Equipment and Suppliers News (June 01, 2003)

Trunnion magnet eliminates grinding ball fragments

by Darrell Milton

Grinding ball fragments discharging from the ball mill of a world-class Canadian copper mining company were causing extreme wear to downstream processing equipment. These ball fragments, circulating in the milling circuit, caused excessive wear to sumps, pumps, hydrocyclones and interconnecting piping. An attempt to remove tramp metal from the discharge stream was only moderately effective, and the screens were expensive.

In 2001, Eriez Magnetics’ first Canadian trunnion magnet was installed in the grinding circuit. The objective was to remove these tramp metal and ball fragments from the discharge flow. The magnet mounts to the mill’s discharge trunnion, and consists of an arc of permanent magnets partially surrounding a blind trunnion. As the mill rotates, the powerful magnet attracts and holds the worn steel balls and chips to the inner surface of the trunnion extension. The ball fragments are carried to the top, where the magnetic arc terminates, and fragments fall into a discharge chute. During the first several hours of operation, the magnet removed nearly 20 tons of tramp steel. The removal rate eventually stabilized at a few tons per day.

Reduced wear and increased production

The company indicated that its decision to install a trunnion magnet would likely pay for itself in the first year of operation. By removing the steel chips that circulate in the ball mill/cyclone circuit, the wear on the feed pump, distributor and hydrocyclone parts should be greatly reduced, which, obviously, would lower maintenance costs and increase copper production. Another advantage was the lower power required, reducing operating costs with no reduction in grinding efficiency.

An improvement in cyclone efficiency will also result as the apex wear life is extended. Better cyclone performance provides a finer flotation feed and improved copper recovery. Testing of ceramic cyclone parts, which are longer wearing, can now be done due to the reduction of steel chips which otherwise fracture ceramic linings. There also should be a reduction in flotation impeller wear as well as anticipated manpower savings for the costs of cleaning steel chips out of the cells.

Tim Shuttleworth, vice-president International Operations for Eriez Magnetics, said, “Eriez appreciates the Canadian company’s willingness to employ new magnetic technology in the milling circuit. Without the benefit of high-grade ore, the innovative staff is always considering new technology to improve the operation. The acceptance of this first trunnion magnet in Canada and the company’s purchase of the second unit in 2002, makes a strong statement to the industry.”

The copper mill’s experience clearly indicates that the Eriez Trunnion Magnet, by eliminating the grinding ball fragments, reduced maintenance and energy expense while significantly expanding capacity.

Darrell Milton is sales manager of Eriez of Canada Ltd., and can be contacted at dmilton@eriez.ca, phone (905) 795-0444.

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Newest version of GEMS available

Gemcom Software of Vancouver has launched the latest version of its successful mine production software, GEMS 5.1. The new software incorporates strategic planning and tactical operations with even greater scalability than older versions. GEMS 5.1 provides access to accurate, real-time information, allowing for streamlined collaboration between cross-functional workgroups.

The newest GEMS version includes many client-requested enhancements as well as new features designed by the corporation. It operates on a Microsoft SQL server so that clients benefit from a secure data repository. Check out the Gemcom site at www.gemcomsoftware.com for a detailed explanation of all the useful features in GEMS 5.1. Of particular interest might be the new add-on Underground Blast Design tool and the upgraded Go Scheduler tool.

Rocanville mine chooses communications system

The Rocanville potash mine operated by PCS Mining has awarded a contract for the largest leaky feeder communication system in recent years. The initial system will cover 62 km along main haulageways. The Ranger leaky feeder system from Varis Mine Technology was chosen to enhance mine safety and productivity.

The system includes amplifiers spaced at 500 m and 36 V DC power supplies, which reduces the number of components and hence their cost. It comes with a two-year unconditional guarantee. Installation began at the mine in April and should be complete in June. Learn more about Ranger communications and where these systems are operational at www.varismine.com.

Dyno Nobel and Ensign-Bickford team up

Dyno Nobel Holding and the Ensign-Bickford Co. have combined their commercial explosives business under the Dyno Nobel banner. The move combines the blast initiation expertise of both companies with Dyno Nobel’s full range of explosive products and blasting services. The new company will have estimated revenues of US$900 million and operate in 35 countries around the world. Corporate headquarters will be in Oslo under the leadership of Dag Mejdell, president and CEO.

Bucyrus earns ISO9001:2000

One of the world’s most recognized makers of mining shovels, drills and draglines, Bucyrus International, announced that its South Milwaukee manufacturing and administration facility has been awarded certification to the new ISO9001:2000 standard. The certification became effective March 14, 2003. Bucyrus has been certified to ISO9001 standards for many years, and qualification to the new “2000” standard represents a significant achievement.

Some of the improved system requirements now integrated into Bucyrus’ new business processes include: achievement of continuous improvement in all facets of business performance; customer feedback is solicited and acted on; performance objectives are established and their status reported; and expanded engineering verification/validation activities are conducted to continuously improve product reliability and customer satisfaction.

New Komatsu units head for Ekati mine

Komatsu America Corp. has announced that BHP Billiton has awarded it a five-year, global supply agreement covering, among others, equipment destined for the Ekati diamond mine in the Northwest Territories. It also calls for the supply of 16 Komatsu 930E trucks, E475 dozers, WA900 and WA 1200 wheel loaders to Australia, and other mining machines to Escondida in Chile and the Douglas colliery in South Africa.

Komatsu is pleased to be among BHP Billiton’s preferred suppliers. The new contract will allow Komatsu to scale back announced lay-offs at its manufacturing plant in Peoria, Ill.

Globalstar acquired by ICO Global

The United States Bankruptcy Court in Delaware has given its approval for ICO Global Communications to acquire a majority interest in a reorganized Globalstar. ICO will become 54%-owner of Globalstar in exchange for investing US$55 million.

Globalstar is the world’s most widely used hand-held satellite phone service, operating in over 100 countries (www.globalstar.ca). The Globalstar name will continue to be seen around the globe as products and services are expanded.

ICO is developing voice, wireless Internet and other packet-data services that will make personal mobile communications possible around the world. See www.ico.com to learn more.

Secoroc introduces Premium Plus drill bits

The popular Secoroc Premium down-the-hole bits, introduced in 1999, are a hard act to follow. That doesn’t mean that the manufacturer is standing still. Atlas Copco Secoroc now offers the Premium Plus DTH bit, which boasts a 10-30% longer life. Added to this reliability is a 5% increase in penetration rates.

The new Premium Plus design has refinements such as a tougher steel grade to resist fatigue. The buttons are repositioned to improve the penetration rate, and they are designed to protrude more, which aids in cuttings removal, less secondary crushing, and easier bit grinding
. Finally, to reduce the risk of jamming in the hole, the taper on the bit head is shorter with a larger clearing. Shanking and chunking are practically eliminated, says Atlas Copco.

Premium Plus bits are now available for 5-inch hammers. Bits for 4-inch and 6-inch hammers will be available soon. They come in several configurations such as flat front HD, SpeedBit, convex front with ballistic buttons, concave front, and concave DGR.

Two new Goodyear products come to Canada

Goodyear Canada’s Engineered Products Division has introduced a series of hose products and a tension gauge for v-belts specifically for the Canadian mining and other heavy industries.

The first, Ultrabraid hose, is constructed in five styles for heavy duty use. The styles are Ultrabraid Air, Ultrabraid HD Plus, Ultrabraid Steel Air, Ultrabraid Supreme, and Ultrabraid Bull Hose. All resist oil and abrasion, giving them superior usable lifespan. They have a wrapped impression cover for easy grip and handling. Several different bright colours are available to improve visibility and identification in the workplace.

Wherever v-belt life and efficiency need improvement try Goodyear’s new TensionRite II gauge. It determines precise belt tension measurements and takes the guesswork out of v-belt installations and applications. It is as easy to use as the so-called “thumb test” or “what feels right”. TensionRite is available to use with v-belts or single belt applications.

Human resources firm specializes in mining industry

Recognizing a need in the resource sector, veteran human resource experts, Russ Buckland and Maurice Harapiak, have joined forces to launch Buckland Harapiak, a unique human resource consulting firm. Buckland Harapiak is a team of highly qualified human resource experts with over 50 years of combined experience in the resource sector.

Says Buckland, “We understand the unique problems faced by companies operating in this area and believe our expertise enables us to create superior solutions to HR challenges, more quickly, more economically, and with better long-term results.”

Buckland Harapiak provides advice in the following areas: project start-up consultation; expatriate management; performance management; employee relations; leadership analysis; project and organization design; managing coaching and development; policy development; succession planning; and communication strategies.

The new firm is located in Oakville, Ont. Phone: 905-337-1954. E-mail russ@bucklandharapiak.com or maurice@bucklandharapiak.com.