalurgia. selling its products to over 15 countries in Europe.5-mm feed for the grinding section. This valve has a unique. Available in bonneted and unbonneted versions. The expansion highlights market demand strength and supports iron ore’s 12 International Mining December 2005 continuous growth trend. followed by column flotation to prepare the product for slurry transport and for the pelletizinng plant. according to the research note. At its highest point it crosses the Caparaó range. Its original mineable reserves totalled 1. Pre-primary and primary ball mills prepare the feed for the flotation circuit. All recovered water is recycled. shallow overburden and low impurity levels. There is then a secondary grinding circuit.200 Mt. Brazil’s No. The beneficiation facility recycles about 93% of its water.8 m/s.5 Mt/y of wet concentrate) is in Minas Gerais. the design includes two constant contact seats. in the municipalities of Mariana and Ouro Preto. but due to careful maintenance. of which 13. from 45%. Belt mining now accounts for some 70% of total ore transport. The pipeline’s useful life was initially estimated at 20 years.200 m3/h. It is also safer. since there is no need for truck haulage. Pumping station I is at an elevation of 1. at current levels. This project will increase 50% owner CVRD’s revenue by about 1. Asia. in the eastern portion of the Quadrilátero Ferrífero.6 Mt/y. This launched the Carajás Iron Ore Project.180 m. It has about an 18% share of the world market.000 and 1. and of its total 396 km. it provides a bubble-tight shutoff in both directions at the full rated pressure. at the current production rate) of iron ore resources. Deutsche Bank said in a research note. In the crushing and screening plant. a unit of CVRD. which insures positive shut off independent of line-pressure.Operation focus continued until 1977. This will expand capacity by 54%. withdrew from the project. in order to increase its presence in this market. consisting of 70% ore concentrate and 30% water.all the staff of Thomas Mining Associates extend their greetings and the opportunity of December 2005 International Mining 13 . The capex estimate is up to $1. based on reserves of 44 Mt containing 1. MBR achieved a new record in the second quarter of 2005 with sales of 12. in 1977. Right: Map of Samarco’s operations. and conceptual studies for other deposits To all our Clients. CVRD says “the extensive infrastructure of Carajás and the process-friendly features of Vermelho . and 2. The expansion comprises $462 million for a new pellet plant.5 km/hour.with an expected commercial life of 40 years. with start-up scheduled for the fourth quarter of 2008. CVRD is also “developing the pre-feasibility study of the São João do Piauí nickel deposit. The 7 Mt/y pelletizing plant at Nova Lima will export about two-thirds of its production.2 billion. environment. Indeed. Steeling itself Besides iron ore. Chief Executive Roger Agnelli has signalled his target to diversify into new countries and metals with the aim of becoming the world’s third largest mining firm by the end of the decade.5% Ni. CVRD has invested significantly in other constituents of steel. and LME-grade nickel cathode was produced. at a speed of 6.800 t/y of cobalt metal . and the one with least risks in terms of operational stability.The ore travels for 63 hours. $282 million for a new beneficiation plant and $15 million for a 4 km ore conveyor belt linking the pellet plant and the processing units. Gerais. the Vermelho nickel deposit in the Carajás mineral province is being developed. Candidates and Friends .With its extension of 396 kilometers. Average leaching extraction exceeded 96%.000 t/y of nickel metal. Since it went into operation. Discovered in 1974. Few doubt that will come about. it has transported over 230 million tons of slurry.” Furthermore. CVRD employed an international team with extensive operational experience in HPAL and nickel producing plants and believes it has minimized the risks of problems similar to those that have been seen in second-generation HPAL plants.8 Mt. CVRD believes that “by choosing the process based on precipitation and re-leaching of nickel hydroxide it has selected the most proven process. through 24 municipalities. and work health and safety. The processing plant at Mina do Pico in Itabarito will produce 10 Mt/y of iron ore concentrate and is due to start-up in the first quarter of 2008. Above: A truck at Timbopeda mine. After almost five years of development of the process and project. Vermelho lies 70 km south of the Carajás iron ore mines and 15 km east of the Sossego copper mine. the Samarco pipeline links the units of Germano (Minas Gerais) and Ubu (Espírito Santo).” Pilot plant campaigns were carried out at a technology centre of excellence in Australia. making the total for the first six months 23. Its estimated production capacity is 46.place the investment cost of the project at a more favourable level than those of other laterite-nickel-based projects.3 Mt. The project involves construction of a high-pressure acid leaching (HPAL) plant to process nickel laterite.in terms rheology and the availability of good quality water at the site . describing itself as “an emerging mid-tier nickel company”. The manganese deposits at Azul. Canadian-based Canico. a high productivity smelting facility based on conventional Rotary Kiln Electric Furnace (RKEF) pyrometallurgical smelting and all related infrastructure and equipment necessary to produce and deliver ferronickel to market from the Onça Puma lateritic nickel deposits. Carajás were discovered in 1971.28 Mt/y of ore over an ensuing two-year ramp-up period. The most prevailing performance figure has been low cake moistures. is developing the Onça-Puma nickel laterite project in Pará State. a single line plant would be constructed over a 37-month period commencing with basic engineering at a total capital cost estimated at $762 million. carbon and silicon alloys used in the steel-making process to remove contaminants or as an alloying element to change the steel’s crystal structure. sinter feed (40%).7 Mt produced. Exploration outlined reserves of 65 Mt of manganese ore: 53. 65 wt% < 45µm. manganese. This plant produces three products: lump ore (50%). Rio Doce Manganèse Europe produces ferro-alloys in Dunquerque. IM The first Larox PF filters have been in operation in CVRD’s Carajas plant for several years already. Mato Grosso do Sul.Operation focus in the states of Goiás.0 – 8. The study considers building a two-line plant in two phases. slurry solids content around 65 wt%).4 Mt of manganese dioxide (for making batteries) with manganese dioxide content of over 75%. would not have the same mechanical properties were it not for the manganese added to it. The increased price represents a premium of approximately 53% over the volume weighted-average trading price of Canico’s common shares on the Toronto Stock Exchange (TSX) for the 30 trading days immediately preceding the September 15. The beneficiation plant. 14 International Mining December 2005 . This year. as we know it. Manganese and ferro-alloys CVRD is also one of the world’s biggest players in the manganese and ferro-alloys market. and Rio Doce Manganese Norway produces ferro-alloys in Mo i Rana. The first line would reach full throughput capacity of some 1. in the range of 8. São Paulo and Paraná. accordingly. When both lines are in full service following ramp-up of the second line. with an annual processing capacity of 1 Mt. aluminum and copper. Rio Doce Manganês (RDM) has three mines and five ferro-alloys plants in the States of Bahia. Minas Gerais and Pará. Initially. CVRD’s consolidated gross revenue from the manganese and alloys business was $666 million. On November 11 Canico announced it had entered into a definitive support agreement with CVRD following agreement with CVRD to improve the terms of its previously announced take-over bid. at a total additional capital cost estimated at $352 million. The feasibility study prepared by Hatch plans an open pit.7 Mt of metallurgical ore (used to produce ferro-manganese alloys) and 11. The company broke records in manganese ore with nearly 2. came on stream in 1985. 2005 date of announcement of CVRD’s intention to proceed with the Offer. France. The properties of steel are changed entirely by adding manganese.5 wt%. In 2004. CVRD’s Technical Advisor in the Manganese sector. Regular and skilled preventative maintenance is needed in order to keep the availability high. Norway.” Part of the Alegria mine’s 8-km belt system that does the work of many haul trucks. and gauge ore (10%). The board of directors of Canico has “determined that the Offer is fair to all shareholders of Canico and in the best interests of Canico and its shareholders and.56 Mt/y of ore. “Steel. The second line would be built over the next two years. Nearly 90% of the ore produced in the world is used in the steel industry in the form of manganese ferro-alloys. while the filter availability has been over 91 % in undisturbed conditions. dewatering fine hematite ore (Blaine value around 1500. The yield will be a refined ferronickel product (about 25% Ni and 75% Fe) for direct sale to stainless steel mills. aiming to turn Brazil into one of the largest nickel producers of the world. Manganese ferroalloys are iron. has unanimously recommended that shareholders of Canico accept the offer. and the amount of manganese alloys added depends mainly on what the steel is to be used for. the company expects to invest $93 million in the manganese and alloys business. the smelter would process approximately 2.” explains Nelson Janotti. Urucum Mineração has manganese and iron ore mines and one ferro-alloy plant in Corumbá. Four CVRD companies produce manganese ore and ferroalloys. Manganese is the fourth most-used metal in terms of volume.” In September CVRD made an offer to acquire all of the outstanding common shares of Canico Resource Corp. second to iron. in co-operation with the World e Managemen t Tools – for Tools. designed to see how mining could add stand to benefit from their activities. and that g the Planning at plans are re Assistance Programme (ESMAP). guid toolkit includes elines and good need for a practical toolkit that would a supporting in practice case st troductory volu udies. Palabora Mining will any projects be supported after the were incorporated and the Toolkit project Co. The imperative I. III. notes Peter in partnership with local people to develop are all covered by the Toolkit. By working together as to the commissioning of five studies companies but also the stakeholders who an industry and with all our stakeholders. which can be applied at dility for implem enting them. Evaluation Tools – for m easuring prog goals. industry. operations and eventually stakeholder regional advisory committee. Particip ress and assess has its roots in southern Africa and the atory monito ing results ag ring is also co to plans durin ainst program vered to ensu momentum of a World Bank workshop of g implementa me re that modifi tion. The to erational stag lasting contribution to olkit offers a st es. achieve genuine and sustainable sociomembers have economic development from mining committed to “contribute to the social. which they are now ols – for desig d. Good practice happening among ICMM’s membership is stakeholders and potential partners? How examples from other parts of the world plentiful. The concept is to ensure This sharing of good practice. Assessmen behind this statement can be seen in the t Tools – for as sessing the so munity mem cio-economic latest batch of community programmes bers. and across organi specific organfor planning th project is designed to foster closer sations and co at may require mmunities. community that last beyond the life of a mining . Topics covered included sustainable can be found within ICMM’s Sustainable sustainable development. participation processes and economic and institutional development What has this meant in practice? In conflict management. are the potential impacts and opportunities fine-tuning the southern African experience The evidence that this is already from a mining project? Who are the key was given a global context. ning participat sustainable de supporting. cations are m the Southern African Development ade The toolkit also Community. from explor ep-by-step ap each tool. V.com. Partnerships n members. The result. Gas and Mining Division “is a Limpopo. Relationsh communities and governments in order to ip Tools – fo r building an all stakeholde d maintaining support sustainable development activities rs. through southern Africa through a small. there are capa alistically reso ble people ta urced and sche king responsib The Toolkit. The International Council on for sound com local perative activ munity develo ities and ther pment progra Mining and Metals (ICMM) is launching emmes. in community and social issues around that they can be accessed and used by all whatever area. South Africa.” short a set of 17 tools covering five key The resulting draft reports were discussed the idea being to enhance the contribuareas relating to a mine’s development. how th environment. Planning To e items covere a new initiative. including effective relatio governments organisations nships betwee . the mining value and support community developThe bottom line or underlying drivers sector can successfully contribute to ment. any ex build and supp Identifying co isting conflicts being taken forward by some of the ort a commun mand the reso ity developmen urces needed world’s leading mining companies and in t programme to are among th II. and the Toolkit project was born. Programm the project. IV. For example.icmm. The gardens provide community baton as a key element in its toolkit presenting all of the stakeholders incomes and produce to feed families. core mission: namely to promote and with the best local and global experience and training in financial. mining operations anywhere in the world. is a core element of mining in the region and their work led the relevant parties – not only mining ICMM’s mission. such es to support lable for intern The Community Development Toolkit as a company al planning in or NGO. ey live. management provide leadership on sustainable that offers practical guidance for all stages and technical skills has enabled the development practices in the mining of the development process – from first project to become self-supporting. the Toolkit project began in The Toolkit project does exactly this by and local community members. including local communities. multiproviding a set of practical tools that to construction. at two workshops in Johannesburg in tion of mineral-related investment to operation and. public Development Framework. of the communities in which they operate. What 2003 and after considerable debate and sustainable development. its closure. Manager of the World the Titirheleni Community Gardens in For its part. ICMM The toolkit a t a glance December 2005 International Mining 15 . activities. IM development assessments. van der Veen.Licence to Licence to operate ICMM and World Bank launches community toolkit M ining companies are increasingly looking for ways to ensure that their There are 17 investments make a longtools that cove r a mine’s op closure. ory developm velopment. a subsidiary of Rio Tinto. has worked mine has closed? These and other issues came into being. co-ordination relationships between mining companies. co are the founda fore essential mpanies and tion of all co-o operation. support good practice in local community decommissioning and closure. The full me and is avai help the various parties work together to lable at www .” Committee members had expertise in development. G ent programm uidance is avai isations. ultimately. ICMM has taken up the Bank’s Oil. Th ation through broader socio-economic development in proach and de ese fall into six to tailed guidance categories: on how to use the areas where they operate. The workshop agreed on the sources key re ferences. contacts between development geologists In fact. This se supporting an Bank and the Energy Sector Management t of tools aim d implementin s to ensure th uled. Once this preparation work has been done. depending on the height of the gallery. When the grout reaches the level of this . The grout is pumped through a placer unit that ensures that the correct amount of water and air is mixed with the powder. Minova reports.6 m.Innovation intelligence Ventilation control Minova provides answers that get fresh air to the face quicker and cheaper A A 16 International Mining December 2005 s workings become deeper and more distant from the ventilation inlet. When using the Tekseal method no hitching is required and the floor is taken to solid. Tekseal is Minova’s answer to these limitations of traditional block seals. Each wall consists of 120 mm square posts evenly spaced across the opening. a small opening in the front wall is left as a means of egress for the construction crew. It is important that the cloth is overlapped at the edges to provide a seal when the Tekseal grout is pumped in.5 to 0. In a working height of 1. 200 x 200 x 400 mm blocks. There is also the high cost associated with the transportation of blocks to remote areas. a seal requires 360. The form work consists of two walls spaced at least 1. A traditional block seal can typically take eight to ten man shifts to construct. Once this form work is complete the Tekseal grout can then be pumped into the form work. the materials required for the job need to be transported to the site. a 24 hour drying period is required when the Installing the filling pipe into a Teakseal stopping A complete Teakseal stopping seal is half built. These can include brittle failure due to roof movement and block degradation from acid mine water.2 m apart. One traditional method of using blocks has a number of associated problems. A pumped seal of the same size using Tekseal takes about half that. mines that experience severe roof and floor movement require seals to remain effective in zones of convergence. This gives a grout with a density of 0. In particular. This is a specially formulated pumpable grout which allows a seal to be erected quickly and safely and also offers cost savings through reduced construction time and transport costs. better seal construction technology is required to ensure that fresh air goes to the working face. The final stage of construction involves nailing or stapling brattice cloth to the inside of the form work. Once the back wall is fully constructed. The grout is pumped through a small hatch that has been left at the top of the form work. Planks of 20 x 150 mm size are then nailed across the posts at 400 mm centres. A block seal requires a large amount of work prior to construction such as keying into the ribs and roof and making a solid footing which may require drilling and blasting to a solid bottom.7. with a second drying period before filling the cavity to the roof. each weighing 15 kg. In addition to this. 0 now produces per cath 00 t/y of copode than 200. into considerati en elevati at the Deep d aggre. your technology. district of its strength $21 million Timika airport by of the operators of satisfying extremely side of the ore bodies [Interm can lose 33-1/3%. effective . a operating environme recently inaugurate tinues to prove dominates through and probab from the alternative. . Is it. and especially l splice can be belts will Ertsberg material robust reserto the aggregate TheInternat to dusty to for Freepo Deep Ore alter“A mechanica coal mines. for example. factors rable nt. “While methods.97 g/t eastern ments for the splice is not as surface and undergrou tely 50% reserves. Also. uptime increasing splice is as strong 43 km north from new production Tipoeka line net ultra-modern trict reserve district with its massiv cave ing 1.09% Timika. tin. operation ators.belt choice include of ContiTech. “minin ’s generally often the pioneering. application. ainous producing a 236.3 particular than the repair. with this risk try and for unity both for the comes the compa host counhost countr ny. Minova can offer an alternative to these cementitous materials.3% – cost of $45 the initial gold pro. In certain situations a seal or stopping must be installed quickly to control ventilation problems. Underg to these orethe from six to eight Shanxi-Phoenix access Phoenix a belt back. and to the Then large or small set up between takes time to cut exploration is a joint venture belt ends together. the port to the ation budge expected to total in underground ies. dwick repo rts Promote your project. Production 000 t/d from the u46° angle. sector is potash. capacity PVC and presses. Highly prosp al crisis of operating million and during exports 1997-1999 in Januar Oxiana acquire ective began grew at – and y 2003. s. coast. for example. ners Lu An Mining of the Shanxi-Phoenix material be loaded will be pressure and allow in the direction but also Anthracite Group. your operation. the mining iron ore.7 million tion of just . mechanica conthe compaof the Moz of gold. from Rio gold at an than 300. full potential. mated to d the followi really ure double that time not at Grasberg PTFI was ick finds. ains Indonesi dwick expland John Cha erground both und ng surface mini and four s. ing.2 Phoenix Conveyor application. quality stanis domin tough ing Rio ediate mining? Belts with most in mind. representing Belt Systems investing are a caving footpr ensure that the the Grasbe sometimes where located some ore convey a panelMt of ore Mt of copper. It in a quarry carrying solid woven fabric belting tends to be at the mine and rg open a conveyor operating cord a height complex dropped from of PVC. The gold of S S Sepon s e sustaina ts model ble Oxiana. The seal is then pressured through pipes and valves that have been placed along the top of the seal.769 The Grasberg River. type of material money finally determine Brazil. Au manufactures specific operating strong as you pit (final and t mill.200 rg compl l es (recov number of factors “Vulcanized splicing Lerch. Gerhard The Grasbe view) illustrates However. to the mine Are 2. This What is the required t/h). Amamapare.longwalls or roadways and for sealing roof cavities against methane build up. 3. nificant Whilst thereare conchallen are siggreat opport ges. were ground or in particularly the end of 2004. ng year. design 0 t/d belt manufactu is shown Block A often requiring d Second.769 Mt and 3. high foaming factor and is non flammable. The vulcanized to complete. incline or decline? nance has two eight hours to and keeping repair by restrict does it have an require six to issues that would no part l splice is installed surprise belt failures. As as a ‘Least . is similar and has in size to a popula 5. The mill three main capital processing plant. tion and which is now loaded edges? steps. In certain areas. although there 3D isometric wear.should be taken is preferred in that ex shown materi€5 million in Changzhi. always be designed at this facility two-ply belt can while a Gossan orebod ated by site connec million Belts produced en route. The that the reduced high quality strongly deposi exports. Sizes range from one page advertorial to multiple-page supplements. By be 100 Mt. Any leaks in the formwork can be sealed using rags or paper. stones and stages. that year concentr this ld producet of copshou 000 about 800. The application of the seal is quick through the rapid reaction time and high expansion of the Carbofill product.500 project is on. Laos. not includingnot conveyor. mine will be exhaus view of the are exceptions of 2-3 m will require [soft material] to a of the few componen will items. get investors. in its develo precious gold. CVRD’s save space and are plied fabric. t. ions. and it complex that constantly stops ed re . such as a heating in the goaf. By ment has to y’s export deposits 2006 it is the econom move out of this were discov gold and coppe revestimated project will status and y has grown r although ered. how the cost of the waiting (usually the downtime ace also conveyor system to and take into account run? This will crew to travel Splice the mainbr Manager . Septemb the numerous additio than its vulcanized handling Zone (ESZ)] Zone (IOZ). The Carbofill range of products comprises a two-component phenolic resin based foam. Access Amamapare on has belonged The Year-en tive drilling reducsplicing has been orebody. eliminating any need for specialised and hazardous solvents. hot or cold conditions? safety requiresaying that a vulcanized A vulcanized airport of con) and block of ore averag there The aggrestatutory heavy-duty conveyor The compl west of the belt is false. The equipment used is easily cleaned as water can be used. is of However. or concentrat with sharp or roundsouth.220 mm wide Duty with Flexco mainteFinally. of the up tant. Where this occurs Carbofill is an ideal solution. Does there any space “The mechanica minimum. helped carcass. The copper mining traditio project is mainly mount an SX-EW operation n. This enables control of such events to be effected easily and efficiently with the minimum amount of material transport. in the mining com Papua. depending on the variant used.05/lb.Heavy the conveyor fast will Market for the vulcanizing The amount of beltKevin Finnegan. which. For t contrib at a staggering and steel cord best belt for the 200. needing a water supply and dedicated placer machine. were consid ts. sec175 Moz and the constraints gold and gold reserve. has produc around 15% 16 Internat Since d Sepon ed more 2000. the This was km north Mill Level ons of 2. comto consider the partConveyor Belt the appropriate It is also essential will the and its Chinese you must apply heat and From what height part of ContiTech. g comfirst to invest They are have been in countr recently ies which sidered to reformed or be ‘risky’. t.” ore bodies splice not only been brough the pit. Benefit y s to the microeconomcome in terms of both improvement ic and macroeconom Above: Location ic Map tion effects s and significant Right: Oxiana demonstra. sharp rocks tors to that ted by about have a very different ts made rubber orebodies of . underground parts. 2. The of tion. But by type and solid woven large. The veyor belts for lose approxima mineable are capable ts the is gate explor tions. a failed user to the or coal 115. A Amamapare.00 of for the bodies totalle High technology and other Shanxiiit drops the ore deposit below tion rate of at the end ls district is therefore important. reserve but that body. Contact: Emma Joseph Publishing Assistant International Mining 2 Claridge Court Lower Kings Road Berkhamsted Herts HP4 2AF UK +44 (0)1442 870 829 Fax: 870 617 emma@im-mining. It proven and round produc es? Is the material facilities at ports. and e open gate proven of 2004 produc above or below Cu. which country. a big classified well the GDP Developed’ by the UN ing there as increas Sepon curren explains country.” d terrains with in began operating great minera in January With little l 2003. an Aust ralian copper and gold and expl mining oration company. These belting. for more identified minerals grew by mine the source of an real GDP Oxiana developroject was sold. splice can take such also be installed Ertsberg probable in and/or valuable. In the 1990s. And benefit developed come in s to the the initial Sepon terms company gold project underexplore of first mover at a cost of $45 advantage million and potential. belt affect capacity points out that set up at your parameters should a 1. The new reserves. with nation of the above ond-largest the bottom of the are preat $0. since 1993 ing about 15% that tly the first of the countr contributes clear goals the Lao Govern Hegarty of the Sepon during which time enue. undermine. any includcondias the original heavy-duty steel-cable nd. today averages whole first copper mine. Chairman of the erable) of mately 1 from primarily and 4. in the right their some 141 1. the belt under Group and Jingcheng Will the The ing conditions. Plied and steel is the Grasbe 2015. Shanxi.00 then it Tinto Tinto in October average highly prospe had identified 0 oz of 2005 cash cost “We have Laos as ctive and of $160/o already expand had been mine and z. exploring deposits for coppe in Thailand other parts of Laos r and gold and China and Prominent and is develo in Hill ping the South Austra copper-gold deposit in Managing lia. Yet its costs s largest world' copper reserve curve. Its rapid reaction time and high foaming factor allows a seal to be placed extremely rapidly even in the remotest of locations. or at of the several thousand does multiply belts. Carbofill can also be used for other applications including foam support in roof cavities on a Indonesi PT Freeportates perhaps (PTFI) oper greatest the world’s plex. The resin foam is generated using a suitable pump. Owen Hegart y. some ex is 118 km belts.IM Injecting a cavity with Carbofill 1 M ISSUE 15/8/05 17:30 Page 25 n Focus Operatio September 2005 hatch it is sealed using a pre-cut length of plank. pounds. Moz of gold.belt is specified for Grasberg into China with material flow. bination that will example. Systems hours north. which is provided by Minova.com P coppe producing oreErtsberg TFI started from the s were estilate 1972. There ions are province of with km. the UK.800 copper cathodes km 2.800 key goals . fig1987. worse produc increas int of approx the south 96 rg minera correct the cleanup is recently moved nominal or drifts. developing to ex was discov 7Mt of copthat is ever ore compl yielded well over contains and to a technology It still has already Moz of gold. Is the conveyor ng of above sea rg minera d an ny to which Phoenix 146-Mt its value as a cost the als handli le recove international PTFI’s port Mt Grasbe old Zone. the lift height The versatile combetween used to make with a 26 m the is this unique of the year. passing 0. and those required approximately Ran’s share) with the safety Mining 7 is imporves three-ply belt installed East Zone (DOZ) the rt McMo ional be conveyed dards.preventing complete. The twin components are passed through a mixing pipe and injected into the cavity or ventilation seal site. The advantage of these products to the user is that a minimum amount of material has to be transported to the seal site. as it to the betwe the results since Executive Board gaining favour affecting (3D isomet wonder and layout ls dislevel. covers on site. and fit the Systems Asia. size continued processing as one despite the annual average econom rate of ped ject at a ic growth the region sharp fall-off in growth 6. the Dom native. The esting minera country does have interl potential resources with known “At presen that include gypsum. Is the conveyor mm or more and Are be considered can be 1. the physical belt conveyor flat or ing used to splice it can ground. In these situations there is often very little time to transport large quantities of materials into remote locations.im-mining. ed the explorare further increasstudying the possibgold ility es in capaci ty. The 1988 and John Chadw its ered in aware of The message. your service Supplements and Advertorials in the world’s bright new publication for the mining industry reach potential investors/buyers in the farthest corners of the world. The than 30% than a decade significantly to mining and government has of ered criteria and meet Rio Tinto’s . km by 1 PTFI’s operat the southwest m from posi. trim lumps. cementitious grouts are not always suitable.as precious metals in storage and faster and easier Stockwork orebodies high reserves During 2004. get buyers . s and more gold in 000 oz/y of that coun John Cha try. cook onto the belt? manuthe belt to cool. An access road 2005. Tinto’s share. and Conveyor Belt ores. cost effective reserve of 23 probable of per and become more nmental proven and massive 61 Moz ges of enviro aggregate r and a meet challen coppe It is the 25 Mt of of silver. Rio ional Mining a year. but ping since 2003 Sepon is when Sepon located in approximately commenced southeastern its operat 600 km Laos. downtime to a one of several width of a conveyor?or does the length or l Mining 29 system is unimportan your crew in any line Internationa of the conveyor critical run in a straight October 2005 the conveyor among the most around curves? belt splicing is combiit need to travel notes that “any Fenner Dunlop P e Conveying th message Service units — on the surface and underground Prospects for 2006 Clean mineral processing F F Freeport Indonesia — the greatest in the world epon is the project in first major mining Laos and beginning represents of a promis the industry ing mining there. deve loped the copper Sepon and Laos over gold mines in years and the past five up to 60.5 r per and a particula Caving is of the PTFI ations expertise ound oper undergr r in P T FI defineslass worldc Operation Focus Conveying www. The the largest projec Laos and private busine t is now the bigges ss in t private Oxiana is employer. etc.” account for more poverty too small and . impact on has made Laos is still from the capital GDP. ($15 should and Big Ore when vulcanized. mining Vientiane. vulcanized splice material be loaded steel-cable belts total cost for the an angle? factures not only dollars. line for current 2. Oxiana Director panies are notes. design shown the Kucing Liar may think. has rapid reaction time.84 g/t Ag. s of highland a.000-240.com December 2005 International Mining 17 Written for miners by miners Get finance. The er 2005 ns Truly flammable. ric some locations. one of the bigges pit. explains there factors may be are right calculated to be enner Dunlop half of basic types sent in any particufor the second 2005 costs essentially three the it Sossego in $420 gold categorized by conveyors at lar conveyor and assuming Metso inclined conveyor belt. coal.” It is one to cave the carrying can be expensive sits to of belt to one take heavy abrasive the then a new t into production for a Conveyor belts in expenditure. or backhoes. It is a practical fit between [wheel] loaders and the electric shovel. “Other major arguments that may steer the decision towards backhoe machines. never forget that wheel loaders also have their role to play. This will reduce cycle times. A very important point is keeping the operator interested and alert. Many of the pros and cons of backhoes versus shovels have been well documented. or wheel loaders.” he says. operators often see the whole of the pit and can stay interested in the whole mine operation.” That booklet devotes 48 pages to machine selection. An operator on a shovel sees little more than the face and each truck as it comes up for loading. and Dr Jörg Lukowski. However. Of these areas. maintenance cost.Loading tools P P Buckets. and minimal total harmonic distortion. And what about bucket wear? bed and can more easily control the dumping of loads to minimize wear and tear on the machines. the backhoe operator has a great view into the truck As noted in the CVRD article. “hydraulic and electric shovels each deserve fair consideration. “are the greater ability to dig selectively and the reduced swing angles in comparison with face shovels. From the equipment point of view. power grid compatibility. the most versatile of the loading tools available. looking at the pros and cons of hydraulic excavators and electric shovels – see table below. efficiency.” &H in the Excavator Selection booklet of its Peak Performance Practices series says. backhoes and more Choosing between electric and hydraulic shovels. one of Liebherr Mining’s Directors feels that the “backhoe is the way of the future. Siemens suggest ongoing loading tool developments that will perhaps have the greatest influence on surface operations over the coming years. he put forward some Electrical wizardry The application of AC drives in electric shovels has facilitated dramatic improvements in production rates. or…. Standing on a muckpile operating a backhoe. And scrapers can provide extremely good economy in the right application. IGBT shovels and draglines using active front-end (AFE) technology will set new standards for dynamic performance. The agile hydraulic is an excellent machine for blending materials and selective digging where frequent moves are necessary or electric power is lacking. reliability. increase reliability interesting points in favour of the backhoe from the operator’s standpoint. much of Samarco’s iron ore is loaded directly by wheel loaders onto bench belts in a mining method the company calls ‘belt mining’ 18 International Mining December 2005 . control of power factor. and system intelligence.” In recent discussions with IM. Fueling 3. Environmental Impact 1. Insurance Liability 5. Digging Phase Controls 3. Manufacturers 7. Debris Removal 3. Proximity to Face 9. Fluid Disposal 3.Machine Selection. fuses LeTourneau offers a range of electric drive wheel loaders for mines.to the latest model. the 495 uses a Siemens AC . Maintenance 1. Cycle Time Very 2. Trail Cable B. Digging Forces 3. Quebec Cartier Mining (QCM) has just ordered another Bucyrus 495 series electric mining shovel for Mt. Following Layers Up a Grade Low 5. Removal of Obstructions on the Mine Floor EMS HMS Equal HMS EMS HMS High High Very High High EMS EMS EMS EMS High Low Low Very High Low High High High High Low Low Equal HMS Equal EMS HMS Equal HMS EMS EMS HMS HMS High Very High Very High High High Low High High High High Low High HMS EMS EMS EMS EMS Equal EMS EMS HMS EMS Equal Equal Source: P&H and lower capital costs associated with power grid infrastructure. Capacity 3. Truck Loading Very 15. Technology Knowledge HMS EMS EMS EMS Very High Very High EMS EMS Very High Very High Very High Very High High EMS EMS EMS EMS EMS High Very High High High EMS EMS EMS EMS C. Project Risk 9. Reliability Very High EMS F. Wright mine in Quebec. Machine Weight 6. Capital Cost 2. Removal of Large Rocks from the Digging Face 11. autonomous operation. Drilling and Blasting Requirements High 4. Already. Rock Handling Capability 13. Support Infrastructure 12. Fuel Cost 4. Preventive Maintenance Schedules 5. Cleanliness 2. Power Selection Options 8. December 2005 International Mining 19 . Maintenance stations that provide contextual. Fill Factors 5. Machine Assembly Time 5. online troubleshooting will enhance on-site diagnosis and facilitate remote fault diagnosis to minimize the mean time to repair (MTTR) and maximize machine availability. Resale Value 11. Reliability Indicators G. in the future. Siemens has been involved in the first gearless mining dragline with all AC drives. Spillage H. Cab Location 2. Cost Per Unit Loaded 3. Geology and Deposit Characterization 1. Material Discharge 8. Visibility High EMS High High High Low High Very High Low High High High EMS EMS HMS HMS Equal HMS HMS Equal Equal HMS 12. the reliable operations of AC shovel drives with AFE front end and IGBT inverters have been proven and we are seeing the expansion to smaller and larger shovel payloads. Reach Very 10. Truck Compatibility Very 14. Greenhouse Gas Emissions 4. Floor Cleanup 6. Here is an L-1850 in action. Floor Level Digging Reach 7. ranging from the largest in the world. the L-950 Pit Bull (also available as a wheel dozer). Power Supply Requirements 9. Like its predecessors. Technology Change Adaptability 10. Relocation 10. Bench Height High 2. Planned Component Replacement 4. where it will join two other 495 series and two 295 series shovels already operating at the site. Machine Operation 1.IGBT electric drive system. Productivity 1. Project Life 8. Availability 2. the L-2350. Use of Propel to Maximize Fill Factors 5. Mobility 7. The AC system eliminates brushes. Canada. Material Abrasiveness High 6. Ground Bearing Pressure (Static) 4. Working Dimensions E. Digging and Loading 1. Ambient Temperature Adaptability 2. Machine Life 6. Ease of Maintenance 2. trend analysis and. Ergonomics 4. Digging Material Layer by Layer Low 3. Digging Below Ground Level 4. Commercial Considerations 1. Selective Mining Face Digging Low D. Technical 1. electric (EMS) versus hydraulic (HMS) mining shovels Criteria Selection Priority Advantage Criteria Selection Priority Low High High High Advantage A. Siemens’ SiRAS/MIDAS systems provide diagnostics. frequency converters with insular gate bipolar transistor (IGBT) technology. It says “the expensive task of replacing bucket components can be reduced by protecting them with Tuffstudds. To further productivity. A low velocity example of this is when a dragline bucket digs into the earth and a high velocity example would be rock Liebherr is launching its R 9250 Litronic model. The Tuffstudds Wear Protection System from Sulzer Metco (Canada) provides wear protection for all types of shovel buckets. and availability and productivity fall. cutting edges and tooth adaptors q Make upper and lower outside wing shrouds last longer q Extend wear life on inside wing shrouds. The resulting wear can be extreme when high-stress or low-stress abrasions are accompanied by some degree of impact and weight. With this drive and control package. this 495 will be equipped with AccessDirect machine diagnostics. Favato. preferably austenitic manganese. Sometimes this is at the expense of harder and more abrasion resistant alloys.” crushing. Carlos A. AccuLoad and MIDAS. After 15-20 years of around-the-clock operation in the tough environment of open-pit mining. tooth adaptors and wear bars. Electrical parts are particularly vulnerable . A fully modularized electrical room ships directly to the field to facilitate the erection process. a new 250-t mining excavator. ABB says a “revamp is a fraction of the cost of a new machine. Carbide containing alloys are used successfully. reported an increase in productivity of 10-20% and a reduction in MTTR from three hours to one hour within weeks of ABB revamping a 16-year-old BE 295 B11 shovel at the Carjás Range iron ore mine. The metal surface receives prominent gouges and grooves when massive objects (rocks) are forced with pressure against them. when supported by a tough alloy. AccessDirect will also be upgraded on this 495 to include two additional systems. but in many cases adjustments or repairs can be made without the need of going to the machine. MIDAS provides a means for production tracking and maintains ongoing detailed records of the various machine motions and activities.” Tuffstudds can be used to: q Give extra protection to high-wear areas such as lips. drive control. CVRD. we bought the most competitive system offered to us.their performance deteriorates. offering complete electrical revamps with AC or DC drives. For machines in remote locations that would otherwise require hours and sometimes days to reach. Machines in remote locations are as close as a modem or Internet connection. for instance. yet achieves the same standards of availability. this can be critical in maintaining a machine’s productivity. walls. ABB is a market and technology leader in shovel renovation. The result is a history of the machines operation allowing managers to track and set benchmarks for improving productivity.” Not surprisingly CVRD quickly placed orders with ABB to revamp the four other shovel excavators at the mine. intelligent control packages and visualization. productivity and estimated service life. floor and back door q Protect underside lips. Gouging abrasion also places a premium on toughness. In both instances the action of the material on metal is similar to that of a cutting tool. AccuLoad provides for the accurate weighing of each individual dipper load. 20 International Mining December 2005 . Maintenance Manager at the mine. said: “This project ends a nightmare of 16 years [of unscheduled downtime]. Then there is the E Design (Extra) for digging in Bucket wear Gouging abrasion is the most common cause of shovel bucket wear.Loading tools and RPC components that are high maintenance items on DC drive machines. This allows for direct access to a machine’s electrical system by a Bucyrus engineer anywhere in the world. The top of the adapter is protected from wear. these machines start to feel their age. AccessDirect not only allows an engineer to view what is occurring on a machine to make a diagnosis. No matter what size of shovel bucket. Tuffstudds can help in the fight against abrasion. for instance the Weld centre/Heavy duty size 250 with mechanical wear cap for excavators in applications where there is extreme abrasion. Metalogenia offers the MTG Kingmet series for loader and excavator buckets. . At the same time. Find more of what you need. Manufacture of the 994 has been transferred to Brazil where one 994 a month will continue to be built. 161 Irving. and another rib to guarantee self-sharpening. The tip has a penetrating profile. contact Hoss Sales by telephone at 1 +(972) 257-1 244 or by e-mail at sales@hossequipment. One Total Solution.. the R 9250 will deliver even greater productivity. tips. One Call. The R 9250 will succeed the R 994 Litronic. and therefore will not disappear immediately. Caterpillar offers advice on loading tools based on its complete Cat GET (Ground Engaging Tool) systems. Cat’s new 657G wheel tractor-scraper. Power is from a 12-cylinder Cummins turbodiesel engine rated at 960 kW. a new 250-t mining excavator. reliable surface mining and heavy construction machinery.or is the scraper the most efficient loading tool. the main mining excavator facility in Colmar has been expanded to cope with high demand. adapters and segments. electrical and hydraulic systems. Buy HOSS! There is a difference when you buy from Hoss™. The driver’s cab on the R 9250 is identical to the well-proven R 996 in size. 26 Service Bays. with more than 200 units sold. have been incorporated in this new mining excavator – in particular. massive equipment inventory. leading-edge machine demo technology and an unwavering commitment to excellence combine to save you time and money on the acquisition of high-quality. These exceptional machines provide 100% the performance of a like-model new machine for about 60% of the cost. However. This provides useful information whatever the make or type of loading machine.loose ground and particularly free-digging of abrasive.com to view our all-new Web site. unblasted rock where good penetration is required. the advanced design of the electronic. The stabiliser further improves self-sharpening. Each machine delivers a lower operating cost than a new machine and is sold with a limited 1-year. while the 994 is 20-year old technology. specification level and ergonomic design.M. which has been in production since 1986 and has enjoyed great success. To protect critical wear areas. The generously dimensioned Whether Buying a Truck or a Fleet.. It is fully air-conditioned and the driver is protected against sunlight and noise by blinds. TX 75062 USA Convenient to the Port of Houston for Global Shipping Requirements December 2005 International Mining 21 . it is a simpler machine and still in great demand the 994.R. Hwy. tinted windows and high quality sound insulation. The standard version is equipped with a 15-m3 backhoe bucket or a 15-m3 bucket suitable for material densities up to 1.com. These help machines apply full force to the work while protecting components from the punishment of severe applications. knowledgeable Sales Force. The Hoss Custom Rebuild program delivers outstanding value. Visit www.. experienced Mechanics and Welders. 42% higher swing torque and exceptional digging capabilities. the R 994 B.hossequipment. Caterpillar’s exclusive Abrasion Resistant Material (A. To experience the Hoss Difference. Three passes are required to load an 80-t truck. and the robust and durable specification of the mechanical sections such as the constructional steelwork. It is in the right application. For wheel loaders the GET systems include bucket edges. 3131 N. The seat is adjustable for the individual size and weight of the operator. Technologies already proven in the larger Litronic excavators.) is available on a variety of machines. 2000-hour Powertrain Warranty. R 995 and R 996. …. Our 30-acre rebuild facility. or four to five buckets for a 120-t truck. more photos from more angles and more detailed information (more answers) about each machine than are typically shown on competing Web sites. One Company. There is a rib on the box to improve material flow. more selection in one physical location.8 t/m3. Seen here. With a 15% larger digging bucket than the R 994. 994’s big brother Liebherr is launching its R 9250 Litronic model. With the R 9250 Litronic. usually loading Caterpillar 793 haul trucks.Loading tools glass area provides an excellent view of the work area.or six-pass load the 233-t 793s and produce some 23 Mt/y (dry). where all aspects of the new design are being put to the test under real conditions – a tough test as the machine is freedigging unblasted limestone. but will now be followed by a three-digit number representing the size category for the particular excavator. and for fuel. A new O&K RH 120-E face shovel was commissioned in September at Lafarge’s Mountsorrel granite operation in the UK. ensuring high. Newmont Mining’s Yanacocha mine in northern Peru ordered its sixth Hitachi EX5500 front shovel. The final fine-tuning of the machine will therefore incorporate not only the results of a host of technical measurements but also the critical opinions of experienced specialists. For example. During this sixmonth continuous trial. various oils. providing input from his perspective. They typically operate at an altitude between 3. The mine plans to run the EX5500 shovels for about 90. heap-leach gold mine. They are also equipped with the latest generation of performanceenhancing systems.6 m3 capacity and two of 50 m3 capacity. has spent a significant amount of time of the R9250. allowing service personnel access in a standing position and offering easy access to the drive components for maintenance. Lube systems and crawlers are also under scrutiny. The Yanacocha seven In late 2004. This open pit is very convenient for the factory in Colmar from where test engineers are carrying out many measurements on a variety of stress points in order to establish via finite element calculations the real-life long-term performance of the steel structures. including the P&H Loading Control Center and P&H Centurion System. Availability on the fleet has been in the low 90% range. All service points on the R 9250 are arranged for easy access and – where possible – are assembled at a central point. In April 2004. A 30. This followed purchase of an EX2500 backhoe and five previous EX5500 shovel purchases. The shovels and the backhoe have been under a full maintenance/repair contract with Hitachi since they arrived on-site. oil change. The engine and pump compartment is spacious. HCMA Peru. For instance.thanks to the excellent relationship that has developed among the three parties. Depending on material density. The Spence shovels will also benefit from monthly predictive diagnostics from P&H MinePro Services . another five-year agreement was signed that covers the entire Hitachi fleet.000 m. one of the company’s strongest mining markets. and Yanacocha .two of 46. The initial ‘9’ continues to be the product identifier. Already a field engineer from Liebherr Australia. The driver can obtain up-to-the-minute operating data via the ergonomically designed monitoring display. The seven Hitachis are the primary loading-fleet for this large open-pit. the shovels five. This agreement has been extremely beneficial for Hitachi. This level of comfort and the ergonomic layout provide ideal conditions for maintaining maximum operator efficiency throughout the shift. The electro hydraulic control system ensures high precision and makes the machine easy and safe to operate. guaranteed levels of mechanical availability at competitive rates. The first production model R 9250 is currently undergoing exhaustive field trials at a limestone operation in France. one of three 4100XPB shovels ordered by BHP Billiton for this new development in Northern Chile.000 hours. the 994 B will next year be renamed the R9350 Litronic. The 22 International Mining December 2005 next two R9250s on test are likely to go to Australian clients. experienced service and sales staff have the opportunity to thoroughly familiarise themselves with the excavator.600 and 4. The passageway between the engine compartment and the counterweight also cuts down service time. the hydraulically activated service panel located at chest height at the rear of the uppercarriage offers optimum access to the service points for lubricants. Improved serviceability was an important goal in the development of this new large hydraulic excavator. All but one of the EX5500s use 29-m3 buckets and operate on bench heights of 10-12 m. The three shovels were delivered with four dippers . Liebherr is changing the model numbering of its mining excavators. windscreen washer fluid.6-m3 bucket has recently been installed on one of the shovels that The first P&H 4100XPB is erected at Spence mine in Chile. Scrapers. Komatsu’s PC3000 is a powerful shovel. The EX2500 backhoe is used in both production and wall-trimming applications. Both feature ACERT Technology for reduced emissions. crowd force of 1.200 kg 55.85 m and a maximum digging depth of 7. designed for mining jobs.7 km/h 425 mm 680 mm 3. tear-out force of 800 kN. The 657G replaces the 657E and is the largest in Cat’s line of eight wheel tractor-scrapers.846 mm This machine also incorporates a new cooling system that reduces clogging.2 m. IM December 2005 International Mining 23 . It can be equipped with a standard bowl or an auger for improved self loading and a broad material appetite. The 657G is designed to be push loaded by a D10 or D11 dozer.8 m. Basic 657G specifications Heaped capacity Rated load Maximum travel speed Maximum cut depth Maximum spread depth Width of cut outside router bits 33. Both engines feature Mechanically-actuated Electronically Controlled Unit Injection (MEUI). The push-pull arrangement allows two scrapers to assist each other when loading. the G-Series cab and controls for superior operator comfort and efficiency. The C18 in the tractor is rated at 447/421 kW and the C15 in the scraper is rated at 337/306 kW. These dual power capabilities enable the engines to produce more power in higher gear ranges for improved gradeability and reduced cycle times. generally loading an 85-100-t truck in four passes and a 150-t truck in six passes. to improve the pass match. Heaped bowl capacity is 33. The backhoe version features a breakout force of 850 kN.000 kN. self loaded or loaded in a push-pull configuration. a ground level reach of 14. the best earthmovers? Caterpillar’s new 657G wheel tractorscraper. Standard shovel and backhoe bucket capacities are 15 m3. and maximum dumping height of 10. is well suited to overburden and waste stripping tasks as well as topsoil removal and stockpiling.With an operating weight of some 258 t and powered by a 940 kW Komatsu SSA12V159 12-cylinder diesel engine.6 m3 47.6 m3. and component changes that boost reliability and durability. enhanced service access. The tandem-powered 657G uses the Cat C18 engine for the tractor and the C15 engine for the scraper.100 kN. The shovel version offers a breakout force of 1. operates in lighter material. The oil and gas industry is the largest private sector investor in Canada. 10 years – and that it will continue to grow. 400-t Caterpillar 797B haul trucks carry raw ore to the Thyssen Krupp crusher. Reviewing the oil sands sector earlier this year. And Canada is also well positioned to grow its energy sector. “Canada is the world’s third largest producer of natural gas…and the ninth largest producer of crude oil. Some projections suggest production could reach as much as 5 Mbbl/d. We enjoy secure and efficient access to markets… we can readily access our resource base… and our energy industry is globally competitive.Oil in the Times have never been better for Canada’s oil sands mines. . Canada’s oil sands production exceeded 1 million barrels per day (Mbbl/d). “We’ve only seen the tip of the iceberg in terms of oil sands production – with only about 3 billion bbl produced to date – and that over a span of almost 40 years. About 80% of the estimated 300 billion bbl of recoverable bitumen will require some Main picture: At Albion Sands’ Muskeg River. Syncrude’s CEO noted that Canada’s oil sands is “a tremendous resource that has the potential to help reduce North America’s growing dependence on offshore sources of crude oil supply. Charles Ruigrok. as John Chadwick discovered. “The Alberta Energy and Utilities Board estimates current established reserves [of oil sands] – defined as those that are recoverable using current technologies – at some 175 billion bbl – placing Canada second only to Saudi Arabia in known economic reserves. and will rise much further in coming years. It is expected that oil sands related production will double in the next I n 2004. Fourth. Each grain of oil sand has three layers: an ‘envelope’ of water surrounding a grain of sand. very little exploration is required to establish the location.Canada’s massive oil resource e sand pit sort of in situ process as they are too deep to economically mine. up-front capital investments required for oil sands development and the long-term nature of project payouts – for both developers and the economy as a whole. However. and electric shovels load the bitumen ore into the largest haul trucks available. Most of Canada’s oil sands are found in Alberta. wellbores or pipelines in its naturally occurring state. Hydraulic face shovels and backhoes. it can be processed into high quality. Bitumen is a heavy viscous crude oil. The mineable Athabasca oil sands are found in thick seams 17 to 50 m below surface. Executive Vice President. except Belaz. and the highest quality resources are the Athabasca deposits of northern Alberta. we have direct and secure access to the US market. “First. All the world’s large truck manufacturers.” There are many challenges facing the oil sands industry. size and quality of reserves. have units in Athabasca. the Alberta and [Canadian] federal governments have introduced royalty and fiscal regimes that recognize the large scale. the location and size of oil sands deposits can be determined with a high degree of accuracy. these two considerations offer a known and stable reserve base with long-term recovery certainty. Third. “Second. . but the oil sands industry has a number of competitive advantages. At minimal cost. synthetic crude oil (SCO) that is in demand for upgrading to gasoline and jet fuels and other refined products. making them ideal for open pits. which contains high amounts of sulphur and will not flow through rocks. with bitumen surrounding the water to form the outer layer. as Suncor’s Mike Ashar. explains. Combined. not least that of environmental stewardship Oil sands are a mixture of sand. overall recovery rates at about 90% are much higher than for conventional crude.” Costs are higher than those for conventional production. bitumen and water. 000 t/d of oil sands. The initial capacity is 155. What Syncrude aimed to do was test the viability of reclaimed land for large animal habitat. The company is in the midst of a major expansion that will see capacity grow to 350. Syncrude. One of its more successful reclamation projects involved the repatriation of Wood Bison to the area in 1993.000 bbl/d. and is the operator of. The establishment Currently there are three surface mining operations. Deer Creek holds an 84% working interest in.000 bbl/d. This.000 bbl/d. and then fed to rotary breakers for further crushing to less than 50 mm. Development will follow expansion of the western portion of Lease 13. with the first targeted to come on stream in late 2010.2 Mbbl. about 70 km north of Fort McMurray. It will be a new.540 ha.000 bbl/d. The current plan is to develop in a staged manner. as might be imagined with the price of oil. or about 238. is an international leader in reclamation research.000 bbl/d. located about 90 km north of Fort McMurray. The plan sees three phases of development over a seven-year period from 2005 through 2012. production at Syncrude’s operation.000 bbl/d.000 bbl/d in mid 2006. reached 87. which is pump to the oil extraction facility. 2017 and 2020. …and on the Horizon Teck Cominco recently became the first major mining company in the Athabasca oil sands (excepting BHP-Billiton which pulled out some years ago and its expertise became Western Oil Sands). The staged development of both SAGD and mining resources is expected to produce more than 200. Two phases of development are expected.000 bbl/d of light.000 bbl/d. with initial start-up by the end of the decade. project management and financial stewardship. These plans will increase the capacity of the mine from 155. encompassing three phases of Steam Assisted Gravity Drainage (SAGD) recovery and four stages of oil sands mining and extraction.8 billion bbl of bitumen resource.7 billion Athabasca Oil Sands Project (AOSP). where ore is dumped into a crusher to reduce it in size to lumps less than 410 mm.000 bbl/d at some point in the future. “Our herd now averages about 300 head of award winning animals. The third and final phase is expected in 2012 and will bring total production to 232. would provide the AOSP with regulatory approvals for mining developments encompassing all of Lease 13. Western Oil Sands is a 20% partner in the $5. It is in the design and engineering stage and is jointly owned by Synenco Energy and SinoCanada Petroleum. On October 12.000 bbl/d.000 bbl/d mining and extraction project on the eastern portion of Lease 13. sweet SCO. Oil sands mining is messy. Syncrude (the largest of the miners). Ore is mined and bitumen is extracted from the sand. received in 2004. stand-alone 200. AOSP is one of the largest projects in Canada and among the top 10 in the world in terms of size and complexity. Muskeg River mine lies 70 km north of Fort McMurray.000 bbl/d of bitumen. after an absence of more than 100 years.152 Mt/d of material to yield 521. Suncor and Albian Sands (Muskeg River). 2014.000 bbl/d. This will require the mining of 1.” according to Ruigrok. but the companies involved make extensive efforts to reclaim the land they disturb. Synenco Energy released an updated Public Disclosure Document for the Northern Lights project.000 bbl/d. along with partners Shell Canada (60%) and Chevron (20%). totaling 500. with an initial mine train with production capacity of about 100. Regulatory approvals are in place for up to 190. each phase is targeted to produce 50. Jackpine phase one is likely to start in 2008. Drilling on the leases indicates an estimated 16 billion bbl of bitumen in place. which co-manages the bison ranch.000 bbl/d of SCO.000 bbl/d into the mix and the four are expected to come on stream in 2011. is a long-life asset with 2. Suncor’s oil sands leases hold a potential 11 billion bbl of synthetic crude oil after upgrading. 90. Northern Lights will produce 100. There is Canadian 26 International Mining December 2005 Natural Resources Ltd’s (CNRL) Horizon project 70 km north of Fort McMurray. Alberta.The newest of the mines is Muskeg River. and it has a 99% calving rate.000 to some 300. This project is a joint venture with the neighboring Fort McKay First Nation. This would be located on portions of oil-sands leases held by Imperial and ExxonMobil Canada in the Kearl Lake area.000 bbl/d of production. Imperial Oil announced the filing of regulatory applications in July for the Kearl Oil Sands project. Suncor plans to invest about . Its estimated life is more than 30 years. diluted and shipped via pipeline to the Upgrader. adding another bitumen extraction train to the existing plant and a number of de-bottlenecking projects. maybe even to 500. The second phase is expected in 2010 with an increase in production of 45. Then Jackpine phase two will access the resources on Lease 88 and 89 and provide an additional 100.000 bbl/d of bitumen production. Waste rock is rejected and warm water (40°C) is added to create a slurry. Fort Hills. combined with the Jackpine mine approval. When fully operational. for example. Plans include an integrated upgrader. SCO will be produced during the second half of 2008 ramping up to a rate of 110. an integrated project to be located 100 km northeast of Fort McMurray. Teck Cominco is in with UTS Energy and Petro-Canada for a 15% interest in the Fort Hills project.000 bbl/d mining project near the settlement of Fort McKay. and it “has been a roaring success. with approximately 6 billion bbl recoverable. Timing at this stage is uncertain. Last year. where CNRL owns and operates leases covering 46. Each mining phase is expected to put 50. the Joslyn project. 88 and 89.” Suncor’s crude oil production is about 260. and this work is proving very helpful in reclaiming mining land back to a natural state. Recent activity in new mining projects has been strong. with downstream refining capacity for about 160. Fort McKay First Nation has publicly discussed plans for a 35. Bucyrus’ 495HF shovels are equipped with wide crawler links to give the shovel the ability to operate in the soft underfoot conditions found in oil sands AOSP Expansion The Muskeg River mine expansion includes developing additional areas on the west side of Lease 13 and Lease 90. Western is providing the AOSP with mining expertise. . The dipper capacity is 47. thereby reducing fatigue over long periods of operation.000 litres/min and produce a breakout force of 2.) “The electrical system is second to none in the industry. It can provide up to 109-t capacity when specified.000 bbl/d around 2010. Hitachi says it is the perfect match for 280-t trucks. operating at 15. The latest Bucyrus order for Fort McMurray is for two 495HF electric mining shovels for Syncrude’s Mildred Lake mine. On a full cycle basis that means that oil sands production is competitive with domestic conventional crude. we are looking at some $35 billion in new construction in the oil sands in the next five years.5 m.4 m3 and the boom length. Furthermore. Powered by the latest Siemen’s AC-IGBT drive system technology. The first EX8000 underwent field tests in the oil sands. and employs proven. The EX8000 features the latest technologies and structure.000 litres. constantly under pressure – in particular from the rising cost of natural gas energy used to process the heavy crudes into refinery ready products. The addition of a Bucyrus FastFil dipper with new spade lip design makes this a most productive electric rope shovel.870 kN and breakout force of 2. the brushless AC motors and fuseless drives are setting new standards for reliability and efficiency in the unique oil sands environment. We’re very thankful to have a great customer like North American Construction Group who is dedicated to the Hitachi line. with an operating weight of 780 t and a shovel bucket capacity of 40 m3. it was designed for maintainability and accessibility with large access doors. Operating costs are. It uses two Hitachi S16R engines that generate combined power of 2. The optimized stress-relieved boom structure maximizes structural life (an exclusive feature. with shovel-type tracks and triple-roller swing bearing. comfortable cab with living quarters! The rear of the wide cab acts offers living space with a table.556 m crawler links.” states Mike Onsager. Hitachi developed the ultra-large hydraulic excavator EX8000 as the largest class in the world. 28 International Mining December 2005 Electronic wrist controls ensure light. Eight main pumps move 8. large open spaces and a flat floor around the engine for easy maintenance and inspection. Bucyrus’ Director of Electrical Engineering. with an arm crowding force of 2. with track shoes 1. however. with an operating speed equivalent to the EX5500 despite the larger body.558 kg and its suspended load capacity is 154. and so is the mining equipment. smooth manoeuvring with a light touch.$2 billion/y over the next several years with most of that sum directed to oil sands. The four 495HF shovels at Albian Sands’ Muskeg River mine are very successful. P&H’s 4100TS shovel is another popular machine around Fort McMurray.351. The dual output planetary hoist and swing provide for reduced maintenance as compared to single pinion designs.230 kN.85 m wide. as well as an electric retractable ladder allowing easy access to equipment. Dean Coleman.”. highly durable systems and components. The cab is almost twice the size of the cab on the EX5500. Its overall height is 9.100 kN. Increased power allows the 495 a 100-t single pass capability. It features a roomy. respectively. Its maximum digging reach is 18. when the bucket reaches its maximum cutting height. It plans to take production to 500. which give the shovel the ability to operate in the soft underfoot conditions found in oil sands. The EX8000 shares a common design with the EX3600-5. Projects take five or more years from conception to completion. These include: q Controlling the operating cost of daily production and the capital costs and related labour demand to build and operate the facilities q The environmental impacts of a growing industry q Pipeline capacity to get the oil sands crude to markets He notes that “operating costs for oil sands are higher than those for conventional production – a median of about $20/bbl for upgraded light crude. The bucket capacity is 80-90 t and maximum digging height 17. While that is considerably higher than average global lifting costs. with an operating weight of 780 t and a shovel bucket capacity of 40 m3 Leviathan loaders The projects in the oil sands are massive. Bucyrus’ 495 High Performance Series Shovels (495HF – high flotation and 495HR – hard rock) carry the new ‘SuperCab’.800 kW. we need to remember that these are massive projects. . efficiency and work-face visibility. compared to a global average of about $11/bbl. It is equipped with wide 3.5 m.000 litres of hydraulic fluid. feed a colour monitor to give the operator an excellent split-screen view all around the machine. Sales Manager with Hitachi dealer Wajax Industries was “very impressed with the EX8000 and the support the Hitachi organization has given us. either Cummins QSK60s or Caterpillar 3516s. allowing 24-h continuous operation without refuelling. Its fuel capacity is 16. It really is a monster. Hitachi developed the ultra-large hydraulic excavator EX8000 as the largest class in the world. This monster uses 10. located on the two back corners as well as on the right side and under the cab.9 m and the undercarriage length is 10. Its working weight is 1. It boasts awesome power and productive output as the largest class ultra-large hydraulic excavator in the world.” O&K Mining’s RH 400 hydraulic shovel was developed especially for the oil sands. it comes with an exploration cost of near zero. And more than time they take money and skilled labour. It has twin engines.360 kg. The machine exceeds the operating weight and loading shovel bucket capacity of the EX5500-5 by 260 t and 11 m3. Suncor’s Ashar explains some of the challenges to growth. it can touch the top of a six-story building. As an industry.000 V. “When we look at future opportunities and how fast we can bring on production. Four wide-angle cameras. microwave and other conveniences to ensure comfort in even the harshest mines. like those in the Athabasca oil sands. The 495HF has the field proven lower works design of the popular 595B shovel in operation at other oil sands operations. designed for operator comfort. The 495HF has proven to be an extremely productive and reliable tool in oil sands.1 m. . Components such as the radiator. most abrasive materials encountered by equipment anywhere. One tyre for a 370-t truck costs over C$35. while the D85s and D155s then work to level and pack the solids as they are pumped into the cell.000-hour undercarriage life would not be uncommon. Suncor relies on low ground pressure dozers such as Komatsu’s D85PX-15 (27. along with a dozer’s undercarriage. Each tyre is 4 m high and weighs more than 15. All the earthmoving equipment in the oil sands is subject to extreme wear.000 hours because of that wear. Two new P&H 4100BOSS shovels have joined two other P&H 4100BOSS machines and two P&H 4100TS shovels at Suncor. Since then. These machines are typically running anywhere from millimetres to.013 .54 m. In a hard rock mine a 12-14. all have to be mounted on the top of the cab. Larger dozers similar in size to the D475 will come into the area first to build a dry dike on the four sides of the cell roughly 5 m high. One reason Suncor chooses larger class dozers is the productivity required to keep up with the very large loads of dirt coming off the haul trucks. requiring a number of alterations to the machine that make them fully operational in this substance and safe for the operator. It employs a Siemens/Liebherr AC drive system. and perimeters at look out areas at the mine sites.000 kg. coolers.300 gross operating hours a year in this challenging application. when the oil sands freeze and become very hard. are among the items that wear excessively in the abrasive.722 kW. 14. GET and structural components. children’s play ground features. Komatsu’s D475. In the oil sands.6 m high.500 to 3. Empty.000. sticky oil sand and require frequent overhauls (hardfacing) and replacement. this machine has averaged an impressive 7. Caterpillar 797s (330 and 345 t) and 370-t capacity Caterpillar 797Bs and Liebherr T 282 Bs. for example.550 kg) and D155AX-5 (39. It takes a lot of pushing power. Waste tyres are then re-used as cattle feeders.84 km/h on crawler shoes of 3. safe exit. Conventionally placed radiators mean machines are constantly and perpetually overheating by getting plugged up with very fine clay particles. Oil sand could have been designed to be a grinding compound – something really hard put it in a matrix with some real sticky material to get good contact.8 m. at the extreme. Its fuel capacity is 6. Its travel speed is just 0.Canada’s massive oil resource 21. where they cope with very abrasive conditions . Safety is a prime concern. A closer look at the day-to-day workings of a Suncor oil sands dozer shows how these are some of the hardest working machines on earth. with the risk of a dozer becoming submerged in the slurry being very real. among the largest in mining and serve two major functions: levelling the land at the overburden dump and working above the shovel/truck operation to push material to the shovel. Ideally each tyre will have a life span one year to 15 months. In an environment where high availability and large production is demanded. It features independent.2. it is more like 2. but outfitted with unique features that make them a perfect match for this mining application. Suncor put the first P&H 4100TS oil sands machine to work in October 1998. 0. The main production dozers at Suncor are Komatsu D475 dozers are popular in the oil sands. The new machines will bring the total of P&H Model 4100 shovels operating in the Canadian oil sands to 17. the Caterpillar 797B weighs 623. Defiant dozers The bulldozer is one of the workhorses of the oil sands. these machines come equipped with an escape hatch on the roof of the machine for operators to make an easy. These include Komatsu 830Es (218 t).193 kg). The dozers at work in tailings cell construction are of a size class generally associated with heavy construction.814 litres. Komatsu 930Es (290 or 308 t). and big dozers have the productivity to keep up with overburden being produced by big shovels.’ the material these dozers are working on is anything but solid. It is 7. oil sands dozers spend 12 hours in a steam bay being washed. While described as ‘solids. It toils both in the abrasive sand above each shovel and in the tailings at the end of the extraction process. they serve the added purpose of ripping through the frozen sand. 24cylinder diesel engine to give a maximum speed of 67 km/h. The engine output of the T 282 B is 2. self-contained.34 m. In the winter. handling one of the heaviest. Tailings dozers endure really nasty working conditions. Every 500 hours. It is powered by the 3524B Series. etc. Ground Engagement Tools (GET) such as blades and rippers. A spill box is placed strategically on one side so that the water portion of the tailings slurry can escape into the pond. giant machines like Komatsu’s D475 offer the blade capacity and pushing power required to keep up with demand both above the shovels and in the reconstitution of overburden (most often for dam construction). The maximum operating weight of this monster is 592 t and its maximum travel speed is 64 km/h. air conditioning condensers.5 m long and the body width is 9. IM Monster movers Most of the mining industry’s largest haul trucks can be found in the oil sands.690 kg. scoured of sand and thoroughly inspected for excessive wear on the tracks.. is equipped with a standard U-blade with a 34-m3 blade capacity. bitumen and heat – a deadly combination to plug up a cooling system.5 m deep in this slurry. oil-pneumatic suspension cylinders on each wheel. . and earnings of Newmont Gold’s operations. Tel. A builder. Marshall was overseeing construction of a sawmill on the American River. 1994 Newmont Mining and Newmont Gold. USA. 1948 Having obtained the original designs of a continuous miner. South Africa. 1974 Cerro De Pasco is expropriated and becomes Centromin (Peru). Each month. On that day the Finning Tractor & Equipment Co was established. 1848 James Marshall discovered gold on the property of Johann Sutter near Coloma. e-mail: [email protected]. 1872 Charters Towers goldfield in Northern Queensland. 4th. 1st.normet. combined assets to form a unified worldwide gold company. 1902 Australian mining engineer Tom Davey discovers Kabwe (Broken Hill). Spraymec 6050 Rock Transporter Himec Spraymec 6050 for underground mines and tunnels with small cross sections. www. Your partner for tough jobs Charmec Utilift Scamec Concrete Transporter RBO Normet has the widest offering of purpose designed underground vehicles Normet Corporation. IM publishes the Mining Milestones of the following month. Shareholders of both companies had identical interests in the reserves. It was the first gold find in California. Australia. of the event. 1919 Northgate was incorporated. 27th. Entries must include the month. Finland. Joy developed two prototypes to be known as 2JCM models. Zambia. 1981 Gold hits $850/oz! 1995 Phelps Dodge Candelaria mine ships its first copper concentrate.Milestones January milestones in mining 1st. Please submit entries for your company to john@im-mining. In 1958. Fax +358 17 823 606. 7th. 1859 George A. 1942 start up of Phelps Dodge Morenci’s new concentrator. 1996 Komatsu established Demag Komatsu (renamed Komatsu Mining Germany in February 1999) in Germany. 24th. 1951 After mining nearly $6 million worth of gold. 1968 An initial agreement was signed between the Indonesian Government and Inco following the cabinet’s decision to accept Inco’s proposal regarding nickel deposits on the island of Sulawesi. 1st. 1933 Earl Finning had managed to secure a business loan as well as the sole distribution rights for Caterpillar products and services for British Columbia. the first going into service in this month. 19th. 29th. Jackson made the first major discovery of gold in Colorado.fi 32 International Mining December 2005 . 1960 Unit Rig’s prototype truck rolled out formally and the first production models entered service in the last half of 1963. discovered. FIN-74510 Peltosalmi. and ideally the day. California. The truck was an immediate success gaining market share steadily. at the confluence of Chicago Creek and Clear Creek in Idaho Springs.com. 1970 the US Environmental Protection Agency (EPA) is born. production. 26th. 1917 Takeuchi Mining Industry (founded in 1894) established Komatsu Iron Works to manufacture machine tools and mining equipment for in-house use. and a chapter of Alaska’s gold mining history came to an end. 1924 First board meeting of Mount Isa Mines. its name was changed to Northgate Exploration. +358 17 83 241.106-ct Cullinan diamond is found in the Premier mine. 30th. under the name Kirkland-Hudson Bay Gold Mines. Ahmolantie 6. 1905 the 3. Independence mine was closed by Alaska-Pacific Consolidated Mining Co. ” One significant Roadbuilder technology development is Getman’s exhaust chiller that reduces exhaust temperatures to below 150°C and reduces maintenance and exhaust filter costs. uses metal straps to hold the end caps onto the filter. A fibreglass exhaust filter is also new. It just does a lot of heavy-duty maintenance work. Getman is the first manufacturer to install the filter on its mining equipment. muddy.” December 2005 International Mining 33 . “Typically you’ve got a mess: sloppy. To achieve their full potential. spreads gravel and grades. Then the The solid steel Caterpillar front axle on Getman’s Roadbuilder has a 32° oscillation. good underground roads are essential. systems. Diesel exhaust temperature spikes can burn adhesive filters and release toxic fumes. heat-resistant fibreglass foam gasket seals the caps and provides a tight seal on the filter element. its new chiller delivers substantial cost savings. Getman says that compared to other exhaust cooling technologies. The Roadbuilder goes through the mess and makes it flat. Nevertheless.Trackless equipment Mechanization in the deep John Chadwick looks at LHDs. underground trucks. No underground machine will perform to its full potential if the haul roads are not of good quality – even if the task is only moving a jumbo from one face to another. it is disappointing to observe the number of underground (and surface) mines that have yet to embrace correct road maintenance. especially with the current tyre supply challenge. “This is another important step in our efforts to lead the way in increasing safety. poorly maintained roadbeds are also expensive when trackless vehicles succumb to premature wear and tear. The new design features an air-to-water shell and tube heat exchanger. Hot exhaust gases are directed to an inlet port in the exchanger shell and passed over finned tubes carrying water/glycol antifreeze. fuel cells T rackless machines continue to evolve and become more productive. higher than the 480°C a diesel exhaust can reach. Getman’s RDG-1504C Roadbuilder incorporates many of these important advances to help create quality roadway T Produce underground roadbed material with MTI’s HydraCrusher. and will use it in conjunction with the exhaust chiller. from Filter Service and Testing. antifreeze circulates back into the shell and the cycle starts again. no-spin Caterpillar rear axle. “By adding this innovative filter to our exhaust chiller system. A fin redesign from previous chiller designs reduces exhaust gas temperature from between 430 and 540°C down to between 66 and 120°C and increases the water/glycol antifreeze temperature only 21°C (from 50 to 90°C).” Getman said. Replacing only the filter element offers mines an economical solution to filter maintenance. The fins and tubes transfer exhaust heat to the antifreeze. .” says President Dana Getman. Recent diesel technology developments have made trackless machines safer. hard-going conditions. creating working roads for other equipment to pass. which then exits to be cooled by a fan-cooled radiator. It is a complete road maintenance and road building machine that rips up road surfaces. “The best thing is to come along and keep that clean. A special. The gasket is rated at 650°C. Furthermore. 18° wheel lean and 50° wheel-turn while chain box final Caterpillar drives are splined to the heavy-duty. rather than adhesives. more efficient and more cost-effective than ever before. drill jumbos and support units – better underground roads. we’ll be able to further improve air quality and lower the risk of fires. The tyre shortage is not confined to surface equipment and it is never good economic practice to shake machines around more than is necessary. reducing the risk of fire and poisonous fumes that can endanger miners’ health. The new filter. MTI President. Its clean. “Most underground equipment operates without suspension. hydraulically operated crusher is one solution. Its much cheaper to handle waste underground and create a stockpile of roadbed material. There are proven ore reserves for five years of production. utility vehicles and in-the-hole (ITH) drilling rigs from two manufacturing plants in Sudbury and one in North Bay. This optimized tuning reduces emissions. throttle position. This nickel operation was originally developed in the 1970s but was out of action for several years. but it also works on some of the incline development headings. all that shock is transmitted to every component of the machine. A quick-attach design allows the unit to be easily fitted to or removed from the LHD.the first of these units in Australia went to Consolidated Minerals’ Reliance nickel operations in Kalgoorlie. drill jumbos. Of course. rather than have a fleet of equipment. Recently it has been pumped dry and is now in development for low level production at a rate of 200. so if you have rough roads. an LHD bucket with a built-in.” The ST1520 is reported to be faster when tramming. “We also offer a grader blade and a compactor so you can use the same vehicle to do all of your road maintenance. engine speed and loading.” said Bob Lipic. An on-site Atlas Copco service team keeps them running and available. more comfortable to drive. diesel engines have been upgraded to make them more efficient and cleaner.600 kg of working effort into the 3. Electronic engines constantly adjust the timing and duration of fuel injection relative to operating conditions and external factors such as intake air temperature. It produces more than 7. Adjustable jaws chew coarse material of up to 305 mm and crush it to any desired size – down to 19-mm 34 International Mining December 2005 material for top dressing. trucks. and the engine does not overheat. “With good road maintenance. raises operator safety to a new level and is easy to adapt to existing operations. The Roadbuilder uses a fourcylinder.000 t/y with a 70% waste to 30% ore ratio. aftercooled. Michael Aspinal. at the company’s Beta Hunt mine said recently: “The unit has been working very well for the past five months now and has 1.Toro’s T60 aims to provide the best possible ownership cost. The bucket. Canada.” said Lipic.” MTI manufactures a full line of loaders. Another new machine is tlas Copco’s ST1520 LHD . Reliance’s Atlas Copco fleet includes the Rocket Boomer L2D for development drifting.700 engine hours. The rock passes through the jaws and the resized material falls to the ground. The operators are very happy with it and it is now the preferred unit on site. a truck that fits into existing tunnel sizes.200 rpm. Underground Manager. thanks to the good legroom. turbocharged. The new electronicallycontrolled smaller engines include design improvements such as cylinder head/ combustion chambers and high-pressure unit fuel injectors to deliver similar or more power than older engines. picks rock from a muck pile. It is keeping details confidential as yet but is developing a Hybrid Diesel Electric Loader. intake boost pressure. Mining Technologies International’s (MTI) HydraCrusher. rail haulage equipment. but it moves dirt. A . Tier 2 Detroit Diesel OM904 diesel engine rated 110 kW at 2.120 kg of tractive effort while applying more than 6. The ST1520 is primarily used for mucking in the main decline. you will definitely reduce the maintenance costs of your equipment. Roadbed maintenance can be expensive if mines have to hoist waste rock to surface for crushing and then send it back down for grading and top dressing. fuel consumption and maintenance while enhancing engine protection and diagnostics. coolant temperature. doubling as a hopper. Getman says the RDG-1504C Roadbuilder moves more dirt than any motor grader available in the USA. the Boomer 104 for narrow vein production drilling and MT5010 Minetrucks for hauling.7-m Caterpillar 120H mouldboard blade. safely and efficiently. THE UNDERGROUND DIESEL GUYS . Call Getman at 269-427-5611 (USA).getman.com. Call the underground diesel guys who have devoted more years than anyone else to developing and supporting the best underground mining equipment available – from mechanical scalers to charging vehicles.SPAIN Underneath it all. or visit our Web site and sign up to receive the latest underground news and tips at www. tractors and more. fax us at 269-427-8781. NEVADA or more than 50 years. miners everywhere have relied on Getman most for dedicated diesel utility equipment designed specifically for hauling. We’ve earned that trust because we’re as dedicated to mining as you are. building and assisting their underground mining operations. MANITOBA miners the world over AUSTRALIA have trusted us INDONESIA above all others. for example. “With diesel engines. Coming soon? Timo Laitinen. “We have to live every day in a profitable world so we can only go as fast as the industry will allow us to go. Much can be done in education to let young people appreciate the advantages that mining provides through the commodities that we all need in our everyday life. enabling the full process to be optimized based on the mineral output. you can only go so far in reducing emissions. “We will see an increasing amount of civil engineering diciplines being applied Tamrock’s Axera 6 Cabin is optionally available with heating as well as air conditioning. Mines will be highly automated based on precision in mineral extraction technology and a process-type environment will have been created. and this editor wholeheartedly agrees.” he said.” Atlas Copco’s Scaletec is equipped with the powerful Atlas Copco SB 300 Scaler. Mining Business sees the current drivers in underground mining (in an up cycle. “There’s a lot more work to do and a lot of training needed to safely and effectively use and service fuel cell equipment. of drilling the face and drilling support holes. but still tough on the rock q Shortage of labour for mining work q From unit to system automation q High environmental focus q Minimize incidents q Focus on operational quality Looking forward she sees: q Decreasing numbers of available mining people q Remote mine locations q Demanding underground mining environment and removal of humans from it q Zero environmental impact q Tough revenue demandsuncompromising business results q Need shorter time to production q Continuous cycle q Standardized mining procedures for global mining companies She expects it to be harder to see where extraction (rock harvesting) starts and the processing continues. As for Tamrock’s revolutionary 1. The quality focus will go through the whole process from rock harvesting to processing since the measurements and techniques will need to change. “The increased focus in quality will have a positive impact in safety and environmental awareness in mines and in the industry altogether.” she says. A member of the Fuel Cell Propulsion Institute. capable. to make itself more attractive to young people and the calibre of young people that it needs to attract. especially designed for scaling. “People. so there’s no doubt about it – the development of new technology is inevitable. a narrow vein hydraulic jumbo with full mechanical power train.” said Lipic. Senior Advisor. As a result the breaker is lighter in weight. the project proceeds as planned with internal testing underway. This can also be seen in the way equipment is specified. but the initial capital cost is high. There is little or no real work quality measurement used in underground mining today whereas they are standard procedures in construction. 36 International Mining December 2005 .” She believes we need to take mining to the people.000 Hz drifter. Tuula Puhakka. “If we have lifted the demand to a higher level due to China and Asian growth all together. and can do. According to Lipic. A fuel cell-powered locomotive has performed well in trials under the auspices of the Institute and trials of a similarly powered LHD are in hand. the cyclical peaks will continue to impact our lives. If any focus was lost earlier when moving from feasibility and development of the mine to production that will be greatly reduced in future mines. drilling technology and excavation machinery qImproved equipment utilization with new technology and services His colleague. a 5. President of Tamrock Underground recently engaged in some gazing into the crystal ball of underground trackless mining and saw: qFurther increased drilling performance and efficiency through new technology qIntegration of excavation process. MTI is closely monitoring the development of alternative energy technologies. a hydraulic Solid Body (SB) concept breaker.its Vein Runner II. Now we just need to be more adaptable and be able to take advantage of the high portions of the cycle and get the mines on line much sooner than before. fuel cell-powered underground equipment is cost-effective to operate. “are a tough call. There is much the mining industry needs to do. first hinted at during MINExpo last year.5 m boom reach and next generation Intellsense III drilling controls. We can also expect to see more multitasking machines. with high sensitivity to market change) to be: q Asian and Chinese GDP growth q From BIG to efficient and utilized q From maximizing to optimizing q Large scale underground mines q More selectivity in selective mining methods in the underground mining environment. We will see much leaner mining operations and they form the basis for larger scale mine automation. . it is based on Toro’s innovative. As with its predecessor Axera D06. it says.15 m man reach without stabilizers. Equipped with the ejector box the capacity is 24 t. Caterpillar has just introduced a second. This editor drove it and found it not much different to driving his own car.83-m chassis and 45º articulation angle.Truck innovation On good quality mine roads. Drilling in comfort Sandvik Tamrock’s Axera 6. BL Corporate was located in Johannesburg to be close to its former parent. Also with an eye on the envelope. and. Solo 5 longhole drills can fit in drifts as small as 3m by 3m and have particular use in small-scale sub-level stoping. The choice is between TB26 or TB40 booms. The compact envelope size of the Axera 6 has not been compromised. The SLP 5000N also has a central oscillation (mid-ship) of 10º to either side that permits four-wheel ground contact on uneven terrain. To provide best operator ergonomics. equipped with 8-10. Anglo American.” she says. So. The latest versions meet needs for modular design and common technology platforms. patented rigid frame chassis and triple axle design.” Dux manufactures a complete line of utility vehicles including the new SLP 5000N scissor lift truck which is specially designed to work in narrow drifts and confined areas thanks to its 1.27 m extended deck height and 6. All panels are insulated and windows are double-glazed thus reducing noise even further. represents a considerable market share in the global market. with great flexibility for different applications. though a little larger! It certainly was easy and comfortable to drive over a basic circuit. feed and cassette. The T60’s ideal loading partner is the new Toro 0011 LHD. and superb driving characteristics. Toro’s Business Line Manager. During 2005 Sandvik Tamrock completed the Solo 5 series. accuracy and full readiness for sensors and instrumentation. The ejector body also offers clean load ejection to eliminate productionrobbing carry-back. when designing the T60. While it is normally best to use a purpose-built underground truck. provide a truck that would fit into existing tunnel sizes. i.49).66 m long platform with 4. Vibration. TB26 is simple to operate. It comes with pipe handlers to facilitate the installation of pipes and ductwork. Such units can of course be useful in spreading backfill underground. Toro is clearly confident of the unit’s potential having established a line in its Turku plant capable of producing about 50 T60s each year. A Detroit Diesel S-60 engine developing 354 kW powers this machine. However. had to raise operator safety to a new level. the wide range of articulated dump trucks (ADTs) available could be used in the right applications. We need to take mining to the people. Dux also has a new generation of cabs for its underground haulers. compact twinboom jumbo was launched in 2004. designed for massive underground production and large-scale development. The large tyre size together with high ground clearance allows smooth operation even if road conditions are not as they should be. It offers a small turning radius. With a total population of over 150 machines in use. of which one third is the latest Axera 6 model. New TFX telescopic feeds are an option.51). Additionally.5 m by 3.e. vein mining and underground benching. Now the Axera 6 is available with a ROPS and FOPS certified safety cab. The Solo 5 range replaces three current models: Solo 126LC10. without raising the body. the proven hydraulic THC controls offer easy and fast boom and drilling operation. As noted in IM September 2005 (p. more than half of BL’s business now emanates . small overall size. noise and heat transmitted from the chassis are reduced to a minimum thanks to the pin/rubber mounting. Boart’s big move The change in ownership of Boart Longyear (BL) was initially discussed in IM September (p. 38 International Mining December 2005 “People. The cab is ergonomically improved with good leg room as well as offering easy to read gauges and electronic displays. Good serviceability is always a key objective. All daily service points are easily accessible. Toro had to provide the best possible ownership cost. a full range of longhole drill machines for underground excavation. “is a revolutionary high payload capacity truck incorporated into a small envelope. had to make a truck that was easy to adapt to existing operations. According to George Tophinke. but not prevent easy servicing of the machine. an automatic.7 m3 buckets. the new SOLO 5 series will introduce the HLX5 drifter. “are a tough call. Covers are designed to protect against falling rocks and water. The TF cylinder rope feed with 25 kN maximum feed force provides stable drilling even with high power levels.5 m and up. The Solo 5 carrier is the same as for the Robolt 5 and Axera 5 products. TB40 is known for robust design. Dux has the ET24/DT25 dump truck.” It is 2. insulated from noise and vibration and pressurized for best operator comfort. equipment such as Toro’s new T-60 truck can be used very effectively. Its capacity is 21 t. finally. Australia.83 m wide x 3. the challenges for today’s underground trucks are: q Mines are getting deeper – more productive trucks are required q Making bigger openings is costly – truck envelope size must be kept to minimum q Safety requirements are getting more demanding – requiring safer equipment and better operator comfort. It is powered by the Deutz BF4M2012 (74kW) diesel engine for fast and safe tramming.2 m wide and fitted with a regular dump box has a load capacity of 25 t. depending on the truck. which. These are isolated from the chassis and noise levels range from 75 to 82 dB(A). The new unit is the second in the Caterpillar line to use a self-cleaning ejector mechanism that allows material to be spread and dumped on the go. have been redesigned using experience and knowhow from the well proven 07-sizeclass Solos. With a total height of 3 m the Axera 6 Cabin is good for cross sections from 3. Mercury LC22 and the Solo RTS. It offers a 1. smaller ejector ADT featuring the Cat C11 engine with ACERT technology. it has gained popularity in underground mine development. it The operator in the cabin of the Paus RL-852TSL controls the hammer’s breaking power or impact frequency. The main components in the drilling module. The Johannesburg corporate office will be closed by year-end and relocated to offices at BL’s Salt Lake City plant in the USA. Air conditioning and heating are standard and the cab is pressurized and filtered. boom. The new generation HLX 5 rock drills are standard on Axera 6. monitoring. USA. high performance regardless of varying operator skill levels or conditions. which is already well established. particularly in electronics. Ergonomics. The main task to get that going is to find ways of safely handling hydrogen underground. It is designed to produce consistent. IT and communication. He also foresees. predictability. reliability and diagnostics. Kesäläinen too sees fuel cells playing an important role in the future. The first track is in strategic acquisitions. Once Boart Longyear has bedded down in the Advent fold and concluded the process of restructuring and consolidating existing operations. To simplify the structure and maximize efficiencies. Toros without cabs operating on the Automine system – thus saving the tramming of dead weight. These things will be achieved. A programme to maximize operating efficiency is already underway. with decreased maintenance costs. compact enough to get into the tightest drilling sites underground.” The third goal is diversification into non-mining drilling services. gases and fluids are the areas to be addressed. Importantly. but what is this rig? Well. it is designed for efficient dismantling. he says. “We enjoy a broad geographic footprint in the global mining market and will seek to further penetrate mining markets in Brazil. electrics. the business has been divided into Drilling Services. in the near future. offering increased productivity. working closely with regional management to ensure a common approach to global strategy and local customer needs. It is ideally suited for drop raises. The success of these centres is in the hands of the team of global product managers. The StopeMaster is a classic BL product. then consolidating BL’s manufacturing plants so the company can single source products from global Centres of Excellence. through basic technical solutions that encompass hydraulics. China and Russia. etc. more communication and more data processing. This aims to reduce existing cost structures by identifying the location at which a product is made most competitively. open systems will be required and provided.Trackless equipment from the Americas and the move will gain closer access to the main business hub and Advent’s (the new owner) key office in Boston. both organic and acquisition growth will be key strategic drivers. at low capital investment. A second target is to increase mining market penetration in under-represented territories. cable bolting. Last month we noted interesting StopeMaster sales to the CIS. India. Increased process/equipment utilization requires automation. There will be new designs and new technologies. it allows longer intervals between scheduled preventative maintenance and this has been proven through millions of metres of drilling experience. serviceability (working from heights. powerline. December 2005 International Mining 39 . Also. Load and haul Agreeing with Sandvik Mining and Construction colleagues quoted earlier on the future and looking generally at the Toro LHD and truck products.) and emissions of noise. And the requirements for even safer operation embrace both operator safety and machinery safety. etc. CEO Paul Brunner says the way forward will focus on a three-track growth strategy designed to mitigate the effects of relying on the cyclical ‘boom or bust’ nature of mining and to consolidate BL’s leadership in its core businesses. Deep hole accuracy is enhanced through superior guidance of the durable feed system and Hercules centralizer. and reassembly for rapid transport into captive areas. fan drilling and parallel drilling. BL is currently finalizing the structure of Products & Equipment. and Products & Equipment. Product Line Manager Riku Kesäläinen foresees better control of the mining process meaning ‘transparency’ of the underground operations with onboard data collection. a fully electric-hydraulic tophammer longhole drill rig. which encompasses the manufacturing operations. mechanics. The configuration of the control sticks and buttons has been adjusted according to operator experience Lifetime of project Fleet Operation Number of manual operators Number of system operators (auto) Labour cost per operator Total lifetime saving 10 years 6 trucks five days/week and three shifts/day 21 (six/shift x 3 shifts + three relief) 5 . would provide an exciting future for De Beers. which would need to go underground in the next ten years.Inmet Mining. De Beers Consolidated Mines Managing Director Jonathan 40 International Mining December 2005 Oppenheimer alluded to De Beers current heavy reliance on open-pit mines and said: “What we are proving here is that we can thrive underground. including Venetia mine. Block Four extends the life of Finsch by a further nine years. using block-cave methods and automation. He explained that Finsch began as an open pit. El Teniente mine – three T0010 LHDs (Pipa Norte section) and three more T0010 LHDs in Diablo Regimiento section On November 3.5-18 t. This was the culmination of four years of joint effort by De Beers and Toro (Sandvik Mining and Construction). tele-operated bucket loading and on-the-fly mode change q One operator for several LHDs q Condition and production monitoring q Production area isolation q Traffic control q Interfaces to external systems q Scalability to different applications Potential savings in labour costs are 60-75 % (haulage automation with large fleet). Roof control Based on experience from long-term testing of Atlas Copco’s first Scaletec rig in Sweden’s Malmberget mine. The cabin lift and tilt system combined with a new design with steel bar protection across the windscreen makes it easy for the operator when scaling in higher areas. Pyhäsalmi mine – one T0011 LHD q Chile – Codelco. South African mining legislation would restrict tramming speed to vibrations. the deepest mining section at Finsch. Safety and visibility have been improved by moving the boom attachment further forward. but automated they can run at 30 km/h. Automine offers: q Semi-automated cycles with automated tramming and dumping. Automation One of the key drivers for Toro’s Automine system for LHDs and trucks is improved safety and working conditions. The front end of the machine was previously only supported by conventional hydraulic jacks.” He noted today’s open pit can become the underground mine of tomorrow and efficient ways of mining underground. but now also uses the shovel blade to ensure a stable set-up.8 million . With drivers. In opening the new tramming loop.6 – 4. For example take this truck haulage case (see box below): The current Automine LHD references are: q Finland . a number of new features have been incorporated in the second unit. and the same would happen to other De Beers assets. De Beers officially opened the world's first automated horizontal truck system with Automine and the Toro T50D trucks at Finsch mine in South Africa. Indeed seven units would have been required if drivers were used. Excellent manoeuvrability is achieved by the positioning system’s proportional functions. A new operators chair with built in pneumatic shock absorber both eliminates vibrations and offers a number of adjustment options to suit each individual operator. Operator comfort has been further improved by reducing The Paus and Schopf LHD product lines complement each other well because Paus is strong in smaller LHDs with payloads of up to 6 t. made possible by allowing the operators to work from a surface control room. while Schopf offers a payload range of 6. on the right an Schopf SFL130 in magnesite. The system uses six 50 t T50Ds to haul kimberlite ore from a tipping point to an underground crusher in the new Block Four.000/y €3.16 km/h. making them much more productive.9 (1 to 2 operators/shift x 3 shifts + 3 relief) €30. Above a Paus PFL8 in an apatite mine. Hydraulic hoses have been relocated to better protect them from rock falls. falls are one of the main potential safety hazards in the mine. the carriers for the twin-boom Boomer jumbos and the Scaletec MC rigs are almost identical. Using mechanized rigs can drastically cut the accident rate. The complete unit comprises an SB 300 Scaler hydraulic breaker. Cemento Melon’s underground Navio mine lies 15 km northeast of La Calera in Chile’s 5th Region. hydraulically driven compressor and water pump. mechanized scaling is a priority.unlike other designs that position the hydraulic hammer pointing at the rock (only one point of percussion) causing fragility and overbreak . which reduces the need for storage of unique parts. Limestone being a stratified sedimentary rock. a Scaler boom. Operators enjoy a safe working environment with good working area visibility.the RL-852TSL attacks the rock using a telescopic arm working together with the hydraulic hammer.5 m and width 2. This is an innovative concept developed by Paus. Its transportation height is 3 m.2 m. for example strategically located water nozzles for dust suppression and the choice between electrical or dieselhydraulic tramming and scaling. That original machine already featured a newly developed boom system with a built-in hammer angle compensation for reduced boom positioning time. length 13. This is the cutting edge of spraying robot technology for the application of shotcrete.Trackless equipment from the Malmberget tests. The Scaletec design is based on years of rock excavation experience. Productivity as well as quality of scaling will increase. December 2005 International Mining 41 . a 75-kW electric motor. Because of the development of drifts and production benches. optimizing the scaling operation since . Scaling is traditionally one of the most hazardous jobs underground. an M-series carrier. Scaletec offers a number of functional features and options. Its total weight is 19 t. The control system for the carrier has been integrated into the RCS (Rig Control System). Earlier this year Navio put into operation its second Paus RL-852TSL scaler unit equipped with a hydraulic hammer. For example. mechanized equipment in Chile. Navio has long been a leader in the use of trackless. scratching the walls and roof to knock off the loose rocks. Paus and Schopf have combined their sales and service activities for Meyco’s Logica 10 mounted on a Cobra is not commercially available but soon will be. It mines some 3. but already an integrated part of the Atlas Copco product family. RCS. Scaletec is a new member.380 t/d of limestone. thereby simplifying maintenance routines when working with a full package of Atlas Copco equipment. Africa and Eastern Europe and are expecting the first successes shortly.4-m reach. “For customers of both companies there will be significant advantages from an integrated product range and service all from one place. The hydraulic valve from the shotcrete boom was moved to the table. “We wanted to see how it worked but it has really done the job.” Finning’s equipment preparation team removed the backhoe attachment. It combines a boom truck frame and an adapted boom function with a fine controlled manipulator arm and can install or remove 0. the rear swing frame. The ingenuity of Finning in designing the shotcrete sprayer and the ability to maintain the equipment is impressive. Other additions included a 600 A main battery fuse. Separate welds on the mounting plate allowed the shotcrete arm. or outside by remote control. at Inco’s Coleman-McCreedy East mine in Canada. the valve group and hand controls. so much so that we need another machine. This removed worker exposure from what can be a complicated and sometimes hazardous operation. “The 420D is a little wider so it is more stable. a central heater system and a stand to mount the shotcrete remote controls. which can be packed away very neatly and can be extended without needing additional room. A 320° manipulator arm rotation allows precision reach into confined or tight working areas and the fine fan positioning adjustments allows workers to perform the most difficult fan changes. Underground. A mounting plate to accommodate the shotcrete sprayer was designed and welded to the rear of the machine. With a well diversified dealer network we are now also in a position to pit ourselves against the major competitors. That’s a serious issue for the mine because it is very expensive to ship parts. We have already started marketing in the traditional mining areas of South America. Shotcrete excellence Meyco says it benefits from being a part of the UGC International organization within Degussa Construction Chemicals.” ready to start. Shotcrete is mixed at the surface. In today’s tight time schedules. All the necessary components on one chassis and the ability to get to all parts of a mine are very important. The Cobra S is the latest generation Meyco spraying mobile for mining. a fire suppression system and a catalytic muffler to scrub the vehicle’s exhaust were added. The machine has become indispensable. The Cobra now includes Meyco’s TDC (Total Dosing Control) system. “As a result of the merger customers will now have the largest loader range on the market with a total of nine models. The sprayer connects to the mixer with a 50-mm thick hose. Meyco’s own research and development is dedicated to shotcrete and the improvement of quality in both application and end result. and a 4 x 4 articulated Paus carrier. it is dumped into the portable mixer carried by the modified backhoe. The rear backhoe mount was sheared off. The whole unit is very robust. In addition the international partners will market the Paus truck and utility vehicle range jointly. “It has worked out well.Trackless equipment customers in mining.” he says. the equipment has to be removed so that the next part of work cycle can begin immediately. “We looked at some other machines.” IM Marcotte developed the M40 Fanhandler. a unit to safely install and remove large ventilation fans.” report Dr Hermann Brüggemann. but they were a bit too unstable. In addition to these changes. The team designed a table to mount the attachments needed for the sprayer and bolted those to the mounting plate. and central lubrication will reduce wear and tear on moving parts and cut maintenance time. The boom rest was attached to the mount allowing for components to be easily removed for repair. poured into 1. The two LHD ranges have been merged.” he explains. which had resulted in a serious injury. complete mobile units and special constructions for specific projects.800 kg with a 2. For 2006 there are some significant new features: cable reel and electric cabinet are hinged to allow instant and full access to the diesel motor. which is why we elected to go with the 420D backhoe and put the shotcrete sprayer on the back.37 m diameter fans in a much reduced time span. As soon as spraying is finished. managing partner of Schopf and Franz-Josef and Wolfgang Paus. using air pressure to blast the shotcrete onto walls. shotcretespraying systems are developed and harmonized for greatest efficiency leading to a better product. following a workplace accident.000 kg bags and transported down into the mine. The machine can be operated from either inside the cab. within minutes. One benefit of the modified 420D backhoe is convenience. it is imperative that spraying set-up is achieved. and the machine is 42 International Mining December 2005 . Its spraying shotcrete every day. transformer and cable reels to be bolted on. fastened to the mount and re-hosed. At Ekati diamond mine. Finning installed two 500-W work lights to the back of the cab. heated electric cabinet and remote control to prevent condensation. For health and safety. managing partners of Hermann Paus. The three main components are Meyco’s Suprema concrete spraying machine. the Minima spraying manipulator. Using know-how and synergies. manipulators (large and small). the underground maintenance superintendent Jack Wanner turned to Finning to build a shotcrete machine based on Cat’s 420D backhoe. It can lift fans weighing up to 1.7 to 1. Parts are easily available at the mine site. It is now part of the regular mining cycle. Wanner ordered another modified 420D. Ekati has a number of 400 series backhoes on surface so there’s no need to stock different fuel filters. These include wetand dry-spraying machines. the HardHat enclosure is produced in recyclable LMDPE (linear medium density polyethylene).de Signing ceremony for Yushen Coal’s Yushuwan project. It is fully UV stabilised. oil and oil-separators offering significant cost savings. self-sufficient from external power sources.00025. So. DBT closed three major contracts with Chinese mining companies. Oiltronix sensors measure the ambient temperature and relative humidity. DBT claims to have achieved a market share of just under 70% for shields and of nearly 50% for conveyors. DBT will have delivered a total of 2. An additional benefit is in cold weather conditions as the compressor can start with a closed inlet. and a complete fully automated plow system.the system automatically determines the optimal oil injection temperature to operate out of the condensate zone.700 shields to Shenhua. These contracts represent a further consolidation of DBT’s domination of the shield market and a substantial strengthening of its share of the conveyor market: In the last 12 months. The HardHat has been designed to eliminate corrosion problems generally Atlas Copco has made extensive improvements in economy. opening as required air is delivered. Together with the compressor controller . several conveyor systems. already acknowledged as offering the best fuel economy at full load. toys and other applications. In the fitting a diesel particulate filter system. is very efficient in soot burning. December 2005 International Mining 43 . Also. driven by 3 x 700 kW motors via CST gearboxes. pressure. To overcome this. oil temperature is therefore maintained high in order to avoid condensation. ‘Continuous Innovation means being state of the art’ is an elementary aspect of the Huss strategy. Quite often the silencer is integrated in the vehicle in an upright position. Fuel Xpert intelligently regulates engine speed and air intake to optimise fuel consumption. Following delivering in the middle of 2006 and compatibility tests with third-party equipment on the surface. This was a challenge for the MK-system. The orders are for a total of nearly 1. DBT has succeeded in more than doubling its Chinese customers from 5 to 11 in less than 18 months and the latest new customer is the up-and-coming Yushen Coal. As an example.atlascopco. the regeneration time is the same – only eight minutes for the smallest filter. unusually short by Chinese standards. as the company – which has not previously invested in state-of-the-art Western mining technology – has aggressive expansion plans and will invest heavily in high-tech equipment to achieve a production target of 40 Mt by 2009. It is significantly lighter than the metal enclosure and offers a more attractive and enhanced appearance. DBT will deliver a complete fully automated plow system for use in low-seam coal to Tiefa Coal Industry in Liaoning Province. in the northeast of China. save 15. www. air ends. The project began in 2002 with initial technical presentations in the Shaanxi and later at project planning and design institutes. HardHat is now available for nine models rated from 32 – 89 litres/s and 7 – 12 bar. for example. with annual production more than twice that of its closest domestic rival and fourth largest in the world – placed the largest-ever order from a single customer in DBT history. and the engine speed . stainless steel cages and modular design. The 28 m PF 6/1542 gate conveyor includes an impact roll crusher and a selfadvancing belt return end.dbt. Compression at high pressure and too much cooling. By the time the contract has been fulfilled. This uses proven technology and special elements of the Huss filter like silicon carbide (SiC). very often the silencer is replaced. HardHat versions are available as an option to the standard metal enclosure. The longwall is designed for an output of 5 – 6 Mt/y. over that period. the R&D department came up with the MK-system vertical.com DBT wins record orders from China Between the end of September and the beginning of November. in order to regenerate faster and to provide solutions up to 450 kW. In a conventional sys- Breathe easy with Huss Huss Umwelttechnik has been developing. A new burner element ensures that the burner is ignited and is working properly in an upright position. On smaller compressors. plus increased safety and prolonged lifetime of components. manufacturing and marketing diesel particulate filters since 1985.000 shields. In particular. The PF 6/1142 face conveyor is some 250 m long. Yushen is of strategic importance to DBT. The MK-system with diesel burner being totally self-sufficient from tem. A contract for a complete thick-seam longwall was signed on October 26 after a negotiation lasting only five weeks.5 m and are equipped with PMC-R automated control. www. a drilling operation that might have the compressor running for about 2. environmental management and resilience to its compressor lines associated with metal housings. Operating with the Oiltronix provides a reduced oil temperature that can in certain regions triple the theoretical bearing life. contains long term antioxidants and is resistant to low and high temperatures. It is also high impact and crack resistant. Its diesel burner technology. the system will go into production towards the end of 2006.monitoring different pressures such as working and regulating. boats. culminating in the major contract after three years of acquisition work. the MK-system was developed. offer more than 10% improved economy compared with competitive compressors at partial load. It is a new electronic system that controls the oil injection temperature and condensate to ensure extended lifetime of compressor components.MMT New technology in AC compressors Atlas Copco Portable Air has introduced two important innovations to its large compressor line used in mining – Fuel Xpert and Oiltronix. This ensures that Atlas Copco compressors. It is the same material approved for use with chemical containers. DBT’s fully automated plow technology was reported in detail in IM November. oil and outlet temperatures. Shenhua – China’s major producer. Atlas Copco has introduced a further six models featuring the HardHat. DBT will supply Yushen roof supports as well as a face and gate conveyor systems. Oiltronix is a new condensation control system offering extended compressor life. strengthening DBT’s position in such operations. making it available for the complete Series 7 compressor range – from January 2006.000 litres with Fuel Xpert. The 150 shields have an extended height of 5.000 hours in a year could. creates condensation in the oil – particularly on partial load where cooling is many times higher than is necessary to cool the compression. Whilst this works well on full load it creates high temperatures even if not required at low humidity. Xstrata Technology CYMG and Xstrata Technology selected MIPAC to specify the measurement and control equipment and installation requirements as well as design. This puts great pressure on mineral processing companies to upgrade smelter capacities.instantel.com. “China is one of the world's fastest Don’t forget to personally request your own copy of Email:emma@im-mining. testing and commissioning. or to receive more information on the Awards Program. configure and commission the Emerson DeltaV control system for the smelter and associated feed system. too – offering more flexibility in narrow spaces This brings more flexibility in implementing the system on specific vehicles. CEO of Clean Life AG.external power supply is one of the big advantages of the system. commissioning of fieldbus system and field instrumentation.mipac. their international project experience and their recent success in China made them an obvious choice for this project with CYMG. “Every year. under contract to Xstrata Technology. CYMG Project Director For the CYMG project MIPAC provided: specification of measurement and control equipment. a safer operating environment and minimise negative environmental effects from the lead smelter. provision of Brisbane-based and on-site training for CYMG personnel.” said Joe Pease. passive and active. configuration. supervision and inspection of field and DCS installation. “MIPAC’s expertise in major control system implementations. Huss Umwelttechnik offers a complete range of diesel particulate filter systems.” said Paul Puusaari. basic installation design. increase productivity and efficiency and reduce negative environmental impacts. ENFI. hot commissioning. As a result. The filters cover engine outputs ranging from 30 up to 240 kW.com growing economies and a large consumer of mineral resources.9% of diesel particulates.” Winners of the inaugural Innovation Award will be announced in major trade publications worldwide. Customers can now choose between a variety of different systems. logic and HMI design. loop tuning and plant stabilisation of smelter controls. we’re constantly amazed at the scope and variety of projects that use our instrumentation. visit www. General Manager. has successfully implemented and commissioned an Emerson Delta V and Fieldbus measurement and control system at China’s newest lead smelter. all customer solutions from one source. the CYMG ISASMELT. Now there is the added advantage of its use in a vertical position. To nominate a project. establishment of remote monitoring facilities to provide control system support for CYMG personnel. Huss reports that the filters capture 99. Instantel rewards innovation Instantel’s new Innovation Awards will honour outstanding achievements the world over and will be presented to organizations demonstrating innovative vibration monitoring on projects with unprecedented success. The Isasmelt at Qujing is part of a major Greenfield plant designed to process 160 000 t/y of lead concentrate. interface with Chinese engineering group. depending on their specific applications. www. “We thought it very appropriate to properly acknowledge and reward Instantel users for their expertise and monitoring capabilities. Continuous product improvement is a necessity for Huss Umwelttechnik in order to remain among the leaders. Huss Umwelttechnik’s partner and dealer in Switzerland. CYMG should realise lower production costs. and special solutions for bigger engines are available on demand. as well as showcased on the Instantel website. The filters are easy to install.au. leading provider of process control engineering solutions. Machines can be equipped with a filter at the site. www.com. Vice President of Instrumentation.huss-umwelttechnik. Clean Isasmelt for Chinese lead MIPAC.com . “The new MKseries in upright design gives opportunities for even the smallest application” explains Urs Rutschmann. Huss can help with this and offers special retrofit kits.” commented Robert Lee. This particular beneficiation plant in Brazil is a copy of an existing plant that uses Multotec spirals. These spirals were specially developed for this particular application to ensure optimum recoveries. The prototype unit was based on the 14/115 model from Ingersoll-Rand. Ampcontrol has continued to expand its export marketing strategy on all fronts.9 m3/min of air at an operating pressure of 20. two orders were received for coal plants in Turkey. The will have application on remote exploration sites and the like.” (info@drilcorp. Successes have also been achieved in Brazil with banks of washwater spirals very recently commissioned in a 240 t/h iron ore plant. lighting. and position in challenging bulk solids applications. Within this system. The 14/115 supplies 11. Groups A. A total tonnage of 800 t/h will be treated between these two plants. The dual-compartment design allows users Mining XcelWobblers . spirals have been ordered for a chrome plant treating 90 t/h.com) Hirecorp UK has mounted IngersollRand compressors on vulcanised rubber tracks to provide the manoeuvrability and low ground bearing pressure needed to deliver the compressors to inaccessible sites. a significant number of substations have been supplied to Chinese mine operators. and Multotec says that the recoveries and reliability of these spirals were the primary reason for this order being placed. www. has received the NSW China Exporter Award. Division 1 and 2. Multotec Process Equipment’s Cyclones Division has recently been granted a TUV/CE certification for its full range of cyclone products. a division of drilling con- tractor. www. For copper heap leach and more. 3.5 to 3. In addition.com December 2005 International Mining 45 Crawler mounted compressors A new range of track-mounted compressors has been designed using Ingersoll-Rand’s compressors to solve the problem of delivering and moving compressors about sites with very restricted access and sites with very soft or muddy ground and uneven terrain. www. Since 2000. non-toxic.3V substation. Multotec says. Drilcorp. Dave Gowans. because the units are simple to operate with two stages in one and very adept at dealing with difficult coals. all-digital design measures any solid surface at any angle with no beam divergence. stable performance and. Hirecorp minimised development and product costs by using power from the compressor engine. The use of radio controls optimises safety by allowing the operator to unload the compressor from the back of a truck and operate its movements onto site from a remote position. All of the Ingersoll-Rand people from sales. these include conveyor substations and development substations to Shanxi Asian American – Daning Energy Co. voice communication and gas detection equipment. no metal parts. said: “For many years. had been nurturing the idea of a selfpropelled.com Multotech Mineral Spiral in Operation shown that by choosing Ingersoll-Rand we got it right first time. These include banks of Multotec SX7 double stage spiral concentrators and SX4 single stage coal spirals for installation on several coal plants in the USA.ampcontrols. regardless of the presence of surrounding vapour or moderate dust. Hirecorp also has a trackedmounted model based on the larger Ingersoll-Rand 21/215 compressor that delivers 20.3 m3/min of compressed air at an output pressure of 14 bar and is a popular power source for applications in drilling. engineering and service departments have provided us with all of the information and assistance that we needed and they have . Manager of the Hirecorp UK.com Lasers challenge bulk solids ASI Instruments new transmitter measures level. for longer life. The low centre of gravity of the tracked compressors allows them travel easily up gradients and across uneven ground. our Managing Director. Sales for spirals in coal applications in Australia have grown with a total of 88 triple start spirals split between two large coal plants. The group is currently commissioning the first all Australian manufactured electrical longwall system for China at the Daning mine. Meeting the requirements for use in hazardous areas (FM and CSA .5MVA 10kV/3. face control and monitoring unit. Ampcontrol has supplied the world’s largest underground flameproof substation. to isolate the wiring and terminations from the sensing elements and internal electronics. The EasyTrak XP laser transmitte measures dry bulk solids. This ensures operation even in the harshest of conditions. eliminating the purchase and service costs of an extra engine in the package. powder coated aluminum enclosure is rated for IP67 or NEMA 4X and DIP ratings. XcelWobbler CMS models are designed for high sulphuric acid (0.0 pH) copper mining solutions.com Ampcontrol’s China success Australian engineering company. part of the new 7/170 family of portable compressors. remote controlled air compressor on tracks to solve access problems we have encountered on sites around the country. biodegradable oil is used in the hydraulic system to mitigate against any possibility of ground contamination. MX7 spirals are currently the benchmark on South African coal plants.multotec. Senninger’s Mining Xcel-Wobblers use a unique off-centre rotary-action to provide extremely uniform coverage at low pressures with very low evaporative losses. This consists of a 6. Ampcontrol. The device is housed in an explosion-proof assembly with screwon cover for quick and easy access. Also in Brazil. for Multotec MX7 spirals. This has resulted in the development of the new tracked units using the Ingersoll-Rand range of compressors. the EasyTrak XP’s rugged. Exporting for 25 years and with export growth sixfold in the past financial year. distance. there is only one moving part. www. This compact.7 bar.3kV DCB.Class I.B.MMT Multotec’s spiralling success M ultotec Process Equipment reports a significant increase in the number of orders for its spiral concentrators.D). Also. the first joint venture coal mining company in China.. These spirals are treating a total tonnage of 900 t/h.C.senninger. Ampcontrol is today recognised as a world leading manufacturer and supplier of electrical and electronic products to the international coal mining industry and an innovator in the area of gas detection systems. Built for durability using high-impact engineering-grade thermoplastics. Russ Cooper..asiinstruments. The new balanced design alows smooth. Continuous mining unit costs are much higher than longwall mining costs. After the 1B and 2B longwall panels have been mined. “Shoemaker Mine is the only mine we have operating in the Pittsburgh Seam that does not have a full belt haulage system moving coal from the face to the preparation plant. The $65 million mine commenced production on time and on budget and is expected to supply 5 Mt/y of thermal coal to Sasol Synfuels when it reaches full production during 2006.63 Mt. 11 km north of Sasol Mining’s now-closed Syferfontein open pit and south of what was Anglo Coal’s Kriel South mine.F. a number of continuous miner development sections at Shoemaker mine in West Virginia will be eliminated. the reserves of which are now the property of Sasol Mining as a result of a deal.6%. or 10. Isibonelo’s coal comes in on an 11-km conveyor to a transfer point close to the start of the Syferfontein system. disciplined growth strategy for coal in the next three years. Anglo Coal will this year supply 3. reflecting improved contract and spot pricing. “We would like to convert this mine to all belt haulage. Average realized price for that coal increased $6. IM . including draglines. in the quarter-to-quarter comparison.” Harvey said. Loveridge. Brett Harvey. or 11. in the period-to-period comparison. CAROLINA Clarksburg ison. there is a 10. has been weak for us.1% in the same compar- Key General Office Mines/Plants Sales Offices Provo CONSUL R&D Philadelphia Baltimore Terminal Norfolk Atlanta Gas Operations Port/Dock Cities OHIO Mahoning Valley Pittsburgh Library Pittsburgh Mine 84 UTAH Price Emery WEST VIRGINIA KENTUCKY Miller Creek Jones Fork Mill Creek Beckley Amonate Miles Branch Bluefield Wheeling Shoemaker Washington Pennsylvania Enlow Fork Alicia T. extending 23 km from the mine to the Sasol Synfuels factory. Shoemaker. matching our increases in production capacity with market demand.” he explained. where the two flows join. Dunlop Belting Products was awarded the contract to supply the steel cord reinforced conveyor belting for the conveyor system to convey coal from Isibonelo to Syferfontein. as main contractor. He said most of the capacity increases will come from efficiency projects that also lower the unit cost of coal production as well as from smaller additions to capacity at various operations in Central Appalachia. Sasol Mining’s investment totalled R320 million and Anglo Coal’s some R770 million. When it was first built.850 t/h.7 Mt to the Sasol Synfuels plant from Isibonelo. historically.5 m/s and loading capacity to 2. Other mines. Total coal production for the first nine months of the year was 46. The upgraded system now accommodates 5 Mt/y from Isobenelo and some 9 Mt/y from Sasol Mining’s underground Syferfontein mine. McElroy and Bailey mines showed strong improvement in production period-to-period. in the period-to-period comparison.58/t. thereby meeting its current contractual obligations.” Harvey said that the plan would allow the mine to run through the spring of 2007.Coal News Shoemaker’s last despite new records Consol Energy reported record earnings of $377 million. but the market price for Shoemaker coal in the next few years will not justify that investment. The conveyor speed has been increased to 6. 46 International Mining December 2005 Miller Creek.6 million for the same period a year earlier. To facilitate two mines feeding to a single conveyor. South Africa. Production of coal increased 1. One of the big task’s was for Bateman Materials Handling.7 Mt.000-t surface bunker at Syferfontein and an 8. Anglo Coal bought equipment from Syferfontein. also improved production.000-t bunker at Isibonelo. “Expanded coal and gas production coupled with higher prices for both coal and gas greatly improved third quarter performance compared with last year. through the expansion of its existing underground operations at Syferfontein Colliery. compared with a loss of $11. President and CEO. “This was solid performance from our ongoing operations in a quarter that. “Demand for high-Btu bituminous coal in the USA is likely to remain strong for the next several years.9%. Harvey said that development work would be completed on the 1B and 2B longwall panels at Shoemaker and then further development at that mine would be suspended.45 Mt.” said J.” Sales of company-produced coal increased 1.” Consol reports. which has openpit reserves of 100 Mt. Total costs for company-produced coal increased $0. and Buchanan mines had production declines period-toperiod.88/t. VP 8. or 2. Anglo American and Sasol initiated a study in 2000 to consider the development of these reserves in Mpumalanga province.” “We expect to execute a steady. An agreement was reached in July 2003 for Anglo Coal to establish a new opencast operation on the northern portion of the coalfield and Sasol was granted access to the southern portion of the Kriel South coalfield. Shoemaker would be shut down. Anglo Coal's Isibonelo mine supplied its first coal to Sasol. Splicing of the 47 lengths of belting supplied for the project began in December 2004. to upgrade the Syferfontein conveyor system that feeds the Synfuels plant to 14 Mt/y at a cost of R170 million. the Syferfontein conveyor was claimed to be the world’s longest system. This was due primarily to higher supply costs. up 20. including Mine 84. “based on expressions of interest for multi-year contracts at today’s market prices by electric power generators.5%. Emery and Isibonelo charges in In July 2005. Bailey McElroy Waynesburg Blacksville 2 Loveridge VP8 Buchanan Robinson Run WEST VIRGINIA Morgantown Fairmont Md VIRGINIA TENNESSEE N. To further control costs. includ permanent paten t moratorium. “The trend to add value in the country of origin is a growing development in diamond producing countries in sub Saharan Africa and we welcome DGI’s investment in the DRC to that end. “Our concern has been the potential impact of REACH on the developing countries. and export to leading world markets. When full production begins. which is steadily restoring confidence in the international community. its subsidiary Emaxon IM .” stated Gertler.susta social responsibi inable developm lity and ent efforts.com INTERNATIONAL LEADERS New job? IN MINING RECRUITMENT micon INTERNATIONAL LIMITED mineral industry consultants .. and large social and economic impact on Kananga.com Expatriate Mining Employment View our other listings at: www. deciding to invest. Reuters reports.” the au Congo (CEEC) to The anti-gold ca mpaign intensif ensure that the pol. Gertler says he hopes other international investors will follow his pioneering move.preparation of feasibility studies 900 . www. and corporate MIBA’s diamond pro. an gest metallurg et-Mex: fourth lar er worldwide. including the pr it contains many ovisions seen in pr of evious Rahall mini the Kimberley ing a ng law bills.Instant M tives: IM. Democratic Republic of Congo (DRC).” said President Joseph Kabila. whose country currently holds the EU presidency. and in 16 of those countries. Carol Ra comulston. currently lishing to mining.expert witness and litigation support . inaccur cterizations of go ate ld mining opera Centre d’ Evaluation in a tions have been campaign again used st our customers et d’Expertise de jewelr in the electronics y businesses. wo tion (NMA) an rld’s premier go d the ld producers ha MIBA. while protec environment. Evaluation and Authorisation of Chemicals) legislation. diamonds mined exclusively in the DRC. TORONTO.. A pr ry analysis of the emeasure indicates lations.risk analysis .limina co-sponsors. “I greatly appreciate President Kabila’s courageous leadership and economic reforms that have enabled DGI to continue to invest in the DRC. The DGI Group has been operating in the DRC for more than five years.market analysis . will soon go into full production. regulations an tary initiatives go d volverning gold mini washing plant and a efits ng.. DGI recently pro. will employ as many as 600 workers. ic benprofiles of award dragline that will boost rec winning mine lan lamation projects d . which I believe has made this DGI investment a reality. far-reaching. South African ambassador to the EU. an Process. “This outstanding investment will have a positive. estab an Abandoned Mine Land Fund operating at a collecte (AML) with mon d from royalties. ny immediately The NMA says it “believes cons advance to full reform tructive and ba should preserve lanced and enhance th p r o d u c t i o n produce e nation’s ability minerals with ce to rtainty and flexib when the DRC ing the ility. countries in Africa have stepped up pressure on the EU to make changes because they say REACH would hamper mining industries and slow down development.” NMA’s senior the Ministry of mun vice president for ications. through CLASSIFIED Thomas Mining Associates To advertise in our classified section phone Emma Joseph +44 (0) 1442 870 829 email: emma@im-mining. ld is produced. perla ber of su les claims a num Industrias Peno the world st silver mine in q Fresnillo: riche Mexico hest gold mine in q La Ciénega: ric ld mine in Mexico : largest go Mexico q La Herradura gest zinc mine in co I. Among its invest. law of a new kimberlite un s. The DGI Group began construction of the plant in August 2004 and completed the project in less than 12 months. the first of its kind in the DRC and Central Africa.go provide informati ld mining practic on on es around the wo vided nearly $15 million inc rld. and additional capacity.. based in Tel Aviv. which has been operational for several months.coinc ied in early Octo ide with the int ber to roduction in th ishing plant is in “Federa e USA of H. Kasaï Occidental Province. l Mineral Develop 3968... Caribbean and Pacific (ACP) states further into poverty.Instan Finance International. “Our intent is to provide objectiv Emaxon is work.Tails Africans against EU chemicals bill Since the leader in IM’s October issue discussing the European Union’s draft REACH (Registration. further lim its on lands open plant.” stated Kasaï Occidental Province Governor Claudel Lubaya.project monitoring . Matjila said 20 ACP states depend on mining exports for more than 10% of their total revenues. It is and important to ge Matieres Precieuses open t the facts out in . will mine pe discretion to de rmits..thomasmining. mine and processing engineering studies . explained. duction to 8. “It’s a great day for the Democratic Republic of Congo and for Central Africa to finally enter downstream of the diamond production process.5 Mct/y. The plant will polish. the econom of gold mining. an td objects to som P a r l i a m e n t of H... UK NR4 6TJ Telephone (44) 1603 501 501 Fax (44) 1603 507 007 www.R. Israel. KESWICK HALL. African nations are heavily dependant on mining.. “President Kabila’s leadership has changed the business climate throughout the country.” said Jerry Matjila. Nick J.mine financing review . The stable and improving economic and political climate in the DRC.” finalizes legislation relating to the export of polished diamonds. The dedicate ludes information d site on the role of go to finance the purchase wh ld in modern so ere and how go ciety.geological. straightforward on to gold cons inforumers and othe ing closely with gold rs interested in m mining practices odern . 39 e of the provisio 68 on those grou ns nds.. roRahall and seven international regu..sit ve launched a ne e. sell locally. qM produc metallic bismuth refined silver and Polished DRC diamonds The Emaxon Polishing plant in Kananga. KESWICK. The return 8% net smelter royalty. Mines and the chara “Recently.respon w web siblegold. and the greater DRC.” IM essage . While some view the DGI investment as a risk. President of the DGI Group of Companies. Madero: lar d largest q Francis ical complex.R. putting faith in international investors. indirectly injecting hundreds of thousands of dollars into the Kananga economy on a monthly basis.micon-international.390 BAY ST.mati e. was an important factor in Dan Gertler. He said the bill would generate costs that would push African. ment and Land compliance with Act of Protection Equit 2005. mining makes up more than 30% of exports.” continued Governor Lubaya. NORWICH. ey a land suitability fraction of its full propos test before a mine al is considered . t Message which markets 88% of the Ne w web site on product of the DRC's Am gold mining erica’s National Mining Associa largest diamond mine. the state-ofthe-art diamond polishing plant..com Tel: +44 1903 753511 Based in United Kingdom worldwide representation December 2005 International Mining 47 . ONTARIO. CANADA M5H 2Y2 Telephone (416) 362-5135 Fax (416) 363-5763 SUITE 10. South African President Thabo Mbeki has written expressing concern about REACH to EC President Jose Manuel Barroso and British Prime Minster Tony Blair. to ments. who was instrumental in bringing the plant to Kananga.org.valuation and evaluation of mineral properties .mineral resource/reserve estimates .” a so-calle y d mining law ref domestic and duced orm initiative int by Rep. micon-international.com Minova International Ltd www.getman. Fax: +1 (630) 420 9763 Email: [email protected] 26-29: 18th Industrial Minerals International Congress.com 39 23 47 29 27–29: SME Annual Meeting & Exhibit. Tel: 81-3-3261-4591 Fax: 81-3-3261-6126 Email: [email protected]/Geology/c/me. India. Canada. Georgia.toro. www.com Dux Machinery Corporation www.au 7-8: JKMRC International Student Conference. USA.com Caterpillar www. Inc Tel: +1 (702) 515 7247.co.uwa. Vancouver. Inc. at V N I T. Toro Loaders www.com Sandvik Tamrock Corp. www.Media Inc Tel: +1 (630) 420 9752.com 31 21 8-10: 2nd International Seminar on Strategic versus Tactical Approaches in Mining.iiconf. conferences@indmin. [email protected] 7-9: Indaba 2006 Investing in African Mining Conference.cl Brazil Contact: Joseph Young Magazine Minerios/Minerales Tel: +55 11 37838990 Email: [email protected] 11 5 37 44 47 13.A.imccapital. 47 48 International Mining December 2005 .com US Mid-West. www. ID. Australia. www.org.htm February 2006 6-8: Conference in Mineral Processing.com Normet Corporation www. www. United Arab Emirates.bc.hcmac.Atlanta. Egypt.edu.infomine.hossequipment. CA.srk.com 13-16: GAW8 – 8th International Conference on The Geology of The Arab World.bucyrus.au 12-16: TMS Annual meeting/exhibition. Eric.asce.html 20–23: 6th International Conference on the Geology of the Middle East Al Ain. Industri AS www. Perth. Cairo University.com/gravityconcentration06/[email protected] Western USA (AZ.smc. 23–26: Mineral Exploration Roundup 2006. Lulea. San Antonio. Perth. www.com Bucyrus www.org 13–14: Gravity Concentration.chamberofmines.cat. USA.snmpe. Western Australia.fi Outokumpu Technology www.ac. [email protected] Sociedad Nacional www.intecvideo.pdac.com Japan Contact: Yuko Ishihara Japan Advertising Communications. Inc Tel: +1 (503) 640 2011.ca/pdac/conv 7: Geomechanics Regulations.com/mining.com Getman www.sandvik.outokumputechnology. Western Australia. [email protected] PAGE FC BC January 2006 11–15: International Symposium on Environmental Issues of Mineral Industry. www.atlascopco.com Boart Longyear www. Inc. Europe. US East Coast. UT) Australia.co. [email protected]. Australian Centre for Geomechanics. USA.uaeu. South Africa.acg. Louis.uk Hoss Equipment Company www.pe SRK Consulting www.smenet.P. Fax: +1 (702) 515 7248 Email: [email protected]/roundup2004. Fax: +1 (503) 640 3130 Email: portland@roymcdonald. St. Tel: +56 2 757 4200. San Francisco. Sweden. www. Canada Central & East Contact: Phil Playle or David Lansdowne Lansdowne Media Services Ltd Tel: +44 (0)1442 877 777.com South America Contact: Ricardo Cortés Editec S.WA) & Western Canada Contact: Jim Olsen Roy McDonald Associates.thomasmining.com Hitachi Construction Machinery Co.sandvik. Risks and Liabilities. www.fsc.com Sandvik Mining & Construction www. NV.com.minovainternational.com/craelius Atlas Copco Rock Drills www.GlobalFuels. Perth. Central & Mountain Contact: Kevin Lapham J. South Africa.org/meetings/AnnualMeeting2006 9 32 ADVERTISING SALES REPRESENTATIVES UK. Fax: +56 2 757 4201 Email: rcortes@editec. Ltd IBC www.com Intec Video Systems. Cape Town.com Diary 27 2 IFC 41 35 41 Global Fuels Conference & Exhibition www. Brisbane.uwa.org/conferences/geocongress06/ March 2006 5 – 8: PDAC.com/comminution06/index.min-eng.htm Micon International Ltd www. Fax: +44 (0)1442 870 617 Email: phil@im-mining. www.com/gaw8 February 26 – March 1: GeoCongress 2006 . Metro Toronto Convention Center.salty2k.com or [email protected] Infomine www. Perth. OR.com Mining Capital www.com Western USA (MT. Nagpur.com.atlascopco.duxmachinery.boartlongyear. and New Zealand Contact: George Roman Roy McDonald Associates.com Gjerstad Mek.com Thomas Mining www. USA.html 15–17: Comminution.min-eng. www.Advertisers In this issue ADVERTISER Atlas Copco Craelius www. Canada. Western Australia.