Haver & Boecker Niagara has realized a demand for the fertilizer industry and adapted their processing technology to process sulfate of potash. Throughout the decades, Haver & Boecker Niagara has developed special processing solutions that grant high production rates, improved material quality and low maintenance intervals. 

Retrofit is playing an increasingly important role in material flow, especially in most critical conveying equipment. With systems that are always up to date, you as an operator achieve, among other things, higher performance, and availability of the plant. In addition, energy consumption is minimized and working conditions become more ergonomic. But you also get new functions and improved plant utilization. André Tissen, our Director of Sales Customer Support shows in this video why rebuilding and modernization are worthwhile and what advantages the user has. You should not miss this video. 

With a seventy-year history in designing, manufacturing, operating and service of pelletizing equipment, Haver & Boecker Niagara has established itself as a leading specialist in the production of the innovative SCARABAEUS© 7500. Sustainability, maximum efficiency and improved product quality are the main reasons for our customer from Ukraine, to place its trust in our team by ordering in total 15 of our pelletizing discs, 7 of which are about to go into production due to the currently signed contract.

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom training modules and on-site training have improved start-up success and operations for clients on nearly every continent. We invite you to experience one of our e-learning training modules. Here you will see a video demonstration of a sample principle of operation from an e-learning module. A principle of operation describes in detail how a piece of equipment or a process works. In this sample, you will learn about Jameson Cell flotation technology and how its design allows for more efficient mineral separation in a much smaller tank than traditional column and mechanical flotation cells. We describe in detail the key components of the Jameson Cell and the operating principles. At the end of the module, a test will help assess what you learned. In a full training program, test results can be recorded and tracked in an LMS. A principle of operation like this would be only one of many included with a full plant operations training program. Note: This is a sample and does not contain the Jameson Cell training module in its entirety. If you would like to try out this e-learning module, please contact Kenneth Slack at [email protected] or +1-520-544-2220.

In an industry that’s flooded with new and improved tools and software systems, we help our clients by providing key insights and custom solutions. Serving our industry to the best of our ability requires us to act as trusted advisors. We start by suggesting the right tool for the job. In part three of our Guide to Drone series, Steele Olsen, Geospatial Field Technician, highlights some specific UAV platforms that are currently in-use at Firmatek and discusses why they fit well within our clients’ operations. Download our resource to learn more about the tools we use and why!

By Eric Marcotte The mineral processing industry usually evolves rather than revolutionizes, but the Horizontal Shaft Impactor (HSI) has revolutionized the crushing process in numerous industries.32 IMPACTOR 400 There are several varieties of the HSI, and their similarities are more numerous than their differences. All varieties feature externally fed horizontal rotors with breaker bars, which propel material into a series of apron-mounted breaker plates that crush or pulverize many different types of materials to specified degrees of fineness. In 1946, Dr. Erhard Andreas of Muenster, Germany, patented the “Andreas Impact Crusher System.” His design utilized old torpedo tubes and steel from decommissioned tanks. Since then, there have been many unique features of the design patented, but they all operate similarly. This article reviews current techniques employed to get the most from this versatile design. Versatility Reduction ratios of up to 30:1 are achievable in a single stage. The simple design offers low capital and operating cost. Low headroom requirements make it easy to install. Product sizes may be varied by changing rotor speed and the clearances between rotor breaker bars (also called blow bars or hammers) and apron breaker plates. HSI applications have gone beyond soft and nonabrasive materials such as limestone, phosphate, gypsum and weathered shales, to harder minerals thanks to the introduction of alloy steel rotor breaker bars. Typical alloy steels contain manganese and/or high or medium chromium content. There are many different crushing chamber designs on the market, and proper selection will depend on the knowledge of the application for proper feed, crushing chamber configuration, metallurgy of the crushing chamber components, gap setting and rotational speed. Finally, computer controls can automatically adjust HSI settings on the fly to adjust for wear or changing specs. Operation HSIs have a lined crushing chamber with rotating breaker bar rotor on a horizontal axis. The size reduction takes place quickly along short fracture lines, producing a more cubical product to meet aggregate specifications. This fast impact fracture is different from the slow compression breaking in cone or jaw crushers that produce more slabby or flat material (5:1 length to height ratio). 32 IMPACTOR2 400Feed enters the primary crushing chamber and meets the rotor breaker bars, which impel the feed against the first apron lined with breaker plates. Impact with the rotor, the breaker plate, and inter-particulate collision all contribute to comminution. Material is reduced in the primary chamber and passes by the front apron breaker plate gap, entering the secondary and, in some configurations, tertiary chambers, for final reduction. A high percentage of the initial size reduction comes from the first impact with the rotor breaker bar. Aprons are shaft suspended at the front and from a spindle in the rear, allowing for continuous gap adjustment as wear progresses. Unlike hammer mills, the open discharge impactor has no screens or grates holding material inside the crusher; material is efficiently processed at high rates for low costs. The rotor breaker bars operate best at specific speed ranges for maximum results. As the total processing capacity and rotors get larger, the number of breaker bar rows increases. On smaller sizes, there are only two rows; on larger rotors, there are four or more rows of rotor breaker bars. The optimum configuration has material delivered to each row of rotor breaker bars in a continuous bed over the width of the rotor for optimum performance and consistent wear part utilization. Some rotor interiors are open, and some are closed depending on feed conditions. For example, concrete recycling requires a closed rotor so rebar doesn’t get entangled. Application The HSI is used for all types of material with compressive strength less than about 20,000 lb. per sq. in. It’s widely used for sand and rock for roads, railways, reservoirs, electrical grid isolation, building materials and many industrial applications such as metal reclamation and recycling.34 IMPACTOR3 400 Wear part metallurgy is critical to proper applications and performance. It’s a good idea to keep a log of these items to determine the best wear part selection and maintenance schedule: feed and discharge information, throughput rates, change out records and measurements of worn parts. Proper selection of wear part metallurgy will result in optimum production rates; longer maintenance cycles and fewer changeouts, which reduce costs in labor, increase the wear part’s life as well as reduce downtime. Materials with high moisture content can be successfully handled by using heaters and air cannons to reduce and dislodge material adhering to the crushing components and chamber. Size Control The spacing between rotor breaker bars and breaker plate aprons can be adjusted to produce different products within one crusher. It is possible to crush soft raw material limestone or high-grade harder limestone for cement or asphalt applications with one crusher by externally adjusting the breaker bar and plate settings. Gap adjustment between the rotor breaker bars and breaker plates by manual or computer controlled systems adjusts the crushing gap so that product particle size distribution remains constant. Maintenance HSIs have multi-turn breaker bars for extended life before changeout. Design simplicity offers safe and easy access for breaker bar replacement and access to all areas of the crushing chamber. Front-opening models eliminate the need for a crane in some cases. Rear-opening models can allow unique installation applications. Summary 34 IMPACTOR 400 HSIs have evolved from humble beginnings through improved crushing chamber design and metallurgy advancements to automation controls. HSIs have proven they are capable of size reduction of all types of material sizes and hardness with minimal maintenance and excellent cubical particle size distribution control. Stedman Machine Co., www.stedman-machine.com Eric Marcotte is inside sales manager for Stedman Machine Company

Small Unmanned Aerial Systems (sUAS or drones) along with exciting new image processing algorithms are enabling a fundamental change in how stockpile volumetric computations are performed. It is now possible to create accurate three dimensional models of stockpile areas using inexpensive cameras carried by a low cost sUAS (drone). From these 3D models, volumetric computations are easily derived. These new technologies result in significantly lower cost of collection, improved accuracy and non-disruptive data collection. Best of all, they keep data collectors out of harm’s way with collection performed from a low altitude drone.

Metso is the only true original equipment manufacturer (OEM) of crusher wear parts for Metso, Nordberg®, Lokotrack®, Superior®, Barmac®, Symons® and many other crusher brands. Genuine Metso crusher wear parts are the only ones on the market designed together with Metso crushers. Metso crusher wear parts are the best and surest way to protect your crusher against hazards such as overload, unplanned shutdowns and premature wearing out of main components. You spend less time worrying, and more time profiting. Minimized downtime, improved performance and consistent end-product quality reduces your cost per ton in the long run.

This underground nickel mine in the Midwest United States is relatively young with only a few years of production blasting. The operation is employing a sublevel stope mining technique. The operator purchases Dyno TITAN® RU emulsion and electronic detonators for blasting. The customer was experiencing poor blast results over a substantial period of time. When the customer first contacted DynoConsult® for assistance, the concern was the under-breaking of the ore which left valuable material along the ribs. At that time the mine engineers were looking for guidance on the delay times they should be using to improve the recovery of ore. During the site visit by DynoConsult, it was also discovered that there were a few instances of benches and bridges being left in the stope after mucking. In one stope it was estimated that over $1 million worth of ore was left unrecoverable in the stope. It was also revealed during the site visit that there were issues related to tight digging of the muckpile even though the fragmentation was adequate.

The primary benefit from the TITAN emulsion technology is being able to note on the post blast reports that no postblast NOx fumes were present. Additional benefits include increased water resistance, increased actual energy yield verses theoretical value, increased product sensitivity resulting in high order detonation, ability to control density, redistribution of energy, increased detonation pressure, same cost per loaded foot, greater fragmentation versus cast movement, and allowing emulsion to be loaded to a lower density in highwall row resulting in the same pounds stretched to a greater height. Success measurements in the overburden truck/shovel blasts included consistent productivity (bucket fill times and bucket volumes) even in harder material located below the sandy strata, reduced post blast NOx fumes based on fume classification chart, few shovel operator complaints, and equal or reduced drill and blast budget. Seventeen blasts were completed without NOx fumes. The pounds per loaded foot was reduced from 51.5 with 40/60 HANFO to 43.1-47.1 range loading TITAN XL 1000. The average difference lbs/ft = 12.36% when 7.6% was needed for cost neutral. Stemming height was reduced from 22 ft to 20 feet to improve surface material displacement. Success measurements in the coal blasts included no roll crusher plugs from slabs, improved shovel production through uniform fragmentation, and equal or reduced drill and blast budget. Ten blasts were completed over afive-week period with no post blast fumes. There was good material movement, uniform fragmentation and generally no complaints or negative comments from shovel operators. Average difference lbs/ft = 11.98% when 4.5% was needed for cost neutral. Pounds per loaded foot averaged 45.33 compared to 51.5 with HANFO.

The mining industry in the 21st Century will use equipment with much greater productive capacity and improved reliability. But, it will also be much more complex. Maintenance must provide the means of applying the newest technology and quality information along with modern management techniques. But, who will ensure that the personnel who do the actual work are used productively?

Consulting Solutions on Maintenance Planning A veteran consultant offers cites proven solutions that have dramatically improved maintenance planning capabilities among clients.

Using Differential Energy, Dyno Nobel was able to reduce the number of boulders at a quarry without adding more blast holes.

As a new mine starting up development, this gold mine in Northern Ontario used much of the blasted rock for infrastructure in building up roads and construction pads.

The use of SHA (Signature Hole Analysis) and electronic detonators allowed the mine to dial in optimum timing sequences regardless of the number of holes per delay, resulting in reduced vibration and better digging rates allowing for faster removal of overburden.

Simulation based operator training has been successfully applied to a range of diverse industries where high risk and high costs are everyday issues requiring smart solutions. Whether piloting a plane or launching a space shuttle, simulation training has been proven to dramatically reduce risk, cost, unscheduled maintenance, increase trainer effectiveness and efficiency while maximizing productivity. Within the often hazardous mining industry, simulation training has quickly gained recognition as a significant method of increasing site safety and profitability through improved operator skill and knowledge. Simulators provide operators a safe environment to learn and practice their skills while allowing the operator to practice for a range of possible emergency situations. Many of these situations are too dangerous, too difficult or too expensive to test in an actual mine. Operators can also be shown and assessed for the proper operating technique much more quickly and accurately than the traditional in machine approach. Focus on improving operator technique with Immersive Technologies’ simulators has delivered proven results including longer tire life, reduced spot time, reduced brake abuse, improvements in fuel use, reduction in engine overspeeds and more. Simulator training allows operators to be shown and assessed without the need to borrow machines from production. This allows new operators to practice many skills before being placed into a production circuit. Because operators are consistently shown and assessed on the proper operator techniques they have a better understanding and knowledge of the real machine. Following Immersive Technologies release of the world’s first mining dump truck simulator in 1998, their customer results, support network, machine range, global mining footprint, level of realism and OEM endorsements are without equal in the industry. Highlighting the benefits of simulation training, four leading Original Equipment Manufacturers, Caterpillar, Hitachi, Komatsu and Liebherr have chosen to exclusively sign technical information licensing agreements with Immersive Technologies, providing access to proprietary technical information necessary to accurately replicate the operation of their mining equipment. After significant supplier evaluation each major OEM has chosen to exclusively recommend Immersive Technologies' Advanced Equipment Simulators. This unprecedented support and commitment from the OEM's has helped to firmly entrench Immersive Technologies' Simulator technology as the industry leader. This provides customers the comfort of knowing they are investing wisely in a proven and accepted technology that is here to stay. As the world’s largest supplier of mining equipment simulators, Immersive Technologies’ has a customer base that includes many of the world’s leading mining operations, mining contractors, training schools and original equipment manufacturers. Widely recognized as the global industry standard, Immersive Technologies’ has extensive experience in delivering complete training solutions to the mining industry with measurable safety and business improvement outcomes. Immersive Technologies has worked closely with thousands of mining training professionals, managers, and executives to deliver comprehensive solutions that have been proven to improve safety and mine profitability.

Small Unmanned Aerial Systems (sUAS or drones) along with exciting new image processing algorithms are enabling a fundamental change in how stockpile volumetric computations are performed. It is now possible to create accurate three dimensional models of stockpile areas using inexpensive cameras carried by a low cost sUAS (drone). From these 3D models, volumetric computations are easily derived. These new technologies result in significantly lower cost of collection, improved accuracy and non-disruptive data collection. Best of all, they keep data collectors out of harm’s way with collection preformed from a low altitude drone.

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom interactive modules have improved start-up success and operations for hundreds of clients on nearly every continent. In this training module, we cover how activated carbon is used to concentrate gold and silver from pregnant leach solution. The concentrating process is based on the concept of adsorption, in which complex gold, silver, and (if present) mercury molecules are adsorbed—or adhered—onto small, millimeter sized particles of activated carbon. The adsorption process is carried out at atmospheric temperature and pressure. During the process, the metals migrate from a cyanide leach solution to the surfaces of carbon pores. In addition to the animation, this module includes an animated process flowsheet, process variable target ranges and control methods, as well as alarm response procedures. This module covers one area of a gold ore processing plant. In a typical plant of this type, there would be another 4 to 8 modules that would cover the other plant areas with each module containing the same type of training materials, but specific to that plant area. In the training environment, some concepts are difficult to explain using still 2-D or even 3-D images. When this is the case, we develop animations and/or simulations in order to ensure better transfer of knowledge to our trainees.

Joy Global rolls out JoySmart Solutions, integrated offerings delivering improved mine performance

Eliminating Large Particle Carryover – Improving Milk of Lime Reactivity STT's Patent Pending VERTIMILL® Retrofit has exceeded performance expectations. After 8 months of operations: Elimination of large particle carry-over.; 16% reduction in lime consumption per ton of SO2 removed; Higher scrubbing efficiency was achieved (less SO2 discharged to the environment); Maintenance intervals and tank cleanout frequencies have been improved due to reduced largeparticle carry-over. This is a ‘Patent Pending’ improvement is suitable for all sizes of Lime Slaking VERTIMILL® in lime slaking duty.

When mining maintenance requires improvement an evaluation is the essential first step of the improvement effort and a guarantee of its success. The evaluation avoids guessing at what needs to be improved, how and the priorities of corrective actions. The result is a realistic plan of action instead of confusion, frustration, disappointment and no improvement. Here’s how to get started.

Senior MineSight Specialist Ernesto Vivas and Luis Zozaya, Chief Engineer, Cobre del Mayo, discuss how the alignment of mine planning with operation has dramatically improved performance at the Piedras Verdes mine.

One of the biggest inefficiencies in the continuous mining process is waiting for a batch haulage unit to arrive and get into position. Any reduction in this wait time is time spent cutting and loading material. Understanding these delays is key to a successful mining operation, and is seldom obvious. A customer in the Midwestern United States recognized this inefficiency in its own operation, but could not achieve long-term results because whenever they focused and improved on one aspect of the process, the inefficiency seemed to take another form. The end result was no overall improvement.

Adjustable frequency drive offering from Eaton improved reliability and enhanced safety with a small physical footprint. Estimated monthly energy savings up to $45,000, as well as an integrated design contributing to reductions in material costs and timely delivery minimizing plant downtime.

This paper is a case study outlining the experience of a multisite cement producer and their experience in implementing an enterprise-wide electrical workplace safety program, including compliance with the National Fire Protection Association 70E-2012 standard.

Originally presented at Haulage & Loading 2015, this is an overview of how targeted training at an ASARCO mining operation improved efficiency and safety.

Productivity has become the new mantra in recent years for the mining industry. Ever since the “super cycle” of the commodities price boom came to an end, industry executives have realized that a blind chase for value can lead to significant structural costs and productivity defects in the mining process, which ultimately decrease profit. Many chief executive officers (CEOs) have responded to this market volatility by making significant cuts in capital investments. Possessing more operational (“back to basics”) profiles than their predecessors, industry leads now realize that in addition to improving short-term cash flows, they need to: ●● Make sustainable gains in productivity. Programs aimed at improving productivity need to have an enterprise-wide impact, beyond pilot programs that address people or equipment. These productivity initiatives also need to be accepted across all operations and made sustainable going forward by emphasizing truly continuous improvements. ●● Respond with more agility to fluctuating market demands. Business agility requires a supply chain design that enables faster responses to shifts in market demands and prices. With improved business agility, it’s possible to optimize net results per quarter—right down to margin-per-hour operations. Transforming the supply chain design in this way requires a forward-looking understanding of market demand, scenariobased planning, optimal resource allocation and flexible scheduling decisions—all of which necessitate changes across people, technology and processes.

A mining customer’s maintenance strategies were producing good availability results, but to achieve consistency, the customer wanted better visibility on potential upcoming causes of downtime. In this tough environment, major component failure events need to be controlled to minimize impact against budget, and an enhanced solution was required to improve margins. Joy Global approached an existing customer about engaging in a trial period where the two would partner through the company’s JoySmart Solutions offering to improve machine reliability and avoid catastrophic failures on major components. The customer agreed to give Joy Global six months to prove the value of the offering at its coal mine in Australia. The JoySmart team proposed implementation of a newly-developed automated monitoring system that trawls through machine data with the ability to detect any changes in component behavior to predict an onset of failure.