The mining industry is a competitive business with operators competing to uncover every advantage. Perhaps the biggest step forward could come from an unlikely source. Read about 10 things you may not have known about LED lighting in mining operations.

Blog post on pipe handling safety in the underground hard rock mining environment.

Prohibitive ventilation costs as mines go deeper and concerns about worker health and safety are ushering in a new era in propulsion options for underground mining.

An ideas instead of mining boom has a nice ring to it as a slogan, but what if mining booms and ideas booms are one in the same? http://www.macleanengineering.com/blog/getting-innovation-right

The successful introduction of battery power to hard rock mining isn’t going to be about the correct choice of battery chemistry alone, it will be about engineering a battery propulsion system that is fit-for-purpose with the mining application and duty cycle, and one with maximum flexibility to allow for the rapid pace of battery technology advances that will inevitably open up options for diesel-free mine planning and retrofitting. http://www.macleanengineering.com/media-en/blog

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the information such systems generate. A systematic management approach to solving problems and implementing solutions is the key to effective maintenance cost control

What would it mean to your process if the variation in your key process variables could be cut in half? For example, consider greatly reduced variation in: • Leach circuit pH. • Thickener flocculant concentration. • CIL circuit cyanide concentration. • Cyclone feed density. Do your operators know if variation is random or non-random? If your operators were more familiar with the process control methodology, would it make a difference? What would be the result if your operators could troubleshoot and optimize each process control loop? At Performance Associates International (PAI) we believe that if the process variables in the plant are controlled at or very near their individual target ranges, the plant should be operating at near optimal efficiency. This translates into the lowest operating cost per unit production. This white paper describes how PAI approaches this component of training for your specific plant. We train on your process variables, their target ranges, the method of controlling those process variables, as well as the impact on the process if the process variables are not properly controlled.

Con demasiada frecuencia, las compañías de recursos naturales ponen en marcha plantas nuevas sin contar con un equipo de operaciones y mantenimiento debidamente capacitado. El resultado puede ser desastroso tanto en términos de seguridad como de ingresos. Obviamente el objetivo fundamental es una planta que funciona de forma segura y rentable. En la mayoría de los casos, la capacitación sobre seguridad que se da antes del arranque de la planta es satisfactoria, resultando en pocos accidentes (o ninguno) durante la puesta en marcha y operaciones subsecuentes. Sin embargo, muchas plantas son negligentes cuando se trata de la buena capacitación de su personal de operaciones y mantenimiento. Un programa de capacitación bien ejecutado compensa con creces los costos de ejecución del mismo. Si se va a presupuestar una ingeniería de alta calidad, un proceso de adquisición eficiente y una gestión de construcción experimentada y comprobada (incluyendo el comisionamiento), ¿por qué dejar a la suerte la capacitación? Performance Associates International (PAI) desarrolló un programa de capacitación por computadora comprensivo, el cual abarca operaciones y mantenimiento, para su planta de oro El Limón-Guajes en el estado de Guerrero, México. En el 2015, los especialistas de capacitación industrial de PAI viajaron al lugar del proyecto para entrenar a los empleados de Torex Gold en anticipación de la puesta de marcha de la planta y la producción de oro. El emprendimiento fue un “éxito masivo,” según Nelson Bodnarchuk, Director, Sistemas Operacionales. Este video cuenta la historia de ese éxito, incluyendo comentarios generosos de los oficiales ejecutivos de Torex, quienes reconocen nuestro papel en la colaboración.

MacLean Hard Rock Equipment R&D Report: The last 12 months at MacLean have seen the culmination of a two-year phase of intense product development activity, including fleet electrification; face bolting on the MacLean 975 Omnia Bolter; and, a new, ultra-versatile utility vehicle for high reach/heavy load applications - the MacLean LR3.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

This paper will explain some of the physiological aspects which give us our hearing capabilities. It will also describe how damage to the ear should be considered as part of an electrical safety program, as well as potential methods for reducing the hazard.

Customer success story on Deilmann Haniel explaining how Eaton increased safety and operational performance in a difficult climate.

FLEET ELECTRIFICATION THAT CONNECTS THE MINING CYCLE TO THE BATTERY CYCLE: The MacLean approach to battery propulsion is built on giving our customers access to best-in-class battery, electric motor, onboard charging, and vehicle analytics technology, and then successfully integrating these components into mobile underground equipment by leveraging our multi-discipline engineering expertise, hard rock mining knowledge, and custom manufacturing experience. In other words, you can’t just understand the battery cycle, you need to understand the mining cycle in which it will be used. This is how MacLean has developed battery power, engineered for life underground.

The drivers pushing mining companies to seriously look at the EV transition encompass a broad range of benefits – reduced ventilation requirements (30-50% less) and associated energy costs, elimination of diesel fuel costs (tens of thousands of dollars per EV unit, per year), reduced maintenance costs (some 25% fewer parts on EV propulsion vs. diesel propulsion rigs), elimination of diesel fine particular matter in the underground environment, and last but definitely not least - less noise, vibration and heat for miners operating the equipment underground. So how do you quantify the operational savings?

This paper outlines the experience of one global cement producer that embarked on site surveys and studies to achieve arc flash safety compliance at 13 cement plants in the U.S. and Canada.

The purpose of this paper is to review a case study of a successful energy project at the ArcelorMittal Burns Harbor facility involving the addition of five new adjustable frequency drives (AFDs) used to regulate flow of the high-volume water spray system for the runout table (ROT). The paper will outline 1) processes used in justifying new technology updates, 2) mill alignment with the serving electric utility to leverage energy credits, 3) equipment selection and installation and 4) metrics used to demonstrate the project delivered the desired payback.

The robots are coming: Taking the miner out of mining is the common theme these days as the pace of advance of artificial intelligence quickens, as big data goes from a buzz phrase to business-as-usual, and as the move through semi to full automation continues. Autonomous operation is on all the major mining companies’ innovation roadmaps. At some point down the road, that is where the bulk of the industry will end up. But we have lots of ground to cover and many years of advances to get through, before we get there in a broad sense. How to manage the transition years is the big question, for mining companies and manufacturers alike.

The Aerodyne Vacu-Valve is an economical alternative to rotary valves. Its unique design allows it to provide an airlock with no moving parts on dust collectors that are operating with a slight vacuum. Material that is fine, free flowing and will not bridge drains from the Vacu-Valve sleeve, while maintaining an airlock.

Sometimes a turning point can only be seen clearly in hindsight. Such is the case for the mine of the future as we begin 2018, coming out of a 2017 where major mining companies continued to demonstrate capital spending austerity and focus on debt reduction. All the while, there were growing signals that digitalization, electrification and automation were all gaining momentum, even though actual examples of minesite implementations could as of yet, still be counted on one hand. MacLean took the opportunity that industry downturn presented over the past several years to focus intensely on three key product development ventures – first and foremost, the battery electrification of our entire fleet, which will be complete by the end of 2018; second, the successful introduction of face bolting as a feature on our 975 Omnia bolter; and, third, the launch of the latest addition to our utility vehicle product line – the LR3 Boom Lift for heavy load and high reach applications. The past year was one where for the first time we had a fleet of battery electric vehicles working underground, allowing us the ability to validate our performance and total cost of ownership (TCO) models with real-world data, while at the same time continuing to build out our EV offer across the product lines. Looking forward, as we work hard to fully electrify our fleet of ground support, ore flow/secondary reduction, and utility vehicles, we’re keenly aware that electrification is but one step in the ongoing mechanization of underground mining, a transition to the mine of the future that will be increasingly efficient through digitalization and automation that will increase production and reduce costs.

The GPC Dust Collector is an efficient way to handle your dust collecting needs. The GPC dust collector’s small size makes it easy to solve dust collecting problems for plants and workshops with limited floor space or overhead clearance, making it an ideal solution for your dust collecting problems.

Evaluate your current dust collection system for operational efficiency. Explore these five crucial areas and assess the effectiveness of your: Pickup points, Duct work, Dust Collector, Cyclone, and Exhaust fan. Pinpoint how these major areas may affect your dust collection.

Do the rotary valves under your dust collectors cause maintenance headaches? Are they clogging? Are you having to drop everything and assign extra labor to fix them? Aerodyne™’s Vacu-Valve ® is the solution! Have a look at this infographic and to learn how the Vacu-valve solves these issues and improves the discharge efficiency of your baghouse, filters and cyclones.

The All-Electric Mine of the Future, and the Need for Good Roadbeds NOW Click the link below to learn more: http://www.macleanengineering.com/blog

The costs of replacement bags, machine downtime and wages accumulate quickly. Our infographic shows how placing a cyclone dust collector in front of a baghouse can lower expenses by extending filter life and reducing maintenance. See the components of an efficient, low-maintenance system. Download this infographic now to get more information about: 1) Components of a low-maintenance system. 2) 5 reasons to use a cyclone before a baghouse. 3) Animation of a counter-cyclonic dust collector.

How Much is Your Baghouse or Cartridge Collector Costing You? This whitepaper highlights: 1) The Top 5 Reasons to use a cyclone as a pre-filter for baghouses or cartridge collectors. 2) How pre-filters help to extend bag or filter life, and improving removal efficiencies.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application.

This video from the Dust Efficiency Clinic discusses five warning signs that your dust collection system needs a pre-filter. Pre-filtering may reduce operating and maintenance costs by extending bag or filter life and improving removal efficiencies.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application. Simply fill out the form and you will have immediate access to the guide.

Is your dust collection system working at peak efficiency? A quick, do-it-yourself examination may identify symptoms that your system needs a check-up. Enjoy this video from The Dust Efficiency Clinic at Aerodyne. You'll be able to identify five signs that may diagnose a sluggish system so that you can return your system to full efficiency.

Planners are most effective when they plan the right work. Here are some recommendations for determining which work should be planned in your organization.

Underground mining is at an interesting place right now, with the availability of diesel-free, battery electric equipment in most of the vehicle categories except heavy haulage, with that gap being actively addressed by a number of OEMs and the solution, not something to be relegated to the distant future as a theoretical. It’s coming, along with fast charge capabilities underground.

StrataConnect WirelessMonitor. Control. Track. Alert.Completely wireless and battery-powered components to build and expand your network, for permanent or temporary needs.

Three dimensional animations integrated into a process plant computer-based training (CBT) program can greatly enhance trainee understanding of process equipment. This introductory maintenance manual and animation provides a narrative description of a jaw crusher’s location in the process, its function, components, and maintenance requirements. The animation introduces maintenance personnel to the jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up. www.perfnet.com 

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.  Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:Process objective of each process system, comprising a group of unit operations.Process objective of each unit operation.Process chemistry and the variables affecting it.Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.Plant control loops, interlocks, and alarms.Safety issues related to the process and control schemes.Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 

The geology report, feasibility study, and mine plan look great. Why do so many mining project start-ups fail to perform? Most mining companies put a great deal of emphasis on the nature of the reserve, the mine plan, the extraction process to be used, and the process plant design—obviously all very important. Even when large, highly regarded engineering, procurement, and construction firms develop the project, operating results are very often disappointing. In this paper, we explore the role of Operations Readiness on the financial impact of mining project start-ups. A relatively small investment in operations readiness produces a huge financial return. Many investment firms, as well as mining company senior executives, fail to consider this important factor in operating success.

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 this interactive PDF, we talk about common training myths and our responses.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.