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AUGUST 2012

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MINExpo 2012 PREVIEW

MINEXPO 2012 PREVIEW▲

Sandvik Mining says it will showcase anefficiency-focused portfolio of newmachines and services. It says it is will

introduce “innovative new products and servicesthat push the boundaries of mining machinerywhile helping customers improve safety andproductivity in today's increasingly competitiveenvironment.”

This bold portfolio includes a new dimensionof comminution. The exhibition will mark theworld premier for Sandvik's revolutionary eco-efficient comminution machine - a machinewhich produces a finer mill feed that boosts thedownstream milling process. This will helpcustomers productively address theenergy challenges facing

them both now and in the future.It will also launch machines which feature

safety-oriented designs, reliable productivityand the latest technology. The bolter miner,MB610, offers fast and easy access tomaintenance points, large and ergonomicworking platforms, enhanced cutting forces, andworld-class performance.

Sandvik Mining will introduce newlyenhanced automation concepts that open up anew era in mining. The Sandvik AutoMineproduct family is already the mostcomprehensive automation offering forunderground and surface mining. Increasingfleet utilisation and production rates, improvingworking conditions and reducing maintenancecosts, it promotes safety, productivity and peaceof mind for mining operations. Sandvik Mining’s

automation focuses not only onequipment autonomy, but also on

mining process automation andmanagement.

"We're driving innovation throughout ourentire portfolio, from new equipment to eversmarter customer services," said Anna Sörelius,Vice President, Business Development. "Fromthe Sandvik comminution machine to SandvikAutoMine, we are bringing compelling, safety-focused and productive new products andservices to the market faster than ever before.I'm incredibly proud of this new equipment andservice advancements." Demonstrating some ofthese capabilities will be an undergroundsimulator, available for ‘test rides’.

"Since Sandvik's major strategic shift only sixmonths ago, the company has found a newenergy. It has provided substantialimprovements in time-to-market, managed todifferentiate on customer services and itcontinues to build on its strong portfolio inmining equipment and services. Sandvik Miningis delivering on its pledges, and is clearlydemonstrating its path to future success."

In addition to key technologies such asautomation, production enhancement, fracturedetection and drilling optimisation, Söreliusreinforces the importance of human talent andcreativity. “MINExpo is an important venue tomeet with dealers and customers, who providevaluable feedback that we use to improve ourservices, tools, and equipment. Sandvik Miningmakes certain we stay in tune with ourcustomers.

The company will also feature severalinnovative surface, underground drilling andload and haul machines, including the high-

Looking ahead to MINExpo 2012

With momentum gathering priorto the event in Las Vegas from24-26 September, IM looks at

some of the machines andtechnologies attendees canexpect to see on the show floor

AUGUST 2012 | International Mining 77

MINEXPO 2012 PREVIEW ▲

78 International Mining | AUGUST 2012

pressure DR560 DTH drill rig, now available withcompressor management system and AutoMineDrilling; the machine also combines differentpressure options, manoeuvrability and reliabilitywith maximum drilling performance.

Since the introduction of its PF300 fully-mobile In-Pit Crushing and Conveying (IPCC)system in March 2009, renewed interest inmobile crushing concepts in the major miningmarkets has been extraordinary. SandvikMining’s newly developed fully-mobile crushingplant makes the IPCC method a betteralternative to traditional truck haulage due tolower operating and maintenance costs, higherenergy efficiency , significant reduction of CO2

footprint, and radical decline in dust emission.The PF300 uses proven crushing technology

to offer a full range of roll crushers flexibleenough to suit even the most challengingapplications. Taking advantage of the manyyears of expertise in designing steel structures,crawler travel systems and apron feeders, aswell as all types of conveyors and conveyorcomponents, the entire system is custom-engineered by Sandvik Mining and equippedwith genuine parts. With commissioning of thetwo first units scheduled for the middle of 2012,Sandvik believes that the PF300, with itscompact and stable design, has major potentialfor future market share for IPCC applications.

On the exploration side there will be an ‘x’version of the DE130 compact core drill for usein explosive underground environments such ascoal, an improved RC hammer with patented bitdesign providing a 30% performance advantage,

and a redesigned line of diamond products.Sandvik continues its mission to deliver high

quality rock tools that provide the bestproductivity in the industry, all with the superioruser experience for which it is known. Newtophammer tools for mine development, theinnovative Sandvik Alpha 330, improves theservice life of the current model by up to 15%,with up to 80% improvement vs. R32 models.

The Alpha 330 is a patented product unique

to Sandvik. The short thread design andhexagonal rods in the tool system result in arigid, integrated power pack drill string withsuperior resistance to bending stresses, inaddition to improved bit guidance and perfectenergy transfer. The sturdy thread is well guidedinside the bit skirt, offering high precision incollaring – even in complex rock formations anduneven surfaces.

Cutter picks featuring the XT grade tungstencarbide can cut materials up to 180 MPa.

Cubex is set to introduce a new In-The-Hole(ITH) production drill at MINExpo. The drilldelivers advances in comfort and safety for theoperator, ease of use, a more rapid learningcurve, and a platform for drilling automation. Ithas been developed through more than threedecades of ITH drilling experience and maintainsCubex's high build quality. Sandvik is the soleglobal distributor for Cubex ITH undergrounddrilling products.

Caterpillar has the largest exhibit at MINExpo2012 and will display many new and upgradedmining products – for surface mining andunderground mining, hard rock and soft rock. Itsays it “will showcase the broadest line ofmining and materials handling equipmentavailable—and backed by the most extensiveand capable product support team in theworldwide mining industry.” It will reveal anumber of innovative mining systems andmachines. One such machine, never before

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presented to the mining public, will offer anunprecedented, efficient means to step upproduction loading of ultra class haulers.“Making best use of size and energy storagetechnology, the new loading tool promises tolower cost per tonne in world class miningoperations.” Whether this is a new ultraclasshydraulic machine beyond the former RH400(now the 6090 FS) or an updated version of theplanned 795 rope shovel design remains to beseen.

In addition to innovative new products,Caterpillar builds on proven ones to make thenext generation of mining machines, technologyand support equipment. For example, the newAD60 underground truck, with 60-t capacity, andthe new R3000H underground loader, with 20-tpayload capability, represent the largest suchmachines Caterpillar has ever made.

For underground coal and soft rock miners,the next generation EL3000 longwall shearerfeatures a state-of-the-art communicationsystem for advanced automation andmonitoring. The Cat longwall system includespersonnel proximity detection and undergroundcameras that can be linked to a surfacemonitoring centre.

Surface miners will see a Cat engine poweringthe MD6240 rotary blasthole drill. They also willget to kick the tyres of the latest edition of theworkhorse 777 truck, the 777G, which meetsNorth American Tier 4 emission standards. The777G also has adjustable fuel saving strategies,performance improvements and enhancedsafety features for sustainable, low cost

production. The next generation D11T track-typetractor also features Tier 4 emissionscompliance as well as the Enhanced Auto Shiftsystem, designed to conserve fuel byautomatically selecting the optimal reverse gearand engine speed, based on load and desiredground speed.

The three largest trucks in the Cat line—797F,795F AC, 793F—will share space with loadingtools, the 994H Extended High Lift designed toefficiently load 250-short-ton size class trucksand the 6030B FS hydraulic front shovelrepresenting the extensive line of Cat shovels.The 6030B is the first of the Cat B Serieshydraulic shovels and features a state-of-the-artnew cab and operator environment withproductivity enhancing on-board electronics.

Support equipment on display includes thenew Cat CT660 vocational truck equipped as aservice truck. TheCT660, available onlyin North America, is thefirst Cat branded on-highway truck and canbe fitted with manydifferent bodies,including a dump body,to serve the needs athand. Additionalsupport equipmentincludes the recentlyintroduced C175-20generator set, whichproduces the greatestoutput, as much as 4

MW, of any single high-speed diesel generatorset available today.

The new 777G WTR is one of the specialisedoff-highway truck chassis that the group offersin a configuration designed specifically for watertruck applications. OEM Solutions also will offerinformation about the new Cat waterdelivery/control system that is being fieldtested now and will be available on the 777GWTR.

Mining professionals in North America willget their first look at what HHitachi describes as“remarkable new AC-drive technologyadvancements in [its] trucks.” The company willintroduce the advancements, which includeHitachi’s next-generation IGBT propulsiontechnology. The technology enhancements willbe showcased in a next-generation rigid-framehauler at Hitachi’s booth.

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MINEXPO 2012 PREVIEW




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“The truck features advanced propulsiontechnology that delivers a whole new level ofefficiency, vastly enhancing machine operationsfor mining professionals everywhere. Inaddition, the new technology, which also powersJapan’s famous bullet trains, outperformsprevious and competitive systems through itssimplicity, improved efficiency, and enhanceddependability.”

“By specialising only on shovels and haulers,Hitachi is able to focus, without compromise, onproducing highly-efficient and productivemachinery,” said Ryan Blades, DivisionManager, Hitachi Mining. “The new AC-drivetechnology advancements are a perfect exampleof the superior quality and performance of thisapproach.”

Consistently delivering a number of newproducts and services to the market, BBoartLongyear will allow attendees to get a first hand

impression of the recently released LS 600 sonicrig. With advanced sonic drill technologyfeaturing innovative and patented designs, theLS600 delivers continuous-undisturbed coresamples and will be onsite at MINExpo.

Product experts will be on-site to highlightthe latest releases in drilling equipment andtools, including the new 10UMX a high-performance diamond coring bit with the freest-cutting matrix available. The 10UMX is part ofthe award winning Ultramatrix (UMX) diamondcoring bit family, which includes the SSUMX,O7UMX and 09UMX.

Boart Longyear also offers water exploration,environmental sampling, energy, and oil sandsexploration services. It offers drilling services inover 40 countries and provides mining productsin over 100 countries.

Thompson Pump and Manufacturing willintroduces the 152-mm (6 in), high-head 6JCCpump. The portable 6JCC delivers 70 litres/s(1,100 g/min), high heads to 150 m (490 ft) and14.6 bar (212 psi) with automatic initial primingand re-priming. The 6JCC is ideal for highpressure applications in mining. It offersThompson Pump’s exclusive EnviroprimeSystem® that provides automatic initial primingand re-priming with the environmental

advantage of not spillingpump fluids duringoperation. Additionaloptions such asThompson’s SilentKnight® sound attenuatedcanopy, accessories,applications assistanceand alternatives areavailable.

Astec Mining's displaywill feature products,such as BreakerTechnology’s RMS 18mobile scaler vehicle,KPI-JCI’s K500 conecrusher and Telsmith’s 3858 mine duty jawcrusher with patented hydraulic overloadrelief. MINExpo 2012 will also serve as theworldwide product launch for the Telsmith T900

mine duty conecrusher. Astec Miningconsultants will beon-hand throughoutMINExpo to discusssolutions that deliverprocess improvements tomine sites throughout theworld.

“By leveraging theindividual experience andexpertise of Astec MobileScreens, BreakerTechnology, KPI-JCI, Osbornand Telsmith, Astec Miningis well positioned tosupport mine sites aroundthe world with equipment,parts and service,” said

Rick Patek, Group Vice President, AstecAggregate & Mining.

Pioneer Solutions LLC, the engineeringservices and project management company, hasintroduced its new front and rear axle oil-cooleddisc brake product line for off-highway dumptrucks. This brake represents Pioneer’s firstendeavour into component supply and launchesa new manufacturedproducts businesssegment. The statementsaid the company “usesits 30 plus years of offhighway equipmentdesign, manufacturing,and product supportexperience to providevaluable lifecyclesolutions to itscustomers.”

Pioneer’s brakes aredesigned to exceedindustry brakingstandard requirementsand easily interface withdifferent OEM axleconfigurations. Eachseries is designed to be

expandable within a given payload range. Thebrakes are manufactured with high qualitymaterials to provide excellent performance andreliable operation. Pioneer’s plans include aseries of brakes for use on mechanical andelectric drive dump trucks with 25 to 400 shortton payloads. The business will supportcustomers throughout new productdevelopment, prototype, testing, production,and field service, including availability ofaftermarket parts.

In addition to the brake product, Pioneer’smanufacturing operations will focus on otherhighly engineered components, such asdifferential gearing and final drive planetaryassemblies. These components requireadvanced manufacturing processes and a highlevel of quality to perform in the extremeapplications of the off highway equipmentindustry. Pioneer Solutions will be displayingone of the new brakes, designed to be used on320 short ton electric drive dump trucks, atMINExpo 2012.

Weir Minerals is to debut a variety of newproducts at MINExpo 2012. A key launch is theLinatex Wear Indicator System, which transmitsand receives messages, providing arevolutionary early warning system to mineoperators. Weir believes the system to besuperior to competitors’ models because itdetects more than just a break in the wire – it



measures a change in resistance for moreaccurate results. The company states that thesystem “saves time, money, and lives bynotifying when a pipe needs to be replaced orfixed.” Overall, the Weir Mineralsbooth will have ten kiosks andtwo seating areas. TheWear IndicatorSystem is not theonly product thatwill be on display,which includeWarmancentrifugal pumps, Cavexcyclones, Multiflo dewatering solutions andIsogate slurry valves.

Flexco will be addressing splicing, cleaning,tracking, belt slippage, and material transferneeds with two booths. Attendees can visit the

outdoor booth forproductdemonstrations and tocheer on the conveyorserviceabilitycompetition. In thiscompetition, Flexcomaintenance teams willrace against each otherto demonstrate quickand safe belt conveyormaintenance withFlexco products.

Attendees can alsostep inside to see howFlexco can help

operations maximise the performance of theirbelt conveyors. Flexco will be showcasing thebreadth of its product offering, demonstratinghow everything – from maintenance tools toconveyor rollers – work in conjunction with each

other for optimal systemperformance.

Newest productswill include an in-depth

look at Flexcotransfer chutes,featuring exclusive

Tasman WarajayTechnology. Flexco will

also be showcasing thePneumatic Single Rivet

Drivers, which speedinstallation of SR fasteners by up to 33%, the EZSeries of impact and slider beds, which

improves performancein the load zone, andthe latest in the line ofinnovative Minelinebelt cleaners forserviceability and wearresistance in thetoughest applications.

Experienced Flexcoteam members will beavailable to discuss theentire system and helpattendees identifychallenges and ways toincrease the efficiencyand productivity oftheir operations.

Flexco is able toaddress almost anyconveyor challenge –from slippage andspillage, to mistrackingand wear and tear, tosafety andenvironmentalconcerns. Even after abelt is up and running,Flexco stays involvedto ensure that itsproducts are deliveringbest performance formaximum productivity.

Atlas Copco has a few surprises in store atMINExpo. Watch out for the next generation ofRCS and the launch of a new Pit Viper. Anotherunveiling will be a new, top secret undergroundproduct that the manufacturer isn’t talkingabout before the show.

On the surface, the new SmartROC D65 DTHdrill rig has advanced automation and is idealfor presplitting. Visitors will also get the chanceto see hands-on how RCS works with an actualcab outfitted with a simulator.

Underground the Simba M7 C tophammerlonghole drill provides efficient, high precisiondrilling for longer consumable life. The BoomerM2 C is a modern, hydraulic face-drilling rig withan EPA III approved engine. The new PedestalBoom System RB600XD is part of the extremeduty series that offers nine models from light toheavy duty for secondary breaking. SwedVenthigh pressure fans deliver air through longductwork with high efficiency for low energycosts.

The Chargetec UV2 provides high speed anddensity ANFO charging with radio remotecontrol. The Unigrout Flex-E grouting system canpump at low or high pressure. Swellex rockbolts are made with patented materials andmanufacturing techniques.

For exploration, the Diamec U8 APC isdesigned for deep hole drilling in an ergonomicand safe manner. The Excore line of premiumdiamond tools is more consistent and lasts upto three times longer than other bits, thecompany claims.

In tools, Atlas Copco Secoroc EDGE isreported to be the world’s first continuousmonitoring system that shows the driller whatthe bit is doing at the bottom of the hole. Othertools that will be on display include PARDhammer, raiseboring cutters, tricone bits, COP44 Gold Secoroc COP hammer, Rocket Bits,COPROD system, sharpening systems andSmoothDrive shock absorbers.

Atlas Copco’s new division, Mining and RockExcavation Service, will be at MINExpo showing

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customers new and improved parts and servicedelivery systems.

WS Tyler Canada will be highlighting its newPro-Deck Consulting Approach, described as “aunique approach to selecting the right blend ofscreening media for each of the three phases of

screening.” The service is designed to optimisescreening operations – both for increasedefficiency and reduced maintenance and wear.Additional products and services that will befeatured include the F-Class Vibrating Screen – afour-bearing, double-eccentric machine,designed to transmit minimal vibration into theexisting structure and deliver constant stroke foroptimal screening results. A Hydro-Cleanmachine will also be featured, a high-pressurecleaning system that can achieve productionrates of up to 400 t/h of material output. Otherhighlights include the Scarabaeus PelletisingDisc, which uses cutting-edge technology toturn fines into saleable material; and the CPA –Computerised Particle Analysis machine, whichoffers more precise particle analysis beyondtraditional sieve analysis. Finally, VibrationAnalysis will be performed onsite by a WS Tyler-certified service technician. This performanceanalysis evaluates the product, screen mediaand vibrating screen, as well as testing thespeed, stroke and overall performance.

For the past 15 years, TThoroughTec has beenapplying high standards of engineering and

production quality to the design andmanufacture of simulators for the miningindustry. This expertise has culminated in the

fourth-generation mining simulator system,CYBERMINE4.

Examples of the latest range of ThoroughTec’sunderground and surface simulator cabs,including a Komatsu 960E haul truck, will beavailable for test drives at MINExpo 2012.ThoroughTec’s unique 3 Degree Of Freedom(3DOF) motion platform and adaptor plate willbe used for these displays, exhibiting how 6DOFsurface cabs can be effectively used on a 3DOFmotion base fitted with the adaptor plate. Thisallows a single simulator to replicate the entireworking fleet of a mine, reducing costs andmaximising return on investment.

All ThoroughTec simulator cabs useCYBERMINE4 technology to create the realisticsensation of driving the actual vehicle in anactual mine, with all the correct visual, auditoryand tactile feedback. Instructors can configuretraining scenarios to specific training objectives– not just generic scenarios, but thosespecifically faced on their mine site. Accordingto ThoroughTec’s CEO, Rob Letschert, “Our newfourth generation mine truck simulators haveredefined the technology benchmark. We nowprovide an enhanced scoring system, a missionplanner for simulating dispatch systems,simulated reversing aids and a replicated two-way radio”. Hands-on demonstrations will beavailable for visitors to the ThoroughTec stand.

ThoroughTec states that it is able to simulateany machine from any OEM in the industry,surface or underground, and has the largestdevelopment pipeline by far, so is able tocustomise on every build it does, going beyondthe OEM specification “to deliver the exactoperating procedure the customer wants andneeds.” ThoroughTec currently simulates over73 different mining machines, covering bothunderground and surface machines, from drillsand bolters to draglines and haul trucks.

Mine Site Technologies (MST), a global leaderin communication technologiesdedicated to mining, has been adriving force in bringing newtechnologies to the industry over theyears, including the creation of the‘ImPact - One Network’ solution fortoday’s digital mine. The companysays “the primary drivers for all MSTproduct development s are inproviding the customer with theopportunity for improving theirproductivity and at the same time

enhancing their safety.” At MINExpo, MST willshowcase its newest and most advancedcommunication technologies. Known as ‘ImPact’

the wireless, 802.11 standards based networkcommunications system provides its users with,MST says, “simplicity, reliability, expandabilityand unsurpassed functionality in the miningenvironment.” There will be operational systemson the stand to provide potential customerswith first-hand, hands-on demonstrations of thereal functionality of the ImPact system. Includedwill be the MinePhone VoIP telephone handsetand the ICCL (Integrated Communications CapLamp) that incorporates text messaging andtracking into a single cap lamp product.

MST will showcase its full range of products,including several complementary partnerproducts: ■ ImPact - Underground Digital

Communications and Tracking System (IEEE802.11b/g, 802.11i, 802.11e)

■ Tagging Systems - Personnel and vehicletracking.

■ VIP - Vehicle Intelligence Platform: real-timevehicle diagnostics and payload data system.

■ VDV - Leaky Feeder Radio System■ Wireless Mesh - High bandwidth mobile

networks; underground and surface.■ ICCL - Integrated Communications Cap Lamp■ MinePhone - In mine / mine purposed VoIP

wireless communications from any area at amine covered by wireless network (includingunderground to surface)

■ PED - Personal Emergency Device: TTE(Through-The-Earth) emergency and generalcommunications system

■ BlastPED - Remote blast initiation systemusing the PED transmission system.Phoenix Process Equipment, the exclusive US

distributor for Diemme recessed chamber andmembrane filter presses and piston-membranepumps, will feature its Diemme filter press fielddemonstration system. The trailer mountedsystem includes a Diemme KE500 filter press,

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10 gallon/min membrane pump, 200 gallon mixtank, and mixer.

Sleipner will be showcasing its uniquesystem of transporting tracked excavators inopen pit mines. The system is based on axlesand heavy tyres with ramps. With the aid of a

set of Sleipners and a haul truck the excavatoris easily and quickly moved to the desiredlocation. In addition, the system offersconsiderable reduction to the wear of theexcavator’s undercarriage and tracks. There arecurrently 11 models in the manufacturingprogram covering excavator weights from 30 tup to 550 t. Most models incorporate differentramp sizes to fit different excavator brands andmodels. The newest model, the E550, is also thelargest one and can move excavators up to 550 tand in some cases, larger. The larger the

transported excavator is, the more proportionalbenefits in wear and work-site efficiency theSleipner system offers.

In the early part of 2012, Sleipner has soldthe system to mines located in Australia,

South Africa, Ghana, Indonesia, Austria, Angolaand Chile. Sleipner shares itsMINExpo stand with HSM Tire Co,which has its headquarters inHouston, Texas. HSM is specialised inheavy mining and OTR tyres and isSleipner’s agent in US and Mexico.

Advantage PressurePro, thedeveloper and distributor of thePressurePro line of tyre pressuremonitoring systems (TPMS) andtechnologies, was incorporated in1991. The company was the “original”TPMS provider to the worldwidecommercial vehicle markets and seesitself as a pioneer in TPMStechnologies. Providing numerousadvanced monitoring options

including large bore Sensors, RS232, J1708 andJ1939CAN, data logging, fully automateddrop-and-hook solutions, remote monitoringoptions and full integration to leading Telematicofferings, the company states that “PressureProbrings your entire mining fleet the tools neededto increase efficiency and profits throughreduced downtime and maintenance andincreased performance and safety.”

At MINExpo, PressurePro’s leading globaldistributors will be showing the market’s mostadvanced TPMS technologies. Featuring

standalone monitoring systems as well asintegrated monitoring solutions, PressurePro’scomprehensive offerings will also be on displayat numerous technology partners’ booths. Theyinclude standalone monitoring options thatutilise RF technology to transmit real time tyrepressure and temperature information from amonitor, which sits in-cab; as well as sensorsthat fit to equipment valve stems. Providing twolevels of low pressure alerts, a user setable highpressure alert and a high temperature alert,

PressurPro’s standalone units give drivers theability to monitor their tyre performance at alltimes and to correct problem situations beforethey become costly or hazardous. Built in datalogging abilities also allow fleet managers ormaintenance personnel the ability to monitortrends in tyre and driver performance, allowingeven greater efficiencies.

Partnering with leading telematics providers,PressurePro’s comprehensive line of integratedoptions allows fleets to utilise PressurePro’s fullTPMS capabilities without the addition ofscreens in-cab. Communicating over thetruck-line, or direct to a box or screen,PressurePro is able to provide real timepressures, temperatures and alerts for driverswhile eliminating driver distraction and cab


clutter. Further integrated options also providefleets with the ability to tie into current or futurecommunications options allowing remotemonitoring to a home base or office.

Mining tyre manufacturer and solutionsprovider, EEurotire, will be unveiling its newEuroCare program at MINExpo, described as an“innovative 360° program” and the first of itskind in the industry. EuroCare is a completeportfolio of value added components “thatprovides customers with the training, tools,service and support they need to run a saferand more profitable mining operation.” TheEuroCare program is designed specificallyaround Key Performance Indicators and iscustomised and tailored to a specific miningoperation. Each component is measurable andits “value” proven by directly answering specificKPI requests.

A team of Eurotire experts will be present torespond to queries about tyre maintenance andperformance, talk through the complete rangeof the group’s leading tyres, as well as advisingon which tyres will deliver

the best results under specific mineconditions, and how the mine operator canpartner with Eurotire’s service and supportnetwork.

Following the launch of an industry leadingthree year warranty on its gearbox repairs inJuly 2012, DDavid Brown is gearing up for theunveiling of a new product range at MINExpo.The group is known as a leading global supplierof mining gearing solutions and services. Thecompany states: “David Brown uses its 150

years of engineering innovation to understandand solve its customers’ gearing problems. Ourgearboxes are renowned for their strength andreliability in critical applications.” Key miningapplications include conveyor drives,stacker/reclaimer drives, pump drives, girthgears, pinions and mill drives, as well as shoveland dragline components. The company statesthat the need to minimise disruption andoptimise capacity in harsh environments hadled to the development of the new productrange backed up with the three year servicewarranty.

The team has also added to its globalmanufacturing capability with service centresand sales offices in the key mining regions ofChile, South Africa, Zambia, Australia,Indonesia, the US and Canada. The companytold IM: “By expanding its global network DavidBrown can now deliver its proven expertise withvital on-the-ground support, helping customersreduce downtime and run their operations with

highest efficiency.”At JJoy Global, P&H and

JOY say they arecombining resources tobetter serve theircustomers worldwide. Asa worldwide leader in thedesign, manufacture andfield support ofequipment for surfaceand underground mining,Joy Global states that itwill be demonstrating its

“singular focus on mining” at MINExpo 2012with innovative products and systems alongwith life cycle services to help make miningoperations safer and more productive.

One of these is the Joy Global Smart Servicesremote health monitoring technology. Visitorsto the Joy Global exhibit will be able to see realexamples demonstrating the power oftechnology that transforms data into valuableknowledge, helping optimise machine andsystem performances.

Joy Global added world-class wheel loadersto its product portfolio during 2011 with theacquisition of LeTourneau. To highlight thisaddition, a “P&H LeTourneau-Series” wheelloader will be on display within the booth.Rounding-out the real-iron examples of highperformance products in the exhibit, will be ahigh-production Joy low seam longwall system,complete with shearing machine, armoured faceconveyor and roof supports. Also, undergroundroom and pillar mining systems will be featured,

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including a Joy continuous miner applicable to afull spectrum of seam conditions.

Joy Global will also showcase several moreexamples of advancing technology that can helpmines increase operations efficiency. Thoseinclude an innovative P&H drill operator cab,the P&H LeTourneau-Series SR or SwitchedReluctance motor technology, and new trainingsimulators. These simulators help supportmines by fast-tracking new equipmentoperators into recommended best operatingpractices that optimise asset utilization, safety,availability and productivity.

In addition to the products and systems ondisplay, a central stage will feature Joy Global’sleadership and direct service support. Thecompany will use this platform to introduce newsurface and underground mining systems –including a “first-of-its-kind” generation ofloading equipment.

Engineering Dobersek, the German specialistfor planning, designing and commissioning ofturnkey plants and plant components in thefield of mining and metallurgy, water treatment,power and environmental engineering as well aschemical and special plant engineering is takingpart at MINExpo this year for the first time. Thecompany will present its latest projects inbackfilling, mine dewatering, mineralprocessing and metallurgy at the GermanPavilion. These include the Conticlass Systemfor separation and classification, with variousapplications in mining and mineral processing.

Conticlass is patented by EngineeringDobersek and provides continuousclassification of ores. An essential precondition

for perfect separation is constant pressure atthe hydrocyclone inlet. The system is designedto enable pressure variations to becounterbalanced by a speed-controlled pump.As an additional effect thepump lifetime is extendedtenfold, because, amongstfurther positive effects,cavitation is avoided.

A regular problem in oretreatment plants is thatconstant ore feed cannot beguaranteed. In order tocounteract feed variations, millsand pumps have to be switchedon and off. This is notnecessary for those plantsequipped with Conticlass.

Martin Engineering is set tolaunch Haul Mass at MINExpo2012, described as “the next big thing” in thebulk materials handling industry, andrepresents a new technology specificallydesigned for the mining industry.

Founded in 1944, Martin Engineering is aleading international developer, manufacturerand supplier of innovations to make thehandling of bulk materials cleaner, safer andmore productive. Martin offers technologiesthat boost flow, reduce dust and spillage,extend component life and reduce downtime,resulting in improved operating environmentsand increased profitability.

The group has an established a network ofsubsidiaries, licensees and representativesacross the globe. Business locations includeMexico, Brazil, China, France, Germany, UnitedKingdom, South Africa, Turkey, Indonesia, India,Canada, Australia, Japan, Chile and Colombia.

The company states: “Throughout the mineand mill, Martin Engineering reduces fugitivematerial and improves productivity. We offer avariety of products and solutions to help makemining cleaner, safer and more productive.”

Visitors to GGemcom’s MINExpo 2012 boothcan expect numerous key productannouncements, see software demos, and

watch informative presentations at its theatre.In addition, Gemcom’s mining professionals willbe present at the booth, ready to helpoperations in all stages of production learn howto address challenges with the use of Gemcom’ssoftware and services. Visitors will also get apreview of how leading technologies from otherindustries can be applied to mining following itsacquisition by Dassault Systèmes.

Dassault Systèmes provides business andpeople with virtual universes to imaginesustainable innovations, with solutions thattransform the way products are designed,produced and supported. With the acquisitionof Gemcom, Dassault Systèmes’ objective is to“model and simulate our planet, improvingpredictability, efficiency, safety andsustainability within the natural resourcesindustry and beyond”. In order to support thisgoal, the company has created a new brand,GEOVIA, which Gemcom will become.

In addition to the acquisition by DassaultSystèmes, the last four years since MINExpo2008 have seen significant changes for

Gemcom, including new releases for all of itssoftware products, new technology introducedto the market, and an expanded portfolio ofservices offerings.

Gemcom’s products include the geology andmine planning software Gemcom Surpac,Gemcom GEMS, and Gemcom Minex (specific tostratified deposits); Gemcom Whittle forstrategic mine planning; and Gemcom InSitewhich supports mine production management.Other software from Gemcom includes GemcomMineSched for surface and undergroundscheduling; Gemcom Hub for secure remotecollaboration and data centralisation; and theblock caving software Gemcom PCBC.

Vermeer is introducing its newest TerrainLeveler surface excavation machine at MINExpo2012. The Vermeer T1655 Terrain Leveler surfaceexcavation machine (SEM) is designed forprecision surface mining applications and is alsofeatured in this month’s Operation Focus articleon the use of the machine at FMG’s ChristmasCreek iron ore mine.

At 181.4 t, the T1655 is significantly largerthan its predecessor — the T1255 Terrain LevelerSEM. It stands 17 5.2 m high from ground to thetop of the cab at full extension. Its length spans




13.4 m and its width is 6.4 m. The T1655 isdesigned specifically for precision surfacemining, a process that allows mine operators toselectively extract mineral seams in surfacemining applications. Operators can alsoinfluence material sizing — producingconsistent-sized material in a uniformconfiguration so minerals can be handled moreefficiently than product produced by drilling andblasting. The uniform product size allows moreefficient settings on secondary and tertiarycrushing systems; savings that can continuewell past the primary crushing stage.

An important feature contributing to the easeof operation is the TEC Plus display, whichallows the T1655 to communicate with thevarious control modules situated throughout themachine, as well as the two engines. The TECPlus display allows the operator to easilymonitor and control machine functions andimproves the onboard diagnostic capabilities.See the in-depth article beginning on page 144for more detail on the new T1655.

The productivity of the T1655 centres on thedirect drive drum with the drive motors attacheddirectly to the cutter drum. The cutter drum islocated on the rear of the machine, allowing thedrum to cut material while the tracks remain onuncut ground so not to spoil the excavatedmaterial. The T1655 has dual hydrostatic tracksfor independent rotation in either direction. Themachine can quickly reposition up to 360° ineither direction for the next cut.

The whole MMTU product portfolio for miningapplications will be shown at MINExpo andcomprises diesel engines delivering poweroutputs of 75 to 3,000 kW for haul trucks,mining vehicles, underground mining machines,wheel-loaders, excavators, and mobile drillingrigs. Services with remote data transmissionenable efficient remote diagnosis, maintenance,and engine condition monitoring. These arecomplemented by automation systems with amodular design for flexible monitoring andcontrol of the propulsion plant. Completing theproduct portfolio is MTU ValueCare servicesupport at over 1,200 locations. Service includesengine maintenance, spare parts supply, andremanufacturing of engine components andcomplete drive systems.

The company is probably best known for the

Series 4000 engines thatwill be displayed at theshow. These are widelyused on ultraclass trucksand large excavators. Ata gold mine in Nevada,the company is currentlyfield testing a 12V4000Tier 4 compliant enginein a Komatsu 930E haultruck.

MTU Series 2000engines cover a powerrange from 561 to 1,163kW (752 to 1,560 hp) andfulfil the EPA Tier 4

interim emissions regulations (as with theS4000 engine) using only in-engine technologyand no exhaust gas aftertreatment. The latestversion has been totally re-designed usingknowledge gained from Series 2000 and 4000engines in other applications. The noaftertreatment has been accomplished througha combination of key engine technologies,including 2-stage regulated turbocharging, apatented EGR system, and a new combustionsystem design.

Finally, the company will be highlighting itsLower Power Range (LPR) of engines, whichinclude the new Series 1000, 1300, 1500 and1600, all based on a cooled EGR, common railfuel system, mutli-valve per cylinder technologyand with no diesel particulate filters, with therange moving to Airless SCR for inline engines.

Flanders, the privately-owned,third-generation company headquartered inEvansville, Indiana, develops advancedtechnologies and designs, manufactures, sellsand services motors, complete power systemsand automation solutions that deliver higherreturn on investment (ROI) and lowest total costof ownership (TCO) for mining, metals,utilities, alternative energy and otherheavy industries.

At MINExpo, Flanders will befeaturing several innovations. TheFlanders Advanced Rotary DrillVector Automated Radio Control(ARDVARC) “revolutionises surfacemining operations” by automating thedrilling process itself—anywhere fromoperator-initiated to complete autonomous

operation—delivering significant improvementsin productivity, safety, fragmentationpredictability, and machine life cyclemanagement. The company will also befeaturing the new Flanders ARDVARC CommandCenter that allows the operator to control allaspects of the ARDVARC drill automation systemfrom the safety and comfort of a remoteenvironment—in the field or the office. TheARDVARC Command Center provides completesurveillance and supervision of up to fourautonomously operating drill rigs. Video anddata integration, together with control andsafety systems, all exist within the CommandCenter configuration.

In addition, the Flanders SureTrip Dipper TripSystem will be featured, which helps to improveshovel productivity by virtually eliminating anunexpected dipper trip system failure, one ofthe largest contributing factors to productivityloss for shovel operations. Failed ropes andcomponents can take 30 minutes to hours torepair and replace, which cripples productivityfor shovel-truck operations. Dipper trips that failto actuate can also be problematic. The SureTripDipper Trip System incorporates astate-of-the-art digital drive system and

excavator-duty components including aring and pinion gear and cable reelassembly. The reel applies constanttension during the dig cycle to maintainfull control of the tripping cable, andoptimises torque to ensure reliable andconsistent gate activation. Flandersbelieves that SureTrip is the only long-lifedipper trip system that shovel operatorscan count on for 99% activation reliabilityor adjust to a custom setting based onthe digging situation.

Finally, the company has completedNorth America’s first DC to AC draglineupgrade, stating: “mine operators who

convert from DC to AC draglines stand to realizea quick ROI and ongoing improvements inproductivity and safety, decreasedcost-per-tonne, and decreased total cost ofownership. Flanders’ designed-for purpose ACmotors and MG sets can breathe new life intoexisting DC draglines.”

Fordia will showcasetwo recent

technologydevelopments atMINExpo 2012. InApril it launched anew diamond bitthat adds to itsHERO range. Justlike the HERO 3,HERO 7 and HERO11, the all-new HERO9 offers “apenetration/lifespanratio that surpasses

other core bits in itsclass.” The core bit is also more resistant to

high drilling pressures, making it easier to use.

▲


Together, the HERO range of four core bits cannow tackle ground ranging from 3.5 to 7.5 onthe Mohs hardness scale. The HERO 9 isdesigned for very hard ground rated between 6and 7.5 on the Mohs scale. It stands out saysFordia, due to its longer lifespan and impressivepenetration rate, which allow it to drill fasterand longer.

Fordia's R&D team created the matrix throughextensive field tests that enabled itsoptimisation. Dozens of tests with numerousdrilling companies across multiple sites havedemonstrated that the HERO 9 has a lifespan asmuch as 150% longer than other bits. It is aimedat projects that are drilling through plutonic andvolcanic rocks, such as granite or syenite, orsimilar rock formations. The HERO 9 is availablein diamond impregnation heights of 13 mm and16 mm to further increase the metres drilled.

In addition to HERO 9, Fordia’s booth willfeature the CorientR, a mechanical coreorientation device that “integrates seamlesslyinto drilling operations and provides easymarking of core samples to record their originalorientation in the ground.” This data allowsgeologists to plan campaigns more effectivelyand optimise drilling costs. Fordia states thatthe CorientR is exceptionally user-friendly,requires no supplies, batteries or calibrationand employs no fragile electronic components.It was first made available forrental in Canada, followed byits launch in Australia andnow in the wider market.

Varel International, theworld’s largest independentsupplier of drill bits to themining industry, will beshowcasing new technology atMINExpo, including more than 60roller cone drill bits for multiplemining applications includingHorizontal Directional Drilling bitswith EdgeGuard features, the RotaryPercussion System (RPS), amassive 44 in drilling bit, claimedto be the world’s largest roller cone

drill bit, as well as introducing the Avengerseries of sealed bearing roller cone bits formining applications.

Specifically introduced for long lastingbearing life in highly abrasive rock formationsand horizontal directional drilling, the newEdgeGuard patent pending insert technologyallows wear resistant material to be directlyapplied to the edge of the bit shirttail resultingin protection of both the bottom and the leadingedge of the shirttail. According to Varel, this candramatically extend bit life in applications whereshirttail wear is aprimary failure mode aswell as protect thebearing by providingextended wearprotection onpreviously vulnerableareas.

Varel acquired theRotary PercussionSystem (RPS) in 2011,and says it hascontinued to improveupon the platform ofusing these highfrequency, low impactpercussion tools in rockdestruction. This

product line, under development since2005, allows drillers to utilisetraditional roller cone drill bits in air,mist, or foam fluid applications,increasing the rate of penetrationthrough efficiently combining thecomplimentary forces of both rotary

and hammer drilling.The record 44 in steel-toothed roller

cone bits are used for top-hole drilling.This design is more than 22% larger in

diameter than any previous roller conebit, and features an advanced cutting

structure with optimised row placement,tooth spacing and cutter geometry forincreased drilling efficiency. These

attributes also work to minimise tooth wear

and prevent cutter tracking in a wide variety offormations and conditions.

Designed and built for long life and drillingefficiency in blast hole applications the all newAvenger series sealed bearing bits add anotherdimension to Varel’s offering. Avenger benefitsfrom the company’s proven technologyinnovations in sealing and bearing technologyused in its successful oil and gas drilling HighEnergy series drill bits.

For the first time in the US, MManitou Group,The Material Handling Reference, will display its

broad range of Manitou, Gehl and Mustangbrand equipment dedicated to the mining sectorat MINExpo 2012. The company states that the“Manitou, Gehl & Mustang brand machinesprovide immediate operational cost reductionfor mine sites because of their versatility….thesemachines can be used for maintenance of largemining equipment, construction of structuresand for operational tasks throughout the site.”

Attendees will be able to learn more aboutManitou telescopic handlers, heavy-capacitytelescopic handlers, rotating telescopic handlersand rough terrain forklifts. Mustang will bedisplaying its compact skid steer loaders. Allmachines displayed will feature a variety ofavailable attachments applicable to the miningindustry. The company will also be releasing



new solutions, tailored specifically to the miningmarket, at the show.

Live demonstrations of the Manitou MHT10225, the highest capacity rough terraintelescopic handler in the world, which has a22.5 t lift capacity, will be conducted throughoutthe event. Demonstrations of high-capacitycylinder and tyre handling attachments,controlled remotely, will also be conducted.

Redpath Group, the international minecontracting and engineering company, is to

showcase the newest member of the Redborefleet of raisedrills, the Redbore 30 at MINExpo2012. Redpath states: “This nimble andeconomical raise drill was specifically built forraisedrillers by raisedrillers, to make light workof rapid boxhole development. It is the lightest,most compact drill in the blind hole, box holemarket. The drill’s energy efficient power packand operating console have been combined intoone unit making this 2 piece compact drillextremely mobile, maximising mobility.” Inaddition to introducing the Redbore 30, TheRedpath Group will be continuing its 50thanniversary celebrations at the event. With fiftyyears of mine contracting and engineeringexperience, the milestone is expected tobe a “reunion of sorts”, with past,present and future clientsinvited to stop by the exhibitand meet the internationalteam representing Redpath’sglobal regional offices.

Cummins Inc will be showingthe new QSK95 mining engineat MINExpo 2012. This enginewill provide a 4,000 hp (2,983kW) capability for ultra-classmine haul trucks, representingthe highest-ever power outputintroduced by the company for severeduty-cycle operation. The 95-litre displacementQSK95 is purpose-designed to provideenhanced strength for 327 and 363 tpayload-class trucks, with the capability toincrease truck speeds for climbingsteep-gradient haul roads and boost haulingproductivity with reduced operating cycle times.

The QSK95 will be available as a globalmining engine platform capable of operating atmine sites anywhere in the world and meeting

all emissions standards, including Tier 4 Final inNorth America by using Cummins provenSelective Catalytic Reduction (SCR)after-treatment.

The 16-cylinder QSK95 reaches the miningpower output previously available only from20-cylinder engines. High power density isachieved with a hardened power cylinderfeaturing the strongest single-piece forged-steelpiston available in the industry. Deep structuralstrength is provided by an all-new ductile iron

skirted block. Thisincreased strengthcontributes to higherengine uptimeavailability, extendedlife-to-overhaul andmore cost-effectiverebuilds.

The output of theQSK95 engine isdescribed as “wellwithin its designcapabilities”, withpotential powerincreases available inthe future to provide the

possibility for the next generation of ultra-classhaul trucks to move beyond 363 t payloadcapacity.

Cummins states: “The stronger engine designof the QSK95 means more reliability in-serviceand less to rebuild at engine overhaul,considerably reducing total life cycle costs. TheQSK95 will provide an exceptionally longlife-to-overhaul, capable of achieving 1.7 Mgaland above of fuel consumed before rebuild, withthe added advantage of no midlife interventionrequired.”

Cumminsnext-generation

ModularCommon-RailSystem

(MCRS)enables theQSK95 to

achieve highfuel-efficiency,

even when operatingat maximum power

output. With up to2,200-bar high-pressure fuel

injection, MCRS reduces noise,offers smooth idle stability and

eliminates visible smokeacross the entire operating

range. Cummins’ new NanoNetfuel filtration gives superior fuelcleanliness and enhances thedurability of the MCRS system –an important advantage formining engines required tooperate anywhere in the worldwith varying fuel quality.

A quad-turbocharging systembrings the simplicity of a

single-stage air handling system already provenon the QSK60 engine. The four compactturbochargers, one arranged for each bank offour cylinders, provide outstanding step-loadacceptance and transient response. This enablesthe QSK95 to deliver more rapid power acrossthe entire rpm range to improve haul truckspeed at full payload capacity.

Advanced electronics enable the QSK95 to becustom-calibrated for specific duty cycles, withthe flexibility for performance to be optimisedamong fuel consumption, transient responseand emissions reduction to suit different haultruck applications.

RDH Mining Equipment’s Muckmaster 800D isthe Sudbury-based company’s first largecapacity LHD. The compact, powerful workhorsecan get into tighter spaces and has more powerthan other models in its class, RDH claims. The14,000 kg tramming capacity LHD can be fittedwith a range of bucket capacities between 4.6and 7.6 m³. To reduce wear and increaselifespan, buckets are fitted with wear strips anda bolt-on lip, allowing users to replace thebucket lip without welding. The loader linkagegeometry has been designed to provide optimalmucking and loading performance.

The Muckmaster 800D’s powertrain providespower and performance to perform under toughconditions. Its powerful 258 kW Mercedes TierIV Interim engine meets stringent emissionslimits while also achieving valuable cost savingsthrough low fuel consumption. The LHD featuresheavy duty Dana 21D axles, a full power-shiftfour speed Dana 6000 series transmission andDana 9000 series torque converter. Itspowertrain has been designed to deliverconstant power to the wheels, providing highoperating efficiency for virtually any application.

With bi-directional seating, the ergonomicoperator station comes standard withROPS/FOPS canopy or optional fully enclosedcab and includes an electronic touch screenmonitoring system which provides a constantdisplay of vital machine functions as well asservice and diagnostic tools. A door mountedelectric joystick provides steering andtransmission shifter controls. A responsivearmrest mounted joystick controls boom/bucketfunctions. The ride control system featuredampens movement of the boom and bucketduring travel over rough terrain, increasingefficiencies by improving cycle times and loadretention as well as providing a morecomfortable ride for operators. IM


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