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EDUCATION Methods for Exploratory Drilling of Deposits of Mineral Commodities Tudeshki, H. ; Hertel, H. Surface Mining and International Mining | Clausthal University of Technology | Germany TRANSFER OF TECHNOLOGY Kellner, M. Impact of financial crisis on the German & global commodity market and the mining Geotechnique, Mining, Petroleum Engineering | Surface Mining and International Mining | Clausthal University of industry Technology | Germany Round Table at Hannover Messe 2009: Climate-Friendly and Energy-Efficient Raw Material ContiTech Conveyor Technology Extraction corporation Northeim | Germany ThyssenKrupp Fördertechnik (conveyor technique): Fully Mobile Crawler-Mounted ThyssenKrupp Fördertechnik GmbH Crushing Plant for Large Open-Pit Mines Essen | Germany Volvo Fleet Under Ground - All Good Things Come From Above Volvo Construction Equipment Germany Methods of Boulder Crushing in raw materials production Tudeshki, H. ; Xu, T. Surface Mining and International Mining | Clausthal University of Technology | Germany Development of the Oil-shale-project El Lajjun in Jordan von der Linden, E. Linden Advisory | Dreieich | Germany The most intelligent chapter in mining history was written by German Engineering Debriv; Tudeshki, H. NEWS & REPORTS

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Issue 03 | 2009 www.advanced-mining.comADVERTISEMENT 3 EDUCATION Methods for Exploratory Drilling of Deposits of Mineral Commodities by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki ; Dipl.-Ing. Heiko Hertel Surface Mining and International Mining | TU Clausthal | Germany Overall

The drilling technique had established itself as a key technology for the search and exploration of mineral resource deposits. However, along with the advancement of mining of raw material deposits which outcrop immediately at the surface or are only slightly covered, we now face the task of finding and opening up deposits that are located deeper under the surface. Introduction

The forming of accessible exploration-excavations at material and its analysis in the laboratory. The rock mass economically and technically meaningful expenses is properties can be derived from the rock properties of the limited to a depth of 30 to 50 m. The unknown geological sample material or can be determined direct from the bore characteristics and rock properties entail a multitude hole with special auxiliary tools in special procedures. In of technical, economical and safety-relevant risks for the interpretation of the samples derived from drillings, underground mining operations. This includes the high the degree of disturbance of the samples both by the expenses for keeping the underground cavities and making mechanically and partly hydraulically supported loosening them again usable, in case nothing is found. For exploration process of the material out of the rock and the consecutive of extensive deposits that are present immediately at the transport from the bore hole bottom to the sampling point surface and deposits with highly irregularly distributed above ground, has to be considered. The quality of the resource contents in compact, and in none and low samples is significantly determined by the characteristics water-bearing formations, mining exploration methods of the formation to be investigated, as well as by the applied (prospecting trenches or shafts) are preferred. Furthermore, drilling method. Here the general rule is that the specific technically simple exploration excavations can be costs for one meter drilled increase with increasing constructed in very remote and hard to reach exploration quality of the samples. In principle the success of a drilling areas. A tendency to explore deposits in increasing depths campaign is to be measured with the following factors: can be expected for future prospection and exploration quality and quantity of the samples to be extracted, as well activities, so that the exploration by excavations will as the economical costs of drilling. The gross costs for further loose importance. The increasingly lower target drilling are composed of specific cost for one meter drilled horizons of exploration activities go hand in hand with the and the drilling length in total. The drilling length is again progress of raw material extraction in deposits near the dependant on the number of drillings and their final depth. surface, as well as with the increasing performance and efficiency of modern mining technologies. If nowadays the This planning approach, which often initiates the usual exploration horizons are located 200 to 300 m under drilling planning, only refers to the process of drilling and the surface, in future years the average target depths will the sampling. The degree of requirements for this drilling reach over 1000 m. Even today these depths are sometimes planning in the true sense is increased with: significantly exceeded by single raw material projects (e.g. Gold mining in South Africa). • The required information from the sample material • The increasing drilling length Through drilling direct access to the deposit can be • An irregular quality distribution in the deposit achieved, with a range from a few meters under the ground level up to several thousand meters, and qualitative and • Stratigraphic and tectonic interfering factors in the deposit appropriate information on the overburden and the deposit and the overburden can be obtained. With a multitude of drilling methods a large variety of rock mass properties can be controllable. In contrast to exploration shafts and trenches, drillings are not accessible by man, so that geological address and determination of rock mechanical, as well as hydrological parameters is done by means of the extracted sample

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During planning of the overall project, a multitude • Degree of preservation of the natural rock formation of external factors, e.g. climatic conditions, location • Specific volume (subject to the bore diameter) of the sample of the drilling site, infrastructure, etc, have to be taken • Completeness of the sample material into consideration. These factors can possibly limit the application of optimum technical means and considerably • Separation of cuttings/material from overlying formations increase the costs for their application, respectively. and avoiding mixing of sample material • Orientation the sample according to their location (in hard Drilling is used for various tasks in research, civil rock) engineering, as well as in mining projects, both for near- • Sampling according to depth, or clear assignment of location surface, as well as deep underground exploration. Apart of sampling from the search for and exploration of solid mineral deposits, some important examples for exploration drilling One of the most important quality criterions of drilling are: samples is the degree of conservation of the natural rock formation, as well as the pore volume and the filling of • Exploring the deep underground the interfaces. The degree of disturbances in sampling • Search and exploration of groundwater levels material is mainly subject to: • Exploration of fluid and gaseous hydrocarbons • The drilling method • Ground exploration for foundations • The drilled rock (loose or hard rock) Differences for the needed information on the rock and • The professional execution of drillings rock mass characteristics, as well as on the economical, • The diligence in sampling technical and operational conditions have to be derived • The transport and (intermediate) storage of sample material from the individual and specific project definitions.

Due to the fact that, based on the application area of the With special procedures it is possible to obtain (almost) drillings, different rock parameters have to be explored, an undisturbed samples with mechanical and partly with increasing specialization of methods, tools and equipment hydraulic processing during the loosening and extraction components has taken place. Three standard drilling process. However, impairment of the sampling material to methods were established for exploration drilling for mineral different degrees cannot be avoided in all standard drilling deposits. In the following report some special drilling methods, including in the common methods of exploration methods for special applications are introduced. Before of mineral deposits. This is due to economically driven the description of the method, significant requirements aspects of the drilling progress. As for the procedurally and background for the selection of the drilling method are conditioned disturbance of the natural rock formation, this explained. can be stated as a planned and previously known reduction of the sampling quality. Depending on the applied drilling Background and Requirements of the methods, the achievable quality of the samples is explained in different norms and regulations. Within the context of Exploratory Drilling Technique procedural mechanical and hydraulic application of drilling forces, rock characteristics also have to be observed. In principle, for drilling and collection of undisturbed samples The primary goal of exploratory drilling is to obtain of rocks without or with low granulation (non-cohesive reliable sampling material in an adequate amount, so that a loose rocks), higher demands have to be met, compared precise and resilient modeling of the deposit can be made. to compact hard rocks. The following general statement The quality of a sample can be determined by the following can be derived from the connection between granular characteristics: binding, extraction force and interference of the sampling material:

• Low granulation a low extraction forces, high interference • High granulation force a high extraction force, low interfe- rence of the sample

The quality category that is supported by the drilling method needs to correspond to the exploration goal. However, based on the goal of the exploration, it is possible

Issue 03 | 2009 www.advanced-mining.com 5 EDUCATION that even samples with a high degree of disturbance deviations from the actual rock mass composition and are adequate. In bigger exploration projects meaningful condition. combinations of various drilling methods lead to a cost- efficient and at the same time reliable results. In addition to the technical quality criteria, and criteria The requirements for stabilizing the bore hole wall in aspects that are planable prior to the drilling campaign, the exploratory drilling technique go beyond the role of certain influencing factors such as qualification of the keeping the operating safety. The extracted material from drilling personnel also need to be heist red. The resulting the bore hole bottom has to be kept free of rocks from the disturbances can appear throughout the entire sampling or already penetrated formations. In drillholes without casing, randomly in individual areas. The reliability of the obtained it is possible that material loosen from the open bore hole information can be ensured by professional and diligent wall – the so-called caving material – and mix with the execution of the drillings, the sampling, as well as their sampling material. In obviously stable hard rock formations storage and documentation. The risk of disturbances by it is possible to generally drill without a casing installation. the sampling and storing of samples is reduced through However, in the case of instable rock formations are special sampling containers (e.g. Liner). encountered (e.g. areas that are loosened by tectonic influences or cleft areas that are filled with loose material), it is possible that the stability of the bore hole wall is highly The area of direct information out of a drill hole altered. Smaller instable zones are usually not detected, so (information window) is limited by its final depth and its that the drilling is done according to plan. During further bore diameter. The bore diameter in particular, significantly drilling it is possible that rocks may fall out of these zones influences the information content and the reliability of the and sink to the bore hole bottom or get into the mud flow. In samples. In principle a drill hole only opens a very small completely obtained samples with high quality the caving window in the rock mass. Therefore it is possible that erratic material can easily be recognized and be separated from changes in the rock mass, e.g. tectonic disturbances or a the actual sampling material. However, in highly disturbed strongly irregular mineral distribution can be missed by and incomplete samples it is almost impossible to do this the obtained borehole area. A multitude of erratic changes separation, so that altered material is addressed. With the can be determined with geophysical methods, which often mechanical stabilization of the bore hole wall the bore are used complementary to exploratory drilling under hole is shut off from the intersected formations, which difficult rock conditions. However, these do not allow ensures an optimal protection from caving. However, the for a precise determination of the resource content. The advantages of a bore hole wall secured by a casing are expected distribution of mineralization can be derived with faced by considerable economic and technical expenses a high probability from the genesis and the evolved type through: of deposit and needs to be taken into consideration in the dimensioning of the borehole diameter and the needed • Costs of the casing installation specific sample volume. • The needed hook load of the drilling rig for casing handling • The additional work and expenses The highest informative value of a sample is achieved by an end-to-end and complete sampling over the • The bigger bore diameter for casing sections entire borehole length. In certain exploration goals • The logistic expenses of establishing the drilling site the composition of the rock mass is mostly known or of secondary importance for the planned extraction of the Alternatively to casing installation it is possible to raw material. In such cases complete sampling is not stabilize weak areas which tend to caving or which necessary and sectional samples are derived in regular impede the stability of the bore hole wall, either through distances along the drilling path. These distances range cementation or through wash over. A possible falsification usually between 60 cm and 130 cm. With this method, the through caving needs to be investigated during sampling secured amount of available data is reduced to the spot and the first geological evaluation on-site. (random) samples obtained along the bore hole axis. A distinction has to be made between the incompleteness of Interfaces can be addressed in (almost) undisturbed the sampling material, which is due to the type of sampling, samples. While interpreting these samples the direction of and the incompleteness which is due to procedural losses strike and dip is of interest. For this reason it makes sense and losses related to the drilling technique. It is possible that to obtain oriented samples. In an additional working step, due to the technical effects on the rock by drilling forces, a mark is placed on the bore hole bottom for orientation individual elements are destroyed or lastingly changed, so of the position (Northern direction) before coring the next that they are not suitable or cannot be identified any more. section. This allows alignment of the samples according to In case these impairments are not recognized during the their original position, which is the base for modeling strike interpretation of the samples, they can cause considerable and dip of the interface structures.

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The quality and thus the secured information content of the drilling samples are mainly determined by the above- mentioned quality criteria. However, it is only possible to reliably process the information with a clear assignment of the sampling position. Furthermore it should be noted that sampling according to position and depth is often taken for granted and inadequately observed. An unrecognized deviation of the drill hole from its given axis always leads to a difference between the recorded sampling position and the real one. The influence of these deviations increases with the inhomogenity of the rock mass. Therefore it can be said that the controlled course of the borehole and as such the exact determination of the sampling position is less a quality characteristic than an indispensable prerequisite for secure and reliable exploration results. The measurement of the drilling direction can be done either after reaching the final depth or already in the drilling process. The measurement of the borehole measurement can be done either as a separate work step in given stages or immediately in the drilling process. Both possibilities allow control of the bore hole path and thus ensure to reach the given target.

In the classification of drilling samples, different technical regulations deal with the relation between the degree of conservation of the natural rock formation and the completeness of samples. The sampling according to depth and location, the extraction in adequate volumes, as well as the prevention of caving are more of basic minimum requirements than quality criteria. In accordance with the German DIN 4021, the following classifications can be mentioned for exploratory drillings of mineral raw material:

• Complete extraction of undisturbed samples • Complete extraction of disturbed samples • Incomplete extraction of disturbed samples

Pic. 1: Completely extracted and (almost) undisturbed samples

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1. Core Drilling 2. RC-Drilling (Reverse Circulation Drilling) or CSR-Drilling (Center Sample Recovery Drilling) 3. Rotary- or Hammer-Drilling

Taking into consideration standards of the global exploration activities, these three drilling techniques can be called standard techniques for exploration of mineral raw material deposits. Because of their high quality samples, core drilling basically has the greatest importance for mineral exploration. Due to their varying sample quality, both other methods come across internationally varying acceptance. In addition, the possible application of the methods should be assessed differently due to topographic and climatic differences of the project area. Pic. 2: Incompletely extracted and disturbed samples The standard drilling methods are complemented by less common drilling techniques, which are even popular In picture 1, completely extracted and almost undisturbed for other drilling applications. Therefore they are called samples (core samples) are shown. The samples shown special technologies for exploration. in picture 2 are incomplete and highly disturbed. These samples can only be used for quantitative assessment of the drilled formations and the determination of the Core Drilling Technique resource contents. With the development of the core drilling method at The informative value of the samples is completed the beginning of the 19th century, a milestone was set for through the documentation of drilling parameters, as well the exploratory drilling technique. The technical principle as through the observations of a qualified drilling team. of cutting out a rock cylinder from the rock beneath the An adequate logging can provide valuable information bore hole bottom, with the help of a tubular drilling tool on completeness, as well as on a possible falsification was able to stand up to a multitude of competing drilling through contamination of the samples by caving, so that methods, due to the high quality of the obtained samples. sufficiently accurate interpretation can even be derived An important contribution to the performance of the from disturbed samples. method was the first application of diamond drilling tools in 1862 by the Swiss tunnel construction engineer A. Leschot. However, the industrial manufacturing of diamond drilling tools could only be realized in the 1950ies. Nevertheless, Standard Drilling Techniques the core drilling technique was closely connected to diamond drilling tools, so that the expression diamond- Deposits of mineral commodities are mainly to be core-drilling technique is often used to name this method found in hard rock formations except for placer deposits in exploration. Diamonds are characterized by a very high and accumulations through substitution processes. The degree of hardness (10 on the Mohs scale), through which framework of requirements for suitable drilling methods, hard rocks with high share of quartz or pure quartzite drilling tools and equipment can be derived from geological can be drilled under technically meaningful conditions. and geo-mechanical rock characteristics, from the The application of diamond drilling tools requires the required quality criteria of the sample, based on the goal of maintaining of a sufficient mud circulation for cooling. the exploration project, as well as from the prognosed size, form and position of the deposit. Although in detail each drilling project has its own and special conditions, but with the high performance and universally applicable equipment of the modern exploratory drilling technique, they can all basically be dealt with by three drilling methods.

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Pic. 3: Schematic diagram of core drilling

In a further development the original core drilling cutting out of the annulus are continuously removed with technique was expanded to a multitude of individual circulating mud. Inside the drill string the mud is first lead core drilling methods, in order to cope with the various to the core barrel, gets out at the drill bit into the annulus exploration goals, which partly have a very specialized and flows loaded by cuttings back to the surface through character. Three core drilling methods have been the annulus (direct direction). The remaining drill core is established in exploration of mineral raw material deposits, constantly rising into the core barrel, until its length does which in the loosening and extraction technique are leaned not allow any further take up. The rock column is connected against the classic methods. to the surrounding rock by its lower surface and has to be loosened by lifting of the bore string (see picture 3). This is done by a core lifter, which is located between the core The applied core drilling methods are suitable to barrel and the drill core in a conical cavity. While pulling completely obtain (almost) undisturbed samples. The the drill string the core lifter wedges the drill core through rock beneath the bore hole bottom is cut out in form of a a friction locking (see picture 4). The core barrel with the concentric rift with a core drilling tool, which is preloaded inside drill core is drawn mechanically to the surface by with static pressure by the drilling tool and in is rotated in a pulling out all drill rods out of the hole. constant rotational speed. Since it is not the entire bore hole axis that is processed, centrically a rock cylinder remains, the so called drill core. The cuttings which result from the

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Pic. 4: Diagram core lifter

Core drilling with Single Core Barrel

The constructional composition of the single core barrel is limited to the basically needed components of a core drilling tool. Picture 5 shows the setup of a single core barrel. The multi-part drill set is composed of:

• The core bit • The reamer • The core lifter • The core barrel • The head of the core barrel

Pic. 5: Setup of a single core barrel

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Due to the slim construction of single core barrels, The application of single-core barrels is limited to the core bits are equipped with a thin cutting edge. The exploration of regular and compact hard rock formations measurement of the required widths of the edge is derived that are close to the surface. In such circumstances very from the wall thickness of the core barrel + outer annulus good drilling progress can be made with the narrow cutting (space between drill string and drill hole wall) + inner edges of the core bits. In comparison with other competing annulus (space between core barrel and drill core). The core barrel constructions, less rock volume needs to be wall thickness of the core barrel is 3.5 to 4.5 mm, an extra removed from the core bits of the single core barrels; 3.5 mm have to be added for both the inner and outer therefore it is possible to achieve a faster penetration rate annulus. The inner annulus creates a clearance between with a comparatively lower energy expense for pressure, the drill core and the inner core barrel wall while the core torque and mud flow. The advantages of the lower specific is rising into the core barrel. Furthermore the mud is lead cutting work have particular effect on application of through this annular space along the core to the bit. The small drilling equipment, whose feeding force is limited outer annulus ensures a friction-less rotation of the whole due to its dead weight. In addition, the narrow cutting drill string and the path for the mud back to the surface. edge of the core bit leads to a more favorable relation of the bore hole diameter to the core diameter. Next to the The reamer, which is directly positioned above the core technical advantages, the single core barrels require a low bit, has the task of stabilizing the core barrel and ensuring investment and have relatively cost-effective wear parts. a constant bore hole diameter. With the progress in drill hole length wear off in the gauge of the bit is unavoidable. Two types of single core barrels are distinguished in the Without the application of a reamer the bore hole diameter technical nomenclature. The single core barrels with the would decrease steadily. model name B are produced from thin-walled material and During the entire time of the coring interval, the drill need core bits of a cutting edge width of 7 mm. A more core is subject to the hydraulic influences of the mud, robust standard single core barrel with the model name Z, as well as the mechanical influences of the rotating and which needs a cutting edge width of 14 mm is also available. advancing core barrel. The high degree of disturbing In the next issue, further details for the dimensioning of the factors can negatively influence the quality of the sample, bore diameters and the resulting core diameters will be as well as the drilling process. The mud flow, which is given. directly running along the drill core, washes out all fines, e.g. rock veins or clay-beds. It is almost impossible to avoid a mechanical impairment of the core through rotation Core Drilling with Double Core Barrel influences. Radially acting strains on the drill core, which are caused by vibrations and unbalances in the drill string, The double core barrel is a versatile drilling tool in the have to be added. Results of this can be impairment of the exploration technique for complete extraction of complete sample quality, as well as considerable disturbances in cored samples. The range of applications varies from the drilling process through broken core pieces. In case exploration work in friable structures and weakly solidified fragments of the broken drill core get jammed in the core formations to drilling of compact quartzite rock. With a barrel, the penetration rate is either strongly reduced or modification of the “classical” double core barrel it is also completely stopped. The entire length of the core barrel, possible to extract cores from loose rock formations. Due which is between 1 and 3.5 meters in single core barrels, to the engineering design of the double core barrels, which cannot be completely drilled out. Along with the restriction in principle are characterized by one inner tube for the of the possible length of the cored section, additional round core recovery and one outer tube for power transmission, trips are needed for the achievement of the final depth. the following criteria should be ensured: These additional processes have negative effects on the gross drilling performance. The extraction of the drill core, • The protection of the drill core from hydraulic influences of which in a single core barrel is done through the removal the mud of the entire drill string (round trip), requires a significant • Protection of the drill core from mechanical influences of amount of time, particularly with advancement into greater rotation depths. In addition, core fragments in the core barrel are • The friction free inclusion of the core into the drilling not optimally retained by the core lifter. These fragments process may loosen under the strains of the mechanical extraction process, and fall back on the bore hole bottom. In case • The secure extraction of a cored section, which should be of such a concurrence of unfavorable circumstances the as long as possible efficiency of the drilling process, as well as the sample • The non-destructive extraction of the core from the core quality is again strongly impaired. barrel

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In comparison with the single core barrel, the technically more complicated construction of the double core barrel consists of the following components (see picture 6):

• The core bit • The outer tube • The reamer • The head of core barrel • The core lifter bush and • The core lifter ring

• The inner tube Pic. 6: • Inner tube with swivel Composition of a double core barrel)

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The power and energy transfer onto the core bit is done dimensioning of the tube wall thickness and the required exclusively through the thick-walled outer tube, which is edge width of the core bits. The double core barrel considerably more robust than the inner tube. The inner systems are characterized by the coding TT, T-2, T-6, D and tube only serves to contain the drill core. The inner tube K-3. Individual components are not compatible with each is connected to the core casing head of the outer tube other. through a swivel, in order to protect the drill core from the mechanical influences of the drilling process. The The global application of double core barrels for the bearing decouples the torque, as well as the rotary motion search and exploration of mineral raw material deposits is of the outer tube from the inner tube. The drill core is only dominated by the T-2, T-6 und D systems. Core diameters influenced by the cutting force of the core bit. The mud, of 22 mm to 84 mm are drilled with core barrel systems which is directed from the drill string over the head of the T-2. They have a low pipe wall thickness, so that core bits core barrel, flows in the annular gap between the outer with small cutting edge thicknesses of 7 mm to 8.5 mm are and the inner tube to the core bit, alongside of the newly used. Core diameters of 47 to 123 mm are obtained with cut drill core. core barrel systems T-6 and D. The cutting edge width of the core bits is between 9.5 and 12 mm. The next issue will The contact area of the drill core and the drilling fluid is provide further explanations on dimensioning of the bore reduced to 5 to 10 cm by the path of the mud escape from hole diameters and the resulting core diameters. the core lifter bush till the cutting edge of the core drill. Even if the contact surface is low, in un-solidified sediments, Taking into consideration an economical, as well as the mud contact leads to washing out of fine elements, up a technically meaningful and achievable final depth, the to the complete loss of the core. For this reason double application range of conventional single and double core core tubes are equipped with a modified core lifter casing barrels is limited by the mechanical extraction of the drill in loose rock formations, which elongates the inner tube cores, through the extension of the entire drill string to beyond the core bit, so that the core can be held without exploration horizons of up to 300 m. With increasing drilling contact with the mud. It should be noted that the core is depth the time expense for round trips of the drill string for “cut” by the non-rotating inner tube, and not by the core the core extraction accounts for a considerable share of bit. In this application a considerable wear-off needs to the effective drilling time. The individual steps that have be provided for. The spectrum of application is basically to be taken into consideration in the drilling performance limited to loose rocks. The core lifter rings of the hard rock are: drilling technique are exchanged with core a lifter clip, which closes the entire diameter of the inner tube with the • Running of the drill string to the hole bottom lifting of the drill string, and thus allows for the complete • Drilling process discharge of the un-solidified drill core. With double core • Breaking off the core tubes it is possible to obtain samples of adequate quality in almost any formation. Highly alternating rock stabilities • Extraction of the drill core through removal of the drill string and grain adhesion are particularly challenging. The rock out of the hole loosening process always has to refer to components • Removal of core with higher stability. Satisfactory results can be obtained in strongly unstable and weathered hard rocks with The final depth, which can in fact be reached with conventional double core tubes, which are equipped with economically justifiable expenses, is mainly influenced by special core lifter bush and core bits. the following factors:

The core lifter bush is extended to the cutting edge, so • The length of the cored section that is actually extracted that the annulus gap is strongly reduced for the mud outlet. above ground. The maximum length of the cored section cor- The core bit has inner mud channels, which only exit at responds to the inner core barrel length. In case this length the cutting matrix. The disadvantage of these special core is reduced, due to jamming in the core barrel or due to core bits is their sensitivity towards small drilling mistakes, so losses during extraction, the total efficiency is also reduced, that their application remains limited to difficult mountain subject to the time of circulation of the tool. With increasing conditions. depth of the bore hole, the length of the cored section which is to be extracted, should increase. Four standard systems are offered in industrial • The effective time for a round trip, which is influenced by manufacturing of double core barrels, as well as of the technical parameters and the operation method of the dril- corresponding core bits; each one is specific to the ling team. The technical factors basically comprise of the respective manufacturer. Their main difference is in the length of the individual drilling rods (and as such the threa- ded connections that are to be disconnected), the solubility

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of the individual threaded connections and the driving speed drill cores without a round trip, has opened up a range for of the lifting unit or the top drive of the rig. In order to achieve application of the drilling technique for complete extraction fast installation and removal of rods, a perfect functioning of undisturbed samples, which significantly exceeds of the drill pipe system has to be ensured. In principle the limiting conditions of conventional double core barrels. technical factors are subject to the correct selection of the With the available wireline core barrel systems, which equipment, as well as to its maintenance. As a prerequisite, consist of a wireline core barrel assembly and special wire the professional handling of the technical equipment, as well line drill rods, it is possible to achieve depths of over 1000 as a command of the tasks to be achieved, requires corres- m in routine operations. In big drilling projects it has been ponding qualification of the drilling team. possible to advance to depths of 3500 m under the surface • The unexpected geological disturbances in the bore hole. with wireline coring systems. However, the performance of Each exploratory drilling in unknown rock is linked with im- the wireline coring has its complete effect only in deeper ponderabilities. These are easier to handle with a careful as- drillings from 50 – 150 m. Therefore wireline coring systems sessment of possible incidents and timely implementation of are applied complementary to the double core barrels, as precautionary measures. This includes for example a casing they show their strength for shallow exploration targets. plan, provision of plugging material to confine mud loses and However it is expected that the importance of wireline of fishing tools for removal of junk from bore hole averages coring will further increase, taking into consideration the etc. development towards deeper target horizons.

A particular challenge for the application of single and The engineering design of the wireline coring systems double core barrels is the penetration of unstable rock is composed of the wireline core barrel assembly, a latch formations. Due to the procedural installation and removal and special wireline drill rods. The wireline core barrel of the entire drill set, the bore hole wall, which is partly to assembly is geared towards the double core barrel, but the completely uncased, is subject to application of hydraulic difference is that the conventional head of the core barrel and mechanical forces. During the fast lifting of the drill has been replaced by a bolt mechanism, which locks the string the core barrel, which corresponds to the bore hole inner tube for the drilling process at the outer tube and can diameter, can produce a piston-like effect in the mud-filled be unlocked for the extraction process. In order to protect bore hole. Thus it is possible that a hydraulic vacuum the drill core from mechanical rotation influences, the inner is produced immediately under the core barrel, which tube is connected with a swivel. In picture 7 the design of a may lead to caving or even a bore hole wall collapse. wireline core barrel is presented as an example. Furthermore the bore hole wall is mechanically strained by possible contact to the moved drill string. There is a Industrial manufacturers offer combinations of inner possibility that parts of the bore hole wall cave into the bore and outer tubes, with which cored sections in lengths of hole from unidentified and unsecured weak zones. The 1 to 9 m are feasible. operation safety can be impeded by caving, particularly in deep drillings. In case weak areas cannot be handled, The wireline core barrel systems are characterized the installation of a casing is unavoidable. The maximum through advantageous core removal, which can be done diameter of the drill string for the deepening of the drilling without the time-consuming round trips of the entire to the final depth is then limited by the inner diameter of drill string. The drill core is recovered together with the the casing. The penetration of unstable mountains with core barrel by a rope. This is done by stopping the mud conventional core barrels requires diligent planning of the circulation after the drill-out of the cored section, then casings to be installed. breaking off the core from the rock by slightly lifting the bore string, and by consecutively disassembling the top One advantage of the round trip that is required for drive from the drill rods. The rope with its overshot is the extraction of the core, is the continuous checking lowered into the drill string by a winch, until it locks at the of the equipment wear-off. The state of the core bit and latch of the wireline core barrel assembly. Simultaneously the drill string can be checked after each cored section. the locking mechanism of the outer tube is disconnected. Furthermore, a flexible adaptation of the core bit to the The diameters of the special wireline drill rods are adapted changing rock characteristics is possible. to the core barrel, so that it is possible to pull the whole core barrel assembly inside the drill rods. After the core removal the inner tube can again be inserted through the Core Drilling with wireline core barrel drill rods to the bore hole bottom.

The wireline core barrel is a further development of the double core barrel, which is specially constructed to mechanically extract the bore core without the need to remove the entire drill string. The method of extracting

Issue 03 | 2009 www.advanced-mining.com 14 EDUCATION

Pic. 7: Composition of a wireline core barrel

Issue 03 | 2009 www.advanced-mining.com 15 EDUCATION

This is done:

• Through free fall in perpendicular to moderately inclined bore hole distances ( less than 45% deflection out of plumbness), in which an adequate mud level is available • Through insertion at the winch in perpendicular to modera- tely inclined bore holes that are almost or completely get dry through mud loss • Through attachment of the top drive onto the drill rods and in highly inclined bore holes and through the use of a moderate pump rate, so that the inner tube is transported to the core barrel from the hydraulic flow rate.

As a principle, before inserting the inner tube, the extracted length of the cores section has to be checked. In case a core stump remains in on the bore hole bottom or in case cuttings are not discharged, a correct engagement of the inner tube can be prevented. In this case the drill string has to be pulled until its lower end is located above the core stump.

During the core removal the drill rods can take over the function of temporary casing through the geometric dimensioning and the installation. This could stabilize the borehole wall in regions with friable zones. Furthermore potential caving out of the bore hole wall is separated from the core sample, which is pulled inside the drill string. However, this cannot substitute a complete casing along bigger disturbance areas, since the drill rods rotate with the required rotary speed and an outer annulus for the mud has to be maintained during the drilling process. In disturbed rock mass areas that are too big and high mud losses are to be expected, the rod friction between drill string and bore hole wall can be highly increased. Under these circumstances it is necessary to install a casing. The advantages of a temporary casing by the drillstring can be found in a higher operational safety during the drilling process, as well as in the possibility of overcoming limited disturbance areas. Moreover the wireline coring drill rods offer the option of attaching measurement tools to them, for example to determine the bore hole direction. This contributes to a higher reliability and quality of the core samples.

Three different wireline coring systems that are manufactured with industrial standards are available. They mainly differ in their construction of the locking and latch systems (see picture 9 and picture 10).

The system that is marked with the coding SK 6 L and NSK, has been specially designed for low drilling depths of Pic. 8: up to 300m, the system that is marked Gebor S is designed IInner tube with locking for medium drilling depths up to 500 m, and the system called mechanism and latch of the CSK has been designed for depths from 500 m upwards. wireline core barrel system CSK

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The bandwidth of the bore hole diameters starts at 48 mm and ends at 176 mm, whereas core sample diameters lie below the diameters of the single and double core barrels, due to the broad width of lips of the core bit. Pic. 9: latch and overshot, system CSK Compared to single and double core barrels, the application of wireline core barrel systems basically requires a higher performance of the drilling rigs. This is due to the fact that the bore rods have higher weights and there is a higher rod friction in the drilling process. Furthermore, a high-performance winch with a corresponding length of the rope has to be available for pulling the inner tube. In connection with the higher expenses for investment and the arising spare part costs fore bore string and core bits, the specific initial costs are higher than in the application of conventional core barrel systems. However, the higher gross drilling progress in deeper drillings of final depths more than 50 to 150 m and the relatively easy handling of difficult drilling conditions compensates for the higher operating costs. The next issue will deal with the selection of core bits and the dimensioning of drilling parameters.

Pic. 10: latch and overshot, system NSK

Issue 03 | 2009 www.advanced-mining.com 17 EDUCATION

Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining Col- Bibliography lege of Shahrud (Iran); following several years of work in the mining industry, he completed [1] Arnold, Werner: Flachbohrtechnik; 1. Auflage, his mining study at the RWTH Aachen in 1989. Leipzig, Deutscher Verlag für Grundstoffindustrie GmbH, Since 1992 he was Chief Engineer at the Insti- tute for Surface Mining (Bergbaukunde III) of 1993 the RWTH Aachen, mainly active in the field of open cast mining and drilling technique. He did [2] Buja, Heinrich: Handbuch der Baugrunderkundung; his doctor degree in 1993 and qualified as a university lecture in 1. Auflage, Düsseldorf, Werner Verlag GmbH & Co.KG, 1997. In 1998 the Venia Legendi was awarded to him be the RWTH 1999 Aachen for the field “Rock and Earth Open Pit Mining”. In Novem- ber 2001 he was appointed as Professor for Surface Mining and [3] Entenmann, Dr. Winfried: Baugrunderkundung, 2. International Mining at Clausthal University of Technology. Auflage, Renningen, Expert Verlag, 2008 He already has over 25 years of experience in the field of project planning and cost-benefit analysis within the frame of various mine [4] Happel, Martin; Homrighausen, Dr. Reiner: planning projects. The international tasks rendered by him mount Bohrkerngewinnung zur Exploration von Baugrund up to more than 300 international raw material-related projects. und Rohstoffen, in: BBR Fachmagazin für Wasser und Leitungsbau, S. 42 – 49, Heft 12/2008 | [email protected] | www.bergbau.tu-clausthal.de | [5] Wirth Maschinen- und Bohrgerätefabrik GmbH: Bohrtechnisches Handbuch, Version 1.0, 2002 Dipl.-Ing. Heiko Hertel, born 1975, graduated in the years 1995 to 1998 trained as a well [6] Comdrill Bohrausrüstungen GmbH: Katalog constructer. The activities of the well Bohrausrüstung, 7. Ausgabe, 2007 constructer he held until 2001. Immediately following the same year he began the study [7] Internetinformation der Firma Archway Engineering of Geotechniques, Mining and Petroleum (UK) Ltd: www.archway-engineering.com, August 2009 Engineering at Clausthal University of Technology. He completed his studies successfully in 2007 and is engaged in silk as a research associate at the Institute for Surface Mining and International Mining at Clausthal University of Technology.

| [email protected] | www.bergbau.tu-clausthal.de |

Issue 03 | 2009 www.advanced-mining.com 18 TRANSFER OF TECHNOLOGY

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Issue 03 | 2009 www.advanced-mining.com 19 TRANSFER OF TECHNOLOGY Impact of financial crisis on the German & global commodity market and the mining industry by Moritz Kellner Geotechnique, Mining, petroleum/gas engineering |Institute of Surface and International Mining | Clausthal University of Technology | Germany

Introduction and Background Controversy – Grudge or blessing for the industrial nations? The collapse of commodity prices The economic impacts of the declined commodity prices The crash of commodity prices in the second half of 2008 are discussed controversial these days. Different views has been an unexpected happening. Although a declension say, that the commodity crisis may be a grudge or blessing was predicted, a historical collapse at an average of for the economics of the western world. In principle, about 50 % within five months was surprising. The oldest following thesis is correct: Cheap commodities must have commodity index, 1957 founded CRB (Commodity Research a good impact to push foreign economies. Bureau), collapsed that quality after its historical peak in The International Energy Agency (IEA) came to that july of 2008. The position at the energy markets seemed conclusion: Due to fallen crude oil prices, the industrial to become even worse. The cruide oil price crashed from nations save costs in a height of one trillion US-Dollars. 150 US $ / barrel to 35 US $ / barrel within that period, i.e. a This must be enough to secure all foreign efforts to push declension of about 76 %. Only the gold price lasted stabil. economic activities. Reason here has been the role of gold as crisis metal, while The other side dissents that view. The German Institute traders lost their belief on currencies and bonds /1/. of economics analysis (Rheinisch-Westfaelisches Institut fuer Wirtschaftsforschung) can see, that this amount of money now is missing at the producing countries. The result Reasons for the rising and declension of commodity is a global stand-off situation. Germany reduced costs prices around 40 Billion US-Dollars, money that is now missing in The reasons for the historical declension of commodity the middle east, Russia or Venezuela. Producing countries prices are to find in direct periphery to the global financial do not have any chance now to invest on world market crisis. Global deleveraging, i.e. the procedure of borrowing products – for example German products. Furthermore, equity to substitute the debt, has been performed for although there is saving, the economy looses consumer. In debt retirement. Traders turned away from the class of that case, the sense of efforts to push activities becomes investment “commodities” due to the possibility of still senseless. The interdependencies between global financial making profit. Together with the signals of a recession crisis and flagging global economies as well as commodity the declension became a dynamic process. Danger of prices are nontransparent. Although the IEA comes to the excess of supply on the worldmarkets lowered the prices conclusion, that commodity prices do have an important even more. Especially the industrial nations got under influence onto global economies, but the other side of the considerable strain. view seems to be sensible as well: Flagging economies To find a conclusion why commodity prices reached that were the reason for the oil price crash, just moments later high levels, which made a crash possible, there are to take commodities crashed as well /3/. parallels to the financial crisis. As on the financial market, the prices had been pushed up speculative /1/. Energetic and industrial commodities prices climbed Influences on the German commodities: much more, than a normal price increase would do. The rising prices over the last years let mining companies Steel industry & Limestone and caking capitalize onto exploration projects, profit seemed to be possible at reserves and resources that have been coal unprofitable before. Beginning excess of supply on the world markets, for example iron ore, had been ignored. Influences on the steel industry Prices much higher than average prices (for example Once there are signs of commodity crisis, steel industry copper was at four times higher than usual) were tempting. is one of the first that gets hurt. Although at the first moment, Finally, the commodity bubble burst /2/. cheap commodities, in that case iron ore and caking coal, seem to be an offer to the steel industry, but consumers got lost.

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Pic. 1: Freight rates

Of course, the steel crisis is a global problem. Iron ore, From global declension towards German mining that has been pushed up by produces like Vale, lost that industry much value, that the production had to be cut down about The flagging German steel industry of course does have 30 to 40 percent /1/. The biggest influence on development influence onto German mining industry. The mining industry of the global iron ore price has the biggest consumer, stands at the end of series of interplays between sectors of China. If the Chinese steel industry, that wasn’t hurt that industry. One simple model is able to show that interplays: brutal as Europe or the United States starts buying ore in The financial crisis directly hits the German automobile 2009 again, the price will become stabilized again. industry. Enterprises as Daimler-Chrysler or Opel start The influence of the problems of the steel industry on purchasing less commodities, i.e. steel. Germany’s largest the caking coal market began few times later. In October steel producer Thyssen Krupp has to reduce production. and November of 2008, steel production sank about 20 to 30 Now the global crash hits one key industry of western % in Germany. The impact was now viewable at the caking world countries. /5/ This has consequences on the mining coal producers, for example BHP Billiton. The market industry, for example limestone production or hard coal for caking coal shrank around 40 percent compared to mining. spring of 2008. The situation became even worse, as the caking coal price was unnaturally high in summer due to production shortages at one of the most importing coal Declension of caking coal price – German hard coal supplier, Australia. The price on the spot market crashed mining in difficulties form 300 US $ / t to 150 US $/t. As already said, the caking coal price crashed from Another indication of steel industry weakness are 300 US $/t to 150 US $/t, demand sinks. But mostly, the the low freight rates from producing countries to China collapse of the steel production put pressure on “RAG or Rotterdam. The influence on freight rates was directly Aktiengesellschaft”, the German hard coal mining visible as they crashed down to values, that were common company. One-fifth of the hard coal production is directly in 2002 /4/. (Picture 1) sold to the steel sector. The power plant section, which makes 76 % percent of the hard coal usage, sinks as well. The reason here is a lower power demand from the whole industry.

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The captive coking plant, “Prosper” at Bottrop is actually Diamond market – A backlash for producers and producing at a capacity of about 70 %, after producing over processing industry the capacity border and above all profitable last summer. Around 50 % of global diamonds are mined at African The last mines at the Ruhr-area (West, Prosper Haniel, countries. While the other diamond producing countries, Auguste Victoria and Ost), politically in any case disputed, i.e. Canada, Russia or Australia, have the possibilities are mainly producing directly to the stockpile. of modern and western standard mining technologies, The high spot market prices during the last years until countries as the Democratic Republic of the Congo do the summer of 2008 and an enormous demand from China have diamond properties near the surface, but do not let the German hard coal mining became more and more have means over that technologies. More than a have stand in better light. Now, the declined prices brings the million people live from diamond mining at the Congo and German hard coal mining industry back into harsh and other producing countries like Tanzania, Angola, Sierra controversial discussions again /6/. Leone or Liberia. Most of them are working without any social coverage and clear judicial situations, i.e. in the so called “informal sector”. Due to shrinking world markets Rheinkalk: The largest limestone producer of consequences for these people are striking. Processing Europe without market countries like India solve the same problematic. Beside the coal industry the limestone production is hurt The most important market for diamonds was and is the as well by flagging steel industries. Limestone is elementary United States. That market is shrinking since September of in metallurgy for producing iron and steel, because it 2008. In 2009, there will be an estimated market lowering of reduces the melting point of the slag and is able to bind 60 %. The price for diamonds, that has been on a historical silicates. About 30 percent of the produced limestone goes height in September of 2008, already fell about ten percent. into that sector /7/. If you focus on the largest limestone The end of that development will not appear in 2009 say open pit mine, Flandersbach near Wuelfrath, the amounts experts. of annual production of the past few years and upcoming So the diamond prospectors in the African nations do years can clearly show the impacts. In 2008, Flandersbach not have markets anymore. Furthermore, countries as the reached nearly 10 Million tons, which has been an historical D.R. of Congo employ many people in national copper and height for the company. The average over the last years cobalt mines. More than 300.000 people got unemployed always was around 8 to 9 million tons. Now in 2009, the already. For a nation that makes 40 % of its national budget amount is estimated at around 6 million tons. Furthermore, out of taxes of the commodities industry, this equals a short-time work became necessary actually /8/. national insolvency /9/.

The declension of the diamond price Consequences for the Third World at the In principle, following assumption seems to be correct: example of diamond mining The diamond price should hold steady as the gold prices does. But while gold became an investment in turbulent times, diamonds seemed to be luxurious goods, on what Direct impacts of the financial crisis on the people could abdicate. In addition, the diamond market developing countries is directly linked to the sector of industrial diamonds, When the first information of financial trouble arrived which cope with the same impacts as other industries do to the developing countries, many of their governments /10/. Picture 2 shows the declined price within the last 12 showed careless reactions. Reason was a simple months. The percentage on the vertical axis indicates the advisement: The developing nations did never invest into price development. Reference is an amount of 100 % from the American estate market, so there would result no June of 2004. The climax was reached at a value of 131 % consequences as the crash became reality. However, in summer of 2008. consequences commenced, but temporally delayed. The sunken willingness to invest of the western nations let markets of the developing countries shrink. While western nations were in fund to secure the social costs of growing unemployment the impacts on third world countries were even harder. A view on the global diamond trading is able to show that results in special.

Issue 03 | 2009 www.advanced-mining.com 22 TRANSFER OF TECHNOLOGY Price developments of metals

Gold – Precious metal with special status

The gold price lasted solid over the last months, even climbed partially. A correlation is obvious: A global downturn of commodity prices lets the gold price rise. The special status of gold can be made even more visible if you have a look at other precious metals. They were hit by the global downswing in the same way as the other industrial commodities. The special status of gold can be made visible by the so called Pic. 3: Development oft the gold price over the alst 12 months “Nickel to gold price ratio”. That index compares the current price of the ounce of gold and the price of a ton of nickel. If the ounce price of gold is at 1000 US $ and the ton The pictures show two aspects: One the one hand price of nickel at 15.000 US $ the “Nickel to gold price ratio” you can clearly see the solid behavior of gold, on the lasts at the nondimensional account of 15. The nickel price other hand the declined nickel prices in fall of 2008. The on the spot market is directly linked to the steel industry account of 15, that was reached last December is valid up due to its role as a refiner. The “Nickel to gold price ratio” to now. Crashes of the “Nickel to gold price ratio” were reached its climax in may of 2007 at an account of 70 and always visible in the past at times of recession as picture 4 declined down to the account of 15 in the end of 2008 /4/. emphasizes. (Picture 4).

Pic. 2: Development oft the nickel price over the alst 12 months

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Pic. 4: Development of „Nickel to gold price ratio“

Platin Group Metals (PGM) Most important reason for the declension of the platinum group metals (palladium and rhodium besides platinum) is their usage in the automobile industry (catalysts). The shrinking market directly led into overplus on the global markets. A rising is not cognizable, nevertheless the prices are behave solid since the end of 2008 /4/. The very limited usage of the platinum group metals is the reason that there is no fast rebound. Rhodium is used in catalysts for 85 %. For the whole PGM there is an amount of 50 % going into the catalyst fabrication. The consequences for the producing countries, especially South Africa and even more drastic Zimbabwe are similar to the diamond producing countries in central Africa.

Pic. 5: Development oft the platinum price over the alst 12 months

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Pic. 6: Development of “Platinum to gold price ratio” and “Palladium to gold price ratio”

PGM Complex prices compared to gold For the declension of the precious metals of the PGM complex apply the same results as at the nickel price. Both “Platinum to gold price ratio” and “Palladium to gold price ratio” showed crashes. In case of palladium, the value already crashed in fall and winter of 2001 and now even declined. Platinum experienced a declension, that was worse than the crash in the shadow of 9/11 terror attacks. Picutre 6 indicates the price declining /4/. Industrial commodities The most important emporium for commodity prices, London Metal Exchange, observed the crash of all industrial commodities back to prices of the year 2003 in the second half of 2008 /4/. Picture 7 shows the development of the zinc price in US $ the last ten years. Clearly visible besides the declension starting in summer of 2007 is a constant development up to 2005, when the price started to grow extra-ordinary.

Pic. 7: Development oft the zinc price over the last 10 years

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Pic. 8: Development oft the copper price over the last 15 years

Looking at the copper prices over the last 15 years makes obvious, that the sharp rising starting in 2005 only could occur by speculations, i.e. runs on the deposits. Also, the metal exchanges at London, Shanghai and New York incorporated shortages on the global markets. Largest consumer of copper was and is the People’s Republic of China. The crash of key industries as the construction sector hit China as well. Therefore, the global copper price is linked to the Chinese exporting rates. Many experts consider that copper has the best chances to get stabile in pricing already in 2010. The graphic of the copper price development over the last six months indicates that fact.

Pic. 9: Development oft the copper price over the last 6 months

Issue 03 | 2009 www.advanced-mining.com 26 TRANSFER OF TECHNOLOGY The role of China Canada’s oil sands

The energy demand of China over the last years has The Canadian oil sands projects deliver exemplarily how been the main reason for global growing on commodities branches of commodity producing can be hit by unsteady demand. Mathematical models deliver the coherences price developments. That affects the temporary boom of of economic implications of the European Union and the Canadian oil sand industry that started about five years United States relative to the rates of growth in China. They ago as well as the problems that arrived nowadays since consider that a retardation of the commodity demand in the oil price turned down. Western Europe and North America of one percent leads Regarding picture 10, it becomes visible that the oil to a declension of seven percent at China’s export rates. price between 2001 and 2008 was extremely rising, Regarding the expectation, that the commodity demand especially since January of 2007. The low level in autumn in 2009 will fall about 3 percent in the G7-nations and the of 2001, i.e. in the periphery of the N.Y. terror attacks, made Chinese export rates climbs at 10 percent in comparison to clear, that a constant level that low can not be normal in 2007, a declension of around 20 % considering the export the future. Constant rising together with predictions of is to expect. growing demand made oil sand mining became more and Generally spoken it is remarkable, that the current crisis more profitable. The crash of the crude oil price in autumn hits China harder than the Asian economic crisis 10 years of 2008 to a level of 40 US $ per barrel was that striking, ago. Although the demand for commodities will rise in 2009 that the value now was lower than it would have been by and 2010, but less than the last years, namely 7 % this year standard rising values. Picture 11 now shows, that now and 6,6 % in 2010. Compared to other countries and regions, quiet a stabile and slow rising oil price is to expect until the rates would be extra-ordinary high, for example in 2010. Price will last around 60 US $ per barrel. Europe, but for the huge imports of commodities of China Location of the oil sands boom is the Canadian province these rates are indices for a crisis /4/. Alberta. Around 1.7 trillion barrel are expected, one third of the global oil sands reserves. Oil sand in this region is a conglomeration of 83 % of sand, 10 % bitumen plus water and clay. The part of bitumen fluctuates between 1 % and 18 % and is the value that makes the profit possible. Generally, contents of at least 6 % of bitumen lead to profit.

Pic. 10: Development of the cruide Development of the criude oil price between 2001 - 2008 (12. Dec) oil price between 2001 and 2008

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Pic. 11: Development of the cruide oil price and outlook until end of 2010

Now the expansion plans are showing first signs of Some of them are afflicted with binary billion values. That slowdown, a correlation to the declined oil price seems leads to negative results during the financial crisis. The to be visible. According to the president of the Mining consulting company McKinsey comes to the conclusion, Association of Canada the oil sand projects are challenged that Alberta’s bitumen has a cost disadvantage of 15 US $ nowadays in its entirety. per barrel on the important US-American market. For the Canadian projects exist three starting points, As seen above, upgrader projects need oil prices of 100 every one for a different way of mining and processing, US $ per barrel. Furthermore there has to be a significant that mark the edges of profitable economics: difference in prices between bitumen and synthetic crude oil. If Alberta processes crude oil and delivers less crude • Oil sand projects that need so called upgrader to process oil to its most important consumer, the United States, the the oil sand after mining require a long-ranging oil price of at US demand for bitumen grows. That leads to a smaller least 100 US $ per barrel. price difference, the most important requirement for the upgrader projects. Instead of that, export of bitumen is • Oil sand projects that are mining per steam injection and do more profitable. However, lots of capital was invested not need upgraders require a long-ranging oil price 70 US $ in upgrader projects, so profitable economic activities per barrel. are hardly to realize today. Concerns as Shell and Statoil • Oil sand projects, which export the mined bitumen directly to delayed plans for new mines by now. refineries in the U.S. (that are able to process the heavy oil) That also has consequences for the region. The absence require a long-ranging oil price of 50 US $ per barrel. of skilled personnel into the summer of 2008 perhaps leads into thousands of unemployed people in the Athabasca region /11/ /12/. Compared to figure 11, that “break-even-points” make clear that today only the third way, i.e. the export of unprocessed bitumen is profitable. It also makes clear, that the planed upgrader projects are deferred for the present or will be delayed. All upgrader projects were close to realization by nearly all global petrol concerns. Besides the fallen oil price a result of the financial crisis became important. Canadian oil sand projects are inherently more capital-intensive than conventional mining projects.

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consumer of commodities reduced import rates clearly. The failure of the mega-deal Excess supply let prices crash, for example the one of copper. Exploration projects that were profitable at high In the direct periphery of the events on the global energy prices are delayed up-to-date. and commodities market in the second half of 2008, one of the largest takeovers in history failed. British-Australian Commences a betterment considering the purchasing mining company BHP Billiton, largest global mining power in the industrial nations, price risings over the company, tried to overtake n°3, also British-Australian average rates are possible again. The lowering of the Rio Tinto. The takeover price firstly lay around 140 Billion production rates of the OPEC nations as well as the missing US Dollars. If the takeover would become reality, a quasi investments in new projects because of lacking exports monopoly would have lasted as a result. The huge iron ore and a low oil price can lead into a rising in the medium term production of Rio Tinto together with the very important when the economies of the consumer nations become role that BHP Billiton plays in hard coal mining would have solid again. let the new concern control one third of the global raw material for steel production. Therefore the competition commission of the European Union demanded already in the forefront that BHP has to give up other commercial lines in case of realization of the takeover. The reason was to prohibit a monopoly position.

The beginning declension of the commodity prices in the second half of 2008 firstly led into a declined takeover price down to 58 Billion US Dollars. Reason was, that BHP Billiton wanted to pay with own stocks. They had been fallen already because of the starting global recession. The final cancellation had the same reasons in principle. The new and unexpected market conditions and the economical lowering led into the decision to delay the takeover /13/ /14/.

Abstract & Outlook

The aftermaths of a global recession and financial crisis lead into direct consequences on the energy and commodity world market. The links often are very complex and nontransparent. Since the year of 2005, commodity prices were pushed upwards speculatively.

Regarding crashing commodity prices, economic impacts appear temporally delayed as well for import as export nations. The interlocking of the events that started as first global crashes and ends at foreign or German mining companies is now clearly visible. The lowered propensity to invest of the western world becomes now, some months later, noticeable in the Third World countries, whose economics ground on commodities export. Furthermore, aftermaths become visible that the global commodities markets are changing if import rates of Chinese goods decline in the western world. China as the most important

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bibliography

/1/ Handelsblatt: Rohstoffpreise fallen ins Bodenlose www.handelsblatt.com/finanzen/rohstoffe-finanzen/_b2118623 /2/ Die Welt: Spekulanten lassen Rohstoffblase platzen http://www.welt.de/die-welt/article2281070/Spekulanten-lassen-Rohstoffblase-platzen.html /3/ Wirtschaft T-Online: Billige Rohstoffe verschärfen Wirtschaftskrise http://wirtschaft.t-online.de/c/17/46/44/46/17464446.html /4/ DB Commodities Outlook 2009; Deutsche Bank AG /London /5/ Wirtschaftswoche: Einbruch in der Stahlindustrie www.wiwo.de/unternehmer-maerkte/einbruch-in-der-stahlindustrie /6/ Handelsblatt: RAG leidet unter Kohlepreisverfall www.isht.comdirect.de/html/news/actual/main.html?C_Timeframe /7/ Heidelberg Cement http://www.heidelbergcement.com/de/de/country/produkte/kalk/einsatzbereiche/eisen_stahl.htm /8/ Rheinkalk AG, Werk Flandersbach /9/ Friedel Hütz-Adams: Diamanten – Finanzkrise trifft Förderer und Verarbeiter hart /10/ Handelsblatt: Diamantenmarkt fehlen kaufkräftige Baker www.handelsblatt.com/finanzen/rohstoffe/diamantenmarkt-fehlen-kaufkraeftige-banker; 2242473 /11/ Germany Trade & Invest: Kanadas Ölsandprojektestocken www.gtai.de/fdb-SE,MKT200811068015,Google.html /12/ DiePresse.com: Ölsand-Industrie tritt auf die Bremse www.diepresse.com/home/wirtschaft/international/441538 /13/ Focus: Finanzkrise lässt historischen Milliardendeal platzen www.focus.de/finanzen/news/bergbau-finanzkrise-laesst /14/ Börse ARD www.boerse.ard

Moritz Kellner studies mining at Clausthal Uni- versity of Technology. This work was created last summer as a part of a seminar at the institute for Surface Mining and International Mining. The presentation of this work was held on 18 May 2009.

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Round Table at Hannover Messe 2009: Climate-Friendly and Energy-Efficient Raw Material Extraction Clausthal University of Technology presents “Energy-Efficient Conveyor Technology and Climate Protection“ study at the ContiTech booth - Panel discussion with experts from mining, industry and government

Hannover Messe, 2009. Conveyor belt units are for the internal transport of these solid mineral resources the energy savers and climate protectors in haulage (currently more than 12.3 billion tonnes a year worldwide) technology. They consume only a fraction of the energy and the related overburden (approx. 28.84 billion tonnes). required by conventional means of transport and emit And for mine operators, the question thus posed is: What much less CO2. With them greenhouse gas could be cut are the most effective, the most cost-efficient and the safest by 340 million tonnes in the next thirty years. This is a processes – as well as the best from the standpoint of global conclusion arrived at in the “Energy-Efficient Conveyor climate pro-tection – for transporting raw materials from Technology and Climate Protection” study, initiated where they are extracted to where they are processed? under the direction of Dr. Hossein Tudeshki, professor at To answer this question, the study compares conveyor belt Clausthal University of Technology’s Institut für Tagebau units with special-purpose heavy-duty trucks, the chief und Internationalen Bergbau [Eng.: Institute of Surface means to date of hauling away what is mined. and International Mining]. At Hannover Messe, Professor Tudeshki is presenting his study for the first time as part The key conclusions: In the next thirty years, 340 million of a round table event sponsored by ContiTech AG. He tonnes of CO2 can be cut by simply making more rigorous will then discuss the findings with a panel of experts from use of conveyors for raw material extraction. What is more, industry, mining and government. the study clearly shows that conveyor belts achieve a much better energy scorecard, requiring only about twenty Raw materials make the world go round. For years now percent of the energy needed by heavy-duty trucks. This the economic coming of age of threshold and developing translates into a big advantage for both the environment countries and the mushrooming of the planet‘s population and industry. have been upping the demand for metalliferous ore, industrial minerals, fossil energy sources and raw materials for construction – what one finds, in other words, in virtually all articles of daily use, in everyday consumables and in Energy generation during raw material buildings and other structures. A growth in demand at an transport average of four percent a year is forecast for the future. During the panel discussion, Hans-Jürgen Duensing, general manager of the ContiTech Conveyor Belt Group What impact does haulage technology business group, evoked the example of a mine operated in Jamaica to highlight another point: Conveyor belts not have on the environment and the global only consume less energy and reduce CO2 emissions. They can also generate electric power. At the Jamaican climate? mine, a RopeCon conveyor unit transports 1,200 tonnes of bauxite an hour across a distance of 3.4 kilometers and an The environment and the global climate are, of course, altitude difference of 470 meters. The braking force applied not unaffected by the corresponding increase in raw during downhill transport is harnessed to generate electric material haulage. That is why the Clausthal University of energy. In concrete terms this works out to 1,300 kW. Technology took a closer look at the consequences that the different transport options have on energy consumption „The RopeCon concept itself is of advantage wherever and CO2 emissions. Raw materials are seldom processed high conveying capacity is required across impassable where they are extracted. On average no less than 25% terrain, wooded areas or wide rivers,” adds Hans-Jürgen of the energy required for raw material extraction goes

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Duensing. “In Jamaica we were able to save the whole tree But industry and the environment have much to gain from population by forgoing construction of a road to haul away rigorous use of conveyor belt systems.” According to the raw materials. The system makes up for the equivalent the mining expert, though, exploiting this potential would of 1,200 truck runs a day and eliminates the corresponding require that the proportion of belt systems be upped from amount of CO2 and particulate emissions.” thirty percent at present to fifty percent in 2034, and then held constant at that level. Taking into account the four- percent annual increase in the demand for raw materials, belt haulage would increase by three hundred forty-five Environmental and climate protection percent through 2034 and by another twenty-two percent through 2039. Should this happen, the specific mass moved with conveyor belt systems by belt systems would grow from 46.97 billion tonnes and It is easy to understand why conveyor belt systems kilometers a year at present to 254.29 billion tonnes and are a more energy-efficient alternative and less grievous kilometers by 2039. In the whole thirty-year forecast period, polluters of CO2 emissions than the heavy-duty trucks CO2 emissions would be cut by over 340 million tonnes as a mainly used in mining operations. As batchwise operating result of the expansion in conveyor belt haulage described conveyances, heavy-duty trucks do both outward – here. loaded – runs and inward – empty – runs. The vehicle’s considerable deadweight is another key factor. For a truck, therefore, the ratio of overall mass moved, on the one Economic benefits hand, and payload, on the other, is around 2.2-2.6 to 1. By contrast, for a continuously operating conveyance like a Higher efficiency, a major reduction in CO2 emissions belt system, the ratio is just 1.2 to 1. Simply stated, belts are and in energy consumption, virtually no negative impact much more efficient. A belt system’s conveying resistance on the natural environment, and the possibility, under ideal is also much lower than what a heavy truck is up against. circumstances, of generating electric power as well – these are a number of the ways conveyor belt units can serve It comes as no surprise, then, that the specific energy the environment and, at the same time, provide economic requirement for heavy-duty truck transport works out to benefits. A cut in the energy costs incurred would, in effect, 1.09 to 1.17 kW per tonne and kilometer, whereas a belt lower the overall expense for raw material extraction. system gets by with a mere 0.14 to 0.25 per tonne and Following ContiTech AG’s round table discussion, Hans- kilometer, i.e. just a fifth of what a truck needs. Jürgen Duensing noted by way of summary: “This is an aspect that would certainly give mining companies a strong incentive to greatly step up their use of conveyor belt units Reduced CO2 emissions and thus do the environment a big favor.“

Accordingly there are also differences in the amounts of CO2 greenhouse gases emitted. Worldwide, power stations emit an average of 0.285 kg of CO2 per kW generated. 0.293 kg per kW is emitted in the combustion of diesel fuel. “When these values are applied to conveyances in mining,” notes Professor Tudeshki, “a heavy truck can be seen to have a specific CO2 emission rate of 0.331 kg per tonne and kilometer. The corresponding rate for a belt system is only 0.055 kg per tonne and kilometer. The specific reduction potential thus comes to 0.276 kg CO2 per tonne and kilometer.”

What exact conditions must be met to achieve a reduction in CO2 emissions of 340 million tonnes in the next ContiTech Conveyor Technology corporation thirty years? The amount cite represents, by the way, well Breslauer Straße 14 nigh exactly the CO2 equivalent amount that the European 37154 Northeim | Germany Union pledged itself to achieving under the terms of the Tel.: +49 (0) 5551 702 207 Kyoto Protocol adopted in 1997. Professor Tudeshki makes Fax: +49 (0) 551 702 504 one thing clear: “Maximum flexibility is demanded in the eMail: [email protected] mining of raw materials. This means that conveyor belt Internet: www.contitech.de/transportbandsysteme systems will not completely replace heavy-duty trucks.

Issue 03 | 2009 www.advanced-mining.com 32 TRANSFER OF TECHNOLOGY ContiTech conveyor belt systems carry the earth’s valuable resources and protects our planet’s natural richness • Active worldwide • New plant in Brazil • Optimistic look into the future

The demand for raw materials is growing. Experts the generation of energy in downhill transport operations. estimate that the worldwide requirement is growing at an In the case of more comprehensive interconnected average rate of four percent a year. As a manufacturer of systems, ContiTech also cooperates closely with scientific conveyor technology, ContiTech‘s Conveyor Belt Group research centers. business unit participates in this growth and, accordingly, At ContiTech’s booth (A16) in hall 5 at Hannover Messe, views the future quite optimistically. At the same time, the Clausthal University of Technology, for example, is the products developed by the company are climate- and presenting a development for acoustically identifying eco-friendly. “Working with rubber, a material with much material. With the enclosed SICON® conveyor belt, Conti- promise for the future, we create technological solutions Tech, moreover, is showing how sensitive goods can be for industry and the environment,” explains Hans-Jürgen protected from moisture and contamination while being Duensing, general manager of the ContiTech Conveyor conveyed and how spillage and dust emissions can be Belt Group. Here energy-optimized conveyor belts, which prevented. also reduce CO2 emissions, play just as big a role as does With sales of €469 million, the Conveyor Belt Group is

The participants at the RoundTable: • Dipl.-Ing. Ralf to Baben: Head of the Technology Center Mining/HW of RWE Power AG, Frechen • Hans-Jürgen Duensing: Division Manager ContiTech Conveyor Belt Group, Northeim • Dr. Heinrich Sönksen: Head of underground-mininig technique K + S Aktiengesellschaft, Kassel • Prof. Dr.-Ing. habil Hossein Tudeshki: Head of Institute of Surface and International Mining, Clausthal University of Technology Moderator: • Andreas Lorek: Free TV and Radio Journalist

Issue 03 | 2009 www.advanced-mining.com 33 TRANSFER OF TECHNOLOGY the world‘s leading conveyor belt manufacturer and the be transformed into electrical energy – as in the case of second largest of ContiTech AG’s sev-en business groups. a streetcar or a hybrid vehicle,” explains Hans-Jürgen With a current workforce of around 3,000, the company Duensing. manufactures belts for mining as well as special conveyor belts for the most diverse transport tasks in machine and plant engineering. The product portfolio encompasses several hundred offerings. Aside from its standard range, Energy generation in the case of raw the company also develops individually customized material transport solutions. It is thus always in a position to supply exactly the right products to satisfy cus-tomer requirements. In Jamaica, for example, a RopeCon® conveyor belt is in operation hauling more than 1,200 tonnes of bauxite an hour over a distance of 3.4 kilometer and an altitude of 470 meters. The transformation of braking force into Active throughout the world – electric energy yields 1,300 kW. The current is fed into the local power grid. Functioning in much the same way now in Brazil as well as a ropeway, for which reason it requires only a few tower stations, the RopeCon® system is of major benefit Conveyor Belt Group products are in use all around the for the environment. “In Jamaica we were able to save globe. Because of the products’ enormous volume and the tree population by forgoing construction of a road weight, transporting conveyor belts to where they are to for the transport of raw materials,” reports Hans-Jürgen be used can be a very involved and expensive undertak- Duensing. The system makes up for the equivalent of 1,200 ing. For this reason the Conveyor Belt Group produces in truck runs a day and eliminates the corresponding amount the markets in which its customers work – in Mexico, Chile of CO2 and particulate emissions. and China, in India, Greece and Serbia, and in Hungary, “For us it is not only a matter of transporting the world’s Slovakia and Germany. resources but also of protecting our planet’s environment,” Before the year is out the Conveyor Belt Group will emphasizes Duensing. “Responsibility for the environment be stepping up its activi-ties in South America, where a also guides us in the development, manufacture and new plant will be opened in Ponta Grossa in southeastern transport of our products.“ Brazil. At a 5,000 m² facility there, a workforce of ninety will be producing textile and steel cord belts. Brazil is the major South American market for conveyor belt systems, accounting for roughly fifty percent. “Thanks to the new plant and the existing one in Chile, we are well poised to establish a firm foothold on the South American market. Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining Col- We shall greatly expand our market position,” explains lege of Shahrud (Iran); following several years Hans-Jürgen Duensing the business unit’s strategy. of work in the mining industry, he completed his mining study at the RWTH Aachen in 1989. Since 1992 he was Chief Engineer at the Insti- tute for Surface Mining (Bergbaukunde III) of Eco-friendly and energy-efficient raw the RWTH Aachen, mainly active in the field of open cast mining and drilling technique. He did material extraction his doctor degree in 1993 and qualified as a university lecture in 1997. In 1998 the Venia Legendi was awarded to him be the RWTH Aachen for the field “Rock and Earth Open Pit Mining”. In Novem- Conveyor belt systems are the energy savers and climate ber 2001 he was appointed as Professor for Surface Mining and protectors in raw material extraction. This is the conclusion International Mining at Clausthal University of Technology. that the „Efficient Conveyor Technology and Climate He already has over 25 years of experience in the field of project Protection“ study comes to. It will be presented at a panel planning and cost-benefit analysis within the frame of various mine discussion at the ContiTech AG booth in hall 5 at the Messe. planning projects. The international tasks rendered by him mount The study was the brainchild of Dr. Hossein Tudeshki, up to more than 300 international raw material-related projects. professor at Clausthal University of Technology’s Institute of Surface and International Mining. It demonstrates how [email protected] conveyor belts make much more efficient use of energy www.bergbau.tu-clausthal.de and emit considerably less CO2 than the heavy-duty trucks usually used in mining. What is more, conveyor belt units are also capable of generating current. “Wherever raw materials are transported downhill, braking energy can

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ContiTech Conveyor Belt Group | Phone +49 5551 702-207 [email protected]

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Thyssen Krupp Fördertechnik (conveyor technique): Fully Mobile Crawler-Mounted Crushing Plant for Large Open-Pit Mines to a conveyable size. Introduction The crushing plants can be stationary (mounted on concrete foundations) or semi-mobile style, supported on As part of a priority research and development steel pontoon feet. As the mining operation progresses, the project launched in 2006, engineers at Thyssen-Krupp semi-mobile crushing plants can be relocated within the Fördertechnik developed the concept for a fully mobile mine using multi-wheeled trailers or transport crawlers. crushing plant to enhance mining operations in large open Typically, shovels load the ROM ore on to heavy-duty haul pit mines (Fig. 1). The key innovations lie with the unique trucks that transport the ore to the crushing plant and functionality and mobility of the machine which allow it to relocating the crushing plant as the mine expands reduces work along side the mining shovel at the mine face. The the distance that the large trucks need to haul the ore from crushing plant feeds a dedicated belt conveyor system and the working face. the need for large haul trucks is eliminated. The objective of the new development was to totally The use of continuous mining technology not only eliminate the need for trucks by having the shovel feed brings economic benefits in the form of higher production the ROM ore directly to a continuous material handling performance with reduced capital cost (particularly when compared to a discontinuous system using trucks), it is also more environmentally friendly because it reduces CO2 emissions. In a cross- segment cooperation with ThyssenKrupp Steel, the developers investigated the use of high strength steel and utilized liners with special wear properties to provide adequate protection from the abrasive nature of the ore.

Background

The use of continuous mining systems is primarily dependent on the type and properties of the ore being mined. In the case of light and loose earth, bucket wheel excavator technology, combined with a system of conveyors, offers the advantages of a continuous mining system. In order to take advantage of continuous mining in harder ore, such as minerals and hard coal, crushers are Fig. 1: Fully mobile crushing plant for an open pit coal mine in China required to reduce the ROM ore

Issue 03 | 2009 www.advanced-mining.com 36 TRANSFER OF TECHNOLOGY system. The crushing plant would Fig. 2: need to be fully mobile such that Feed hopper and skirtboard lined it could follow the movements with XAR®400 wear of the shovel, would have to be resistant plates designed to suit the movement of the shovel boom and bucket and would have to match the operating capacity of the shovel. To achieve this result, ThyssenKrupp developed a fully mobile crawler-mounted crushing plant which allows for continuous material handling while providing an economical solution not yet realized in a high capacity mine.

Cross-segment improvements in material use

Possible changes and improvements to the fully mobile open-pit mining system were investigated at an early stage in the priority project and various products produced by ThyssenKrupp Steel were reviewed and analyzed. A common approach to reducing the construction weight of the supporting structural steel work is to use higher strength steel. To optimize the heavy components, it was found that further benefits could be realized by utilizing special alloy fine grain structural steels. in China, the customer was convinced by the advantages offered by wear-resistant XAR®400, a special purpose structural steel manufactured by ThyssenKrupp Steel The know-how possessed by ThyssenKrupp Steel, along (Fig. 2). When working with hard rock, XAR®400 offers two with valuable feedback from the employees at ThyssenKrupp to three times the expected life compared to conventional Marine Systems, resulted in employing structural steel in steel. ways that could improve those components not governed by fatigue, such as the large crawler assemblies. The demand for abrasion resistant wear materials Customer benefits increases with highly abrasive ore. There is a definite benefit to employ wear resistant steel where load bearing members must be protected against abrasion caused by continuous High level of system availability direct contact with the conveyed materials. In a fully mobile Conventional shovel / truck operations in open-pit crushing system, typical high wear areas are the hopper, mines leads to loss of efficiency due to the discontinuous chutes and feeder skirtboard. For the referenced facility transportation of the ore because the shovel needs to wait

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Fig. 3: System chain shovel – fully mobile crushing plant – mobile transfer conveyor – bench conveyor

for the loaded truck to leave and for the empty truck to spot examples. itself beside the shovel. Depending on the number of trucks Thanks to the overall saving of a truck operation, savings available, the shovel waiting time can be a few minutes of the large truck tires is another benefit. Compared to or more per truck. In contrast, the fully mobile crusher is the rubber necessary for belt systems, for comparable always positioned next to the shovel meaning that shovel transport systems the rubber is reduced by up to 95 %. operation is not interrupted. Ideally, the crushing plant is as mobile as the shovel such that neither has to wait for Use of a continuous system each other as they advance along the working face. The crusher comminutes the ore to a conveyable size In many cases, the replacement of a truck transport and discharges to a system of shiftable and fixed mine system with an innovative fully mobile crushing system conveyors. To increase the flexibility of the system a short forces customers to think of other technology that they can mobile transfer conveyor can be added to the system (Fig. use to make their systems more efficient. ThyssenKrupp 3). Fördertechnik has a broad range of products for such In most cases, existing cable shovels or hydraulic needs, extending from long overland conveyor systems, excavators can be used if a mobile crushing plant replaces stockyard equipment, ore process plants, train loading and the truck fleet. The hopper height and geometry is similar unloading systems as well as port facilities. to the truck box so the shovel operation is similar if loading trucks or the mobile crushing plant. Long life expectancy extending in some cases to several decades A characteristic feature of continuous open-pit mining Lower operating costs technology is the long life expectancy. The large number A mine based on truck haulage requires a large of such examples includes the in-pit crushing system number of drivers and support staff while a continuous at the Morenci open-pit copper mine in the USA which style operation allows customers to reduce personnel commenced operations in the late 1980’s. Another example without affecting production output as only 3 to 4 workers is offered by the open-pit mining facilities and equipment are required per shift to operate and control a crusher / employed by RWE in the Rheinish lignite fields. conveyor system. In addition to saving wages and wage related costs, customers can reduce their safety related costs as well. One of the hidden benefits of the continuous After Sales Service system is the fact The expected long life noted above yields a positive that the scarcity of tires for the large haul trucks image and provides the potential to create long-term becomes a no issue. Further, it is common for large mines customer loyalty with regards to repeat business and after to utilize trucks from several manufacturers and the sales service. expense involved in stocking duplicate spare parts can be considerable while the spare parts inventory for a crusher / conveyor system can be tailored to meet the clients exact needs. Cost savings for customers

Efficient use of capital Environmental considerations Due to the high system availability previously mentioned, Fully mobile crushing plants with conveyors operate a continuous system directly contributes to the efficient use exclusively with electrical power which leads to the overall of invested capital. Associated with this is an increase in CO2 balance favoring a continuous mining system over the the capacity utilization of the shovel or hydraulic excavator diesel-powered haul trucks, as illustrated in the following and the downstream process equipment.

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Reduction of operating costs Because fewer employees are needed, ongoing operating costs are reduced not only as a result of lower personnel costs, but also with regard to safety. The ratio of each ton of extracted mineral to applied cost is optimized through the decreased cost of wear parts, the standardization of spare parts, and, above all, the elimination of truck transport and the associated significant reduction in diesel and tire costs. Fully mobile crushers can attain hourly output rates that could otherwise only be achieved with a large number of large mining trucks. These trucks have useful payloads of between 140t and 350t and the tires need to be replaced, on average, once per year. Depending on the size of the truck, a set of six tires currently costs between € 90,000 and € 300,000 and delivery can take up to two years.

Innovation and degree of implementation of fully mobile crushing plants from TK Fördertechnik The high degree of innovation is characterized particularly by the following: The primary features are the plant’s degrees of freedom in combination with a single slewing discharge conveyor as well as the arrangement of the supporting structure. The large machine is supported on the two crawlers without the need for additional supports, thus providing for a “true” fully mobile crushing plant. In the fall of 2007, the first fully mobile crushing system commenced operation at the YiminHe open-pit mine in China. The crushing plant processes ROM coal at a rate of 3,500t/h. Fig. 4 shows the crushing plant while being relocated from the assembly area to the mine face while the continuous conveyor system is visible in the background.

Fig. 4: Reference plant in China on its way to its operating site

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Fig. 5: Winter operation in temperatures down to -48° C

Once commissioned, the fully mobile system was able to demonstrate in harsh winter conditions – in Inner Mongolia down to -48° Celsius – that with optimum operation of all system components, the required production rate is met. Heating plates installed at the receiving hopper guarantee the trouble-free discharge of the coal from the hopper by the apron feeder (Fig. 5).

Another plant will be supplied by Krupp Canada, a subsidiary of ThyssenKrupp Fördertechnik, in the near future and will go into operation as the first fully mobile crushing plant operating in the oil sand mines of Northern Canada. Recently, the company has signed a contract with another Chinese customer, in this case for the supply of four fully mobile crushing systems, three for handling overburden at an hourly nominal capacity of 6,000 tons. Figure 6 shows the existing open pit coal mine preparing for the future conveyor technology with fully mobile crushing plants.

Fig. 6: Open pit coal mine Baiyinhua – In preparation for conveyor technology

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Worldwide market potential Summary

The continuous crushing system has worldwide market The newly developed concept of a fully mobile crawler- potential particularly in the area of mining for coal and oil mounted crushing plant has already proven successful in sand. Not least the economic boom of China and India is worldwide surface mining. resulting in a rising coal demand in the Asian-Oceanic The innovative feature of this new concept is the facility region. for moving the crusher during operation, guaranteeing The fully mobile concept can conceivably be utilized in flexibility and mobility. In combination with a continuously all mining operations where a shovel can excavate the ore operated conveyor, the entire truck transport that would directly at the face, with our without blasting. otherwise be necessary is eliminated. For large open pit ore mines, which on account of A first reference plant has been successfully operating the deposit characteristics mainly extend downwards, now for almost one year in China, working at full production potential applications are currently being examined. rate since the first day. A second plant is soon set to go Compared to coal and oil sand mines, which typically have into operation at a Canadian oil sand producer. relatively wide benches, the planning and realization of a In addition to the cost savings to the customer, the fully fully mobile concept in an iron ore mine is com-plicated mobile crushing system has huge potential for reducing by the chiefly vertical alignment of the deposits. The fully operations related CO2 emissions providing a greener mobile system, however, promises considerable savings footprint. in capital and operating costs and it is very likely that a solution can be realized.

Environmental Contribution of the CO2 Reduction ThyssenKrupp Fördertechnik corporation Altendorfer Str. 120 Accompanying the development of the fully mobile 45143 Essen | Germany concept, potential CO2 emission savings were examined Tel.: +49 (0) 201 8 28 04 based on the use of a fully mobile crushing system Fax: +49 (0) 201 8 28 45 10 compared to conventional shovel truck operation. The eMail: [email protected] result was CO2 reductions of up to 100,000 t per year. Key Internet: www.tk-mining.com factors contributing to CO2 reduction are lower transport distances, lowering of the masses and rolling resistances as well as the utilization of electric energy. As an example, in China a fully mobile crushing system with associated conveyors replaced about 26 large haul trucks. The mining trucks consumed about 190 liters of diesel for every hour of operation. Considering that annual production remains constant and factoring in the higher availability of the continuous system, the diesel fuel savings amounted to 22 million liters per year leading to a favorable carbon footprint for the continuous system. Another environmental consideration is the savings in rubber that can be achieved. In the scenario just described, the expected life of the conveyor belt is 8 years and, comparing this to the tire needs of the 26 trucks over the same time period, a savings of 400 t of tire rubber could be realized.

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VOLVO CONSTRUCTION EQUIPMENT: VOLVO FLEET UNDER GROUND - All Good Things Come From Above

In a genuine logistic work of art a transport chain, consisting of Volvo-construction machines, spectacularly arrive at the lowest point of Europe. How can the extraction of a big underground mine receive new impetus? How can productivity and delivery rate be increased? Actually the answer is obvious: through the application of an effective Volvo transport chain. However, in this case, this is easier said than done. The reason is that the construction machines we are talking about – two L110E and four articulated dumpers A25D (4X4)- cannot just roll into the drift system of the potash mine and start their work. Rather, all six Volvo-construction machines have to be taken apart and be lowered piece by piece into a narrow material pit of only five meters. Such an enterprise required a lot of know-how, an extensive planning, and an elaborate logistics. After all, the re-assembling of the dismantled machines “down” in the mine was to be done in narrow and difficult circumstances, including the test-run and test-application. In addition, numerous modifications were needed to adapt the Volvo-standard machines to the extreme conditions in the mining operation. For this reason the experts of Volvo CE came together with the appointed dealer of “Baumaschinen Könicke GmbH & Co. KG” and the “K+S KALI GmbH”, Sigmundshall plant, in order to work out a very special logistics concept. Furthermore the delivery of the underground mining fleet meant a rearrangement of mining and extraction techniques of the mine, which required further detailed planning.

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After all, each one of the four A25D (4x4) has a payload capacity of 24 tons. This is double the amount of a tractor shovel. Being a compact and versatile articulated dumper, the four-wheeled A25D (4x4) that has a broad rear wheel track, a 13m3 shovel content and up to 53 km/h speed, is also suitable for quarries and other extraction operations. However, under ground, the speed is limited to a maximum of 35 km/h. In special cases, the vehicle is adapted to specific application profiles like for underground mining; in this case it was equipped with a low driver’s cab. The Volvo low-emission motors of the dumpers efficiently use the fuel and achieve high engine torques at low number of revolutions. A board computer controls the automatic transaxle, so that an exact adaptation to driving conditions can be done at any time. Thus fuel savings in the planned inclination drives with load should be ensured. A loaded A25D, which weighs up to 44 tons, cannot exactly be called a slight vehicle. Actually it is 3.13 meters wide and 8.9 meters long over its outer edge. Whether it was the The K+S KALI company breaks new grounds with its application of rear end of a wheel loader, or one half of the the Volvo- construction machines in underground mining. The aim is split shovel, there was always too little space to give up complicated customized constructions resulting from the available to lower the components, which use of wheel loaders and dumpers, and to use well-proven standard were split to a an exactly defined maximum machines of high quality instead. size, as well as the assemblies of the Volvo- Among the factory-owned modifications of the Volvo equipment are construction machines. They all had to be a lower driver’s cabs, axial oil cooling, fire extinguishing equipment, lowered to a depth of 940 meters into the coolers, air filters and air conditioners with higher performances, as “Kolenfeld” pit. There was no room for any well as other details for underground operation. It has to be taken into bad planning. consideration that the equipment has to operate in depths of 1,400 m The disassembling of six big construction and below, and in rock temperatures of 40 to 60 degrees Celsius – and machines, the “just-in-time” delivery at the all this in very dust-laden pit air, in three shifts and for 7 days a week. mine, which was according to schedule, The responsible parties hope that the construction machines have the sequential fitting of all components and significantly higher extraction- and transport performance than the so assemblies into the material pit, and lastly far used 17 tractor shovels, with shovel capacities of only 12 to 17 tons. the assembly under narrow and difficult circumstances under ground, all these require an extremely precise logistic, which runs like clockwork. In collaboration with the plant management of the Sigmundshall plant, the specialists of the Volvo-authorized dealer of construction machines set themselves a tight timeframe: The disassembly, delivery, the fitting in the Kohlenfeld pit, the assembly under ground, as well as the first test-runs were to be completed within only six weeks. What appeared to be relatively daring and delicate, in reality proved to be excellently planned and optimally prepared: Under the leadership of Hanno Schoene - in charge of service and assembly at Koenike – and the

Issue 03 | 2009 www.advanced-mining.com 43 TRANSFER OF TECHNOLOGY underground mining-engineer Dr. Jan Tegmeier of the Sigmundshall plant, the disassembled construction machines took shape almost one kilometer under ground, exactly according to the timeline. Why should conventional construction machines be used in the Sigmundshall plant instead of the so far used tractor shovels? “Proven and tested serial machines offer numerous advantages over small series engine like tractor shovels. This is not only related to the availability of spare parts, but also to the service”, Dr. Tegmeier explains. “We have found a clear-cut solution with “Baumaschinen Könicke“, he adds, “our workshop personnel on the 940 m brine is already running at full capacity. Therefore we have agreed with Könicke on a full service program. This includes Volvo machines. In case you believe this is too an 85% contractually committed availability of little: under ground an availability of 85% is very high, Dr. Tegtmeier explains. However, through the application of wheel loaders and dumpers the personnel expenses by no means are doubled. The reason is that only one driver will operate both the L110E, as well as an A25D (4x4), alternately. When times of circulation amount up to 20 minutes, the waiting time for the drivers will be too long, and he can also be assigned to a articulated dumper each. During application, the equipment has to defy the most difficult circumstances. Most of all, the extreme temperatures and the high dust formation can be mentioned. Within the framework of the full-service program the service technicians of Baumaschinen Könicke will attend to all emerging services on site in the fully equipped main repair shop on the 940 m brine. The flexibility, with which Volvo CE altered the machine fleet to the desired low-height construction deserves special

Issue 03 | 2009 www.advanced-mining.com 44 TRANSFER OF TECHNOLOGY acknowledgement: Through special low-profile driver’s cabs the L110E were “shortened’ from a height of 3.36m to 3.09 m, the dumpers were even lowered to only 3.05 m. Dr. Tegtmeier is full of praise and says: “This is really not seen everywhere. According to our knowledge no other manufacturer offers wheel loaders in low-height construction”. In this connection it is even possible to define some new terms: If someone calls these wheel loaders and dumpers construction machines, he does not really get the point. In fact, these modified specialists that are applied around the clock are no construction machines any more. They can therefore safely be called high-performance underground construction machines.

How did the salt get under the earth? Whoever drives through the landscape west of Hannover, who might want to visit the beautiful lake, the “Steinhuder Meer”, can hardly imagine that the enormous salt dome “Bokeloh” is located up to 3.5 km under this landscape and extends itself in a length of twelve kilometers and a width of 1.4 km. The question that arises is: How could these unimaginable salt masses get under the earth? The conditions under which this salt was formed, have to date not been definitely clarified. Besides other scientific theories the so- called BARREN theory is believed to be the most likely. 250 million years ago, in the coal-mine-stone age (ZECHSTEINZEIT), central Europe was mainly covered by a marginal sea. Shallow straits – called BARREN- separated the inland sea from the open ocean. In those times a desert-like climate prevailed, even in our latitudes. Due to the strong solar radiation, the water of the inland sea evaporated like in a giant pan. As a result the salt content of the water was increased, until the solute minerals crystallized and formed potassic layers. Thus several hundreds of meters of huge sedimentations were formed; they were covered by water- impermeable layers during the further geological development and therefore protected from being dissolved again. Therefore the raw material from the salt dome is counted a natural product, which was created by the heat of the sun from pure sea water.

At the lowest point of Europe The potash and magnesium products of the K+S KALI GmbH are being exported globally and are mainly used in agriculture and the industry, either for the production of fertilizers or in chemistry. The K+S group, to which the Sigmundshall plant belongs, globally belongs to the top flight of the suppliers of special and standard fertilizers, plant protection/-care and salt products. In the global potash production scale of 2006, the K+S group occupied the fourth rank with 6.7 million tons and a total share of 13 percent. The enterprise is continuing on the road to suc- cess: In the second quarter only, their sales volume increased by eleven percent at 778,6 million Euros, this is 78.5 million Euros more than in the previous year. Above all the global strong demand for potash and nitric fertilizers has contributed to this result. Visitors, who drive in a conveyor cage into the old-established Sigmundshall mine (located near Wunstorf close to Hannover), are mostly amazed because they see one of the biggest potash mines of Europe. Annually 778 employees extract more than 2.8 million tons of raw salt. Between the six main brines that lie between 350 and 1.400 m, a gigantic transport network, which is already longer than 250 km, has been formed. On the lower brine you are at the lowest point in Europe: The walls of the mine hall emit temperatures of up to 60 degrees Celsius, a fact that makes extreme demands on both man and machine. The reason for this unusual heat for this depth is the salt dome, which has set itself vertically in the past. Since salt is a good heat conductor, the high temperatures of the interior of the earth descend into the mine and as such into the mine openings.

Salt has been extracted for more than 100 years in the Sigmundshall plant. The first pit drilling was done in 1898, extraction started from 1905. The value and the economic worth of the potassium salt were only recognized mid of the 19th century. The chemist Justus von Liebig discovered the worth of the carelessly stashed away potassium salt as fertilizer for the agriculture. At that time, the booming expansion of the potash mining promised lucrative profits not only to the mine operators, but also opened a welcome source of income. The dimensions which the mine has to deal with can be shown alone by the ventilation: In the widely ramified route system the amount of 22.000 m3 fresh air is delivered. This air supplies and cools the workplaces of 422 men under ground.

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Volvo-construction machines in a coil

The new Volvo fleet is to work in a coil, which is to be driven into further depths. The 1,800 meter long coil, in which the dumpers carry their load on an inclination of 16 percent, leads them to one third through useful material and to two thirds through rock salt. In increasing depths, separate intermediate levels are dirft in useful material, as five to seven meter wide roads, up to a length of 800 meters and tangentially continuative from the coil. It is there that the two L110E and A25D (4x4) are loaded. Here considerably higher extraction and production performances can be expected. The so far used tractor shovels, which are difficult to maneuver, are inefficient for transport distances of over 400 m. Due to the fact that the visibility conditions of the tractor shovels are neither ideal over the shovel nor the engine hood, in the future the drivers will be in a much better position to work better, more secure and more speedy. Due to its compact design the A25D (4x4) has a curve inside radius of only 3.2 meters, despite its high payload. This is ideal to cruise the seven meters wide gallery of the coil. It is important to note the unique characteristic of the underground version of the A25D (4x4): It can always cruise the coil forward, therefore the driver has an optimal sight. The articulated dumper has a patented reversing device, which has been developed by the Volvo engineers, and with which it can turn 180 degrees in a gallery width of 9.5 meters in only 25 seconds. Through a supported traverse that can be hydraulically lowered, the empty or even loaded rear end can be lifted. In case the articulated joint is activated with blocked front wheels, the rear end rolls over on two wheels which are located under the supporting traverse, to the maximum possible kink angle of the frame, making it possible to turn- over in the narrowest space. Further advantages of the Volvo-dumper: With increasing length of galleries the time of circulation of the dumper can more than double and thus halve the extraction performance. Then more articulated dumpers have to be used, and care has to be taken that they come across each other without colliding, therefore they have to ensure optimal view for the driver. Furthermore the dumpers have to fit into the curved roads of the coils, together with the vital air tubes (big, long, flexible hoses for ventilation). Furthermore the rims should not be too high, so that there is

Issue 03 | 2009 www.advanced-mining.com 46 TRANSFER OF TECHNOLOGY enough room for the wheel loaders under the stick-ridge for quick loading. And lastly the shovel should also not be too long, because otherwise it would use up too much space over the underground crusher plant while tilting.

Shift in Direction in 25 Seconds! Thanks to a patented turnover-device, the A25D (4x4), it can turn 180 degrees in less than half a minute and in a width of only 9.5 meters. Only a width of 9.5 meters is required, so that the A25D (4x4) turns 180 degrees in a three-step maneuver. The turning wheels are operated hydraulically from the driver’s cab and lift the empty loading unit in way that the steering hydraulic can swing the loading unit for 90 degrees.

On 17 Juli 2006, Walter Michels, the Volvo CE Europe Company, met for an initial conversation with Dr. Jan Tegtmeier from the K+S KALI Company. Shortly after he visited the Sigmundshall plant, together with Erich Kribs, Volvo CE Europe GmbH, and Dirk Rinne (area manager Nord Baumaschinen Könicke), in order to get a first hand impression of the local circumstances. The aim was to exactly determine the passage height and width, as well as to consider the entire routing and the extreme temperatures deep inside the earth for their project planning. Is the driver’s cab of a conventional Volvo-dumper of type A25D low enough?

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Will the entire electronics bear up to the aggressive surroundings? Is it technically possible at all, to cope with the standard equipment of Volvo? These were only some of the many questions, which needed to be answered. Erich Kribs prepared a drawing, in order to determine the exact special circumstances. Walter Michels, Hanno Schöne (Könicke) and Scelder Clas Schwarze (Könicke) visited the Swedish Volvo-plant in Braas, in order to monitor the taking apart of the modified dumper

1. Zum Wendeplatz vorfahren, mit Zugeinheit bis zum vollen Lenkeinschlag schwenken und die Bremse eingedrückt halten.

2. Ladeeinheit anheben und maximal 90 Grad einschlagen.

3. Ladeeinheit absenken und vom Wendeplatz aus zurück- setzen.

in separate parts and arrange for the consecutive transport to Germany to Baumaschinen Könicke. The modified dumper had a heightened and elongated shovel (15.5 m³).

The four articulated A25D, whose maximum speed was reduced to the 35 km/h, which is prescribed under ground, all have special Goodyear tires. The motors of the dumpers were also specifically certified for Erich Kribs. The two A25D, which are being used in the roadheader (WAV), possess a turning device. The other two,

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which are en route in the coil, do not need this.

“It was clear after the first conversations and the visit to the pit that planning and implementing this project would be a huge challenge. But through the intensive cooperation of all involved parties and the well though- out logistic we managed to bring the slightly modified construction machines to the desired location and prepare them for the challenging application.“ Walter Michels, Sales Engineer Hauler & Loader Business Line.

“With this unique project of K+S KALI Company, the Vovo CE, the Volvo certified dealer Könicke Baumaschinen, as well the responsible staff of K+S have entered completely new grounds. This big challenge could only be met with a constructive and highly efficient cooperation between the Volvo-plants, the Volvo CE Europe GmbH, the Könicke Baumaschinen GmbH and K+S“ Erich Kribs, Sales Engineer Volvo-Radlader.

Issue 03 | 2009 www.advanced-mining.com 49 TRANSFER OF TECHNOLOGY Methods of Boulder Crushing in raw materials production by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki | Dipl.-Ing. Tao Xu Surface Mining and International Mining | TU Clausthal | Germany

number of boulders accumulate, in order to avoid disturbing Introduction the operations and conducting a concentrated special operation. Based on the amount of boulders they can be Oversized rocks, which emerge during mining of mineral crushed in-house, or the service can be outsourced. raw material, are called boulders. The geometrical size and frequency of occurrence of boulders in excavated material are determined by two main factors the evolutionary history of the mountain on one hand, and the technology of extraction on the other. Methods and Appliances of Boulder Boulders are usually found in accumulations of loose rocks, which have sedimented in a relatively short distance Crushing from the previously weathered block of hard stone. Such circumstances are encountered in glacial and fluviatile Autogeneous Crushing sediments. A further frequent manifestation is the deposits In autogeneous crushing one boulder is lifted by a loading of dumpings in slopes and mountains. device and is dropped on another boulder. Compared to In areas near to the surface of hard rock formations, the following methods this method only frees relatively low boulders that are formed through weathering appear; they forces, as only gravity, in connection with the net weight of have volumes of up to several cubic meters. In deeper the material, act as components. In addition, this technique mountain zones, which are less affected by weathering, is limited to boulders that can be lifted with the bucket of tectonically-related slicks in form of disturbances and clefts, the loading device. Furthermore it cannot be influenced, as well as stratigraphically related inhomogenities assume which boulder is crushed to which degree. a major role in the formation of boulders. Furthermore the type and quality of the blasting technique in open cast mining has a significant influence on the number and size Drop Ball of emerging boulders. Drop balls are often used in quarries for secondary Boulders reduce the performance of loading equipment, crushing. In this simple method an iron ball of several due to low filling of the shovel. In extreme cases boulders are tons weight is lifted by the loading device and dropped on too big for the shovel. In the latter case a time-consuming the boulder that is to be crushed. The impact of the ball sorting of the rock pile needs to be done. Consecutively produces stress peaks in the boulder, which spreads with the separated boulders need to be crushed up separately. various speeds and lead to crushing. Big, loadable rocks can lead to damage of the loading The drop ball usually has a weight of 3 to 9 tons, with a area/shovel during loading of the transport vehicle. At the diameter of 1 to 1.3 m. Along the lines of the autogeneous primary crusher, boulders bring about a reduction of the crushing, in this method potential energy is transformed to throughput and can even lead to the complete obstruction kinetic energy. In case the drop ball is lifted to 3 to 5 m above of the plant. the boulder, approximately 90 to 450 kJ potential energy It is for this reason that extraction businesses strive is accumulated in the ball. In free fall the accumulated to avoid or at least minimize occurrence of boulders. potential energy is transformed into kinetic energy and Nevertheless these blocks more or less emerge in upon collision with the boulder, it is released as destruction almost every hard rock opencast mining. Therefore the energy. boulders that emerge during the loosening process have Due to its simple structure, crushing with the free-fall to be crushed prior to the loading process. For this further ball is a particularly low maintenance method and needs crushing, methods such as autogeneous crushing, drop little repair. However, in highly abrasive material there is ball, buster or hydraulic breakers, as well as explosives a possibility that a pronounced wear-out can occur on and boulder busters are applied. In the current document the ball, which then looses weight and at the same time these methods are introduced, and their advantages and efficacy, due to the abrasion. disadvantages, as well as their areas of application are An efficient application of the drop ball can only be compared. achieved with a face shovel dredger with a clamshell, The commonality of all methods is the fact that since only this type of dredger can grasp the ball and, boulders initially have to be uncovered and separated. what is more important, can vertically drop the ball. Back- The secondary crushing is usually done when a sufficient actor dredgers or wheel loaders have difficulties in loading

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Pic. 1: Face shovel dredger with free-fall-ball the ball, as there is the possibility of inadvertent rolling. support frame (usually backactors) which supplies them On the other hand, due to the rolling of the ball up to the with hydraulic energy. The high pressure oil affects a cutting edge, there is always a horizontal component with pressure reservoir (e.g. a nitrogen accumulator with a a resulting bent falling curve, which makes an exact hit membrane), that in turn abruptly releases the pressure to difficult. the subjacent ram of the air hammer. The oil then flows In principle there is a danger of an uncontrolled rolling back again through the output pipe from the hydraulic of the ball after the collision. This leads to the fact that the breaker to the support frame. loading device cannot perform while standing, but often The energy of the ram of the air hammer is transferred has to be moved unproductively. to the plug tool, the bit, and through that it is transferred to During the collision of the ball there is the danger of the material to be crushed. For different material, different chipping and flying rock splinters. Therefore the front plug tools are used in form of single-point thread chaser, screen of the driving cab of the dredger needs to be chipping chisels, or blunt chisels. equipped with a protective device (grid). Furthermore it The forward motion of the chisel through the socket has to be ensured that no other persons are present in the is detained by a holding wedge in the lower area of the danger area. hammer. In order to avoid damage to the holding wedges A very import role in bouldering with drop balls is and the socket, the hammer should not be idly operated, assumed by the operator, since the efficiency of the stroke i.e. without stroke resistance. is dependant on the marksmanship of the ball. The same The hammer mechanism is usually embedded in a closed, applies to the stroke frequency, which can reach up to damped casing, in order to absorb noise and vibration. 6-times per minute by experienced operators. This casing is usually wider at the top, since there the The advantage of applying the drop ball is that no more hammer mechanism, the hydraulic control, as well as the technical equipment is needed. Furthermore it is possible distribution is located, and narrower at the bottom, since to use idle time of the loading device for bouldering, so that this part is only needed for the sliding of the chisel through the method is often a cost-effective alternative. the socket and the lock-axis. For the operation of a hydraulic breaker it s necessary on one hand to rightly adjust the hydraulic pressure (in Bar), and on the other hand the correct adjustment of the Hydraulic Breaker oil flow (in l/min) in the hydraulic system of the support Hydraulic breakers are also often used in boulder jobs. frame is necessary. Furthermore attention has to be paid to They are attached as accessory equipment on a suitable the oil temperature and the counter pressure on the reflux

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oil pipe. Globally there are many manufacturers of hydraulic breakers. Both the dimensions, as well as the areas of application keep increasing. Meanwhile the large equipment classes are seen as economical alternatives to blasting in the explosive-free extraction of rocks, and as such they are not only been applied in the secondary crushing, but also in the primary crushing. In Bauma 2007, Atlas Copco presented the 10 ton hydraulic breaker HB 10000, and as such, after over a decade, replaced the HB 7000 (7t), which had been the biggest serial hydraulic breaker up to that date. The new breaker requires a minimum excavator weight of 85 t. Envisaged application areas are direct mining in quarries and the heavy retreat. The frequency can be regulated between 250 and 380 hits per minute. Based on specifications provided by Atlas Copco, the breaker, which has a chisel diameter of 240 mm, achieves an impact of 16 kJ and 760 t respectively. Attached to a Komatsu PC1250, the new HB 10000 reached 50% higher excavation rate in comparison with the HB 7000. The technical data of the model range is depicted in the following table:

Pic. 2: Heavy hydraulic breaker as accessory equipment on a hydraulic excavator

Pic. 3: Hydraulic breaker at the crushing of boulders in hard rock mining

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Buster A buster is a tool, with which the stroke impulse is created by the by the free fall of a weight, which is directed in a pipe. Currently two different models are offered, which are explained in the following. The buster is accessory equipment for backacters, whose active principle is based on a drop weight, in analogy to the drop ball. The weight, which can be over 10 tons, is conducted in free fall on the rock to be crushed in a tube. Contrary to the drop ball this hit can be directed to an inch, by the boom of the excavator. The buster is connected to the hydraulic circuit of the support frame. The redirection of the falling weight to its initial position is done after the stroke through a hydraulically operated appliance.

Pic. 4: Technical data of HB hydraulic breakers of Atlas Copco

HB Hydraulic breakers HB 2200 HB 2500 HB 3000 HB 4200 HB 5800

Category of the support t 26-40 29-43 32-50 42-75 55-100 frames

Service weight kg 2200 2500 3000 4200 5800

Oil flow rate l/min 140-180 170-220 210-270 250-320 310-390

Operating pressure bar 160-180 160-180 160-180 160-180 160-180

Number of blows /min 280-550 280-550 280-540 270-530 280-460

Plug tool mm 150 155 165 180 200

Thanks to technological developments, much can be expected from the hydraulic breakers of the heavy range: Pic. 5: “Stone- and Steel- Buster“ from Fractum Company • Maximum performance and highest productivity • Robust layout and high durability • Optimum Energy conver- sion and excellent run- ning smoothness • Consistent impact ener- gy, independent of the oil supply of the supporting frame

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The energy which is generated in free fall is conveyed through a icone point to the boulder which is to be crushed. Based on the type, hardness and size of the boulder differently shaped cone points from steel are available. They are easily to be exchanged, without having to change the entire drop weight. Compared to the drop ball, a buster reaches a higher number of strokes of 6 to 20 strokes per minute, according to the building dimension. The “stone and steel buster”, which has been developed by the Fractum Company from Switzerland, is specially suited for the effective crushing of big concrete elements, rock blocks and slags. It is the biggest hammer in the world and can unleash energy of up to 400 kJ with each stroke. The stone and steel buster, which has a weight of up to 15 tons, can be attached to almost any commercially available dredger; however with increasing size of the buster bigger support frames are needed. The assembly is done in one hour only. The technical data of the series developed by Fractum company can be reviewed in the following table.

Pic. 6: Technical data of the series by the Fractum Company Model Model 80 Model 100 Model 200 Model 400

Energieniveau [J] 80.000 100.000 200.000 400.000

Gewicht [t] 4,5 5,5 10 14,5

Hydraulik-/Öldruck [bar] 180 180 215 290

Hydraulik/Ölfdurchluss [l/min] 160 160 200 260

Min carrier-stick mount t 23-27 30-35 50-60 65-70

Min carrier-boom mount t 20-23 25-27 35-40 50-60

The “stone and steel buster” is particularly suitable for oversized boulders, since it pass the strokes in a quick sequence into the rock and as such can create a crack (see picture7). A second version of the free fall hammers are the so-called crash-crushers of the TERMINATOR-series, which were developed by the ROCKTEC Ltd. company from New Zealand. Contrary to the stone and steel buster, the free fall weight itself does not collide with the boulder, but the kinetic energy of the drop weight is conveyed to the rock through a chisel. As such this technology combines the mode of operation of the free fall hammer with the hydraulic breaker. The dimensions of the TERMINATOR series are smaller than the ones from the „stone and steel buster“. The weight of the device is only up to 8 tons. They offer a single stroke energy of up to 100 kJ (RX750). The shock crushers can strike every three seconds (RX100) and five seconds (RX750) respectively. Accordingly even bigger rocks can be crushed within one minute.

Pic. 7: Crushing of an approx. 150 t basalt boulder by a “stone and steel buster 200”

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Pic. 8: Composition and mode of operation of the TERMINATOR of ROCKTECH company

Technical data RX 100 RX 200 RX 300 RX 500 RX 750

Power of impact per [Nm] 13.500 27.500 38.000 62.000 100.000 stroke Number of strokes per 20 18 15 12 12 minute Weight without support and quick die change [kg] 1.265 2.020 3.345 5.100 8.350 equipment

Required pumpage [l/min] 80 130 130 160 250

Hydraulic operating [bar] 125 160 125 160 160 pressure Diameter of the beating [mm] 100 125 150 180 195 chisel Total working height of the [mm] 4.360 5.500 6.000 6.370 6.780 Teminator Minimum weight of the dredger (Assembly on the [kg] 8000 12000 17.500 30.000 40.000 boom) Minimum weight of the dredger (Assembly on the [kg] 10.000 18.000 22.000 38.000 60.000 Pic. 9: oscillating motion boom) Technical data of the Minimum weight of the TERMINATOR [kg] 7.500 15.000 18.000 30.000 40.000 wheel loader

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Blasting of Boulders drilled holes. The cartridges to be applied are the same for Besides the above-mentioned special technologies, both impulse tubes. it is also possible to apply explosives for secondary crushing. In principle however, blasting of boulders leads to considerable noise emission and there is the danger of flying rocks. In order to reduce the danger of flying rocks, each rock to be crushed has to be measured separately, so that an exactly adjusted amount of explosives and positioning can be reached. Blastings of boulders are divided, based on type of fitting of the explosive on the rock:

• With applied load • Blasting in a borehole.

In boulder blastings with applied load the explosive charge is applied flatly on the boulder and ignited. This type of boulder blasting is quick and easy, however it has the disadvantage of high noise emission and high consumption of explosives (low effectiveness). Compared applied load, in boulder blastings with borehole, only 30% of the amount of explosive charge is needed. Here the effectiveness is increased, while at the same time there is lower noise emission compared to applied load. The explosive is applied into the previously a drilled bore holes, where the explosive effect unfolds directly in the boulder. The disadvantage of this method is that the bore holes usually have to be drilled manually, so that there are considerable mechanical, temporal, as well as personal additional expenses. Theoretically the blasting method has no limitation of use, since the size and position of the boulder to be blasted, as well as the type of rock only play a secondary role in this method. However, the boulder blasting method has progressively become less important, due to the high cost of labour, the difficult drilling per hand, the environmental disturbance and the danger of flying rocks. As a result, the above-mentioned automated methods are increasingly used. b Boulder Buster Besides the blasting, the „boulder buster“is another method that works with usage of bore holes. However, in that case, a so-called hydrodynamic impulse is applied instead of explosives. As portrayed in picture 11, the boulder buster is a portable device. Its function is similar to a shotgun. A specific cartridge can be loaded into the boulder buster and ignited. In principle the boulder buster consists of an impulse tube, a sealing body and an ignition unit, as well as of an additional safety mat (see picture 11). For transport and storage, the components of the buster can be packed in a suitcase. Two different impulse tubes with diameters of 26 mm and 34 mm can be used, based on the size of the c

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d e Pic. 10: Boulder blasting: Measurement, drilling, loading, blasting and check-over (Pic. a, b, c, d, e)

Pic. 11: Boulder Buster and its schematic design

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a b

c d

e f

g h Pic. 12: Steps of procedure of boulder crushing with boulder buster (a – h)

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Picture 12 shows the procedure for the application of the boulder buster. In order to prepare the boulder to be Conclusion and System Comparison crushed, a bore hole is drilled in its middle (a), which is The so-called boulders, i.e. oversized rocks, can be found consecutively filled with water (b). It is then closed with a in almost every hard rock open cast mining. The boulders cap (c) and the safety mat is added (d). After the insertion significantly affect all open cast mining processes. It is for of the loading unit (d) and the attachment of the ignition this reason that boulders need to be separately crushed unit (e and f), they are ignited. The ignition of the loading after the extraction process, and before they are delivered unit can be operated by remote control (g). Compared to to consecutive quarry and processing processes. This blasting, this method is safer. It is only necessary to secure article deals with the description of various methods and the area in a radius of approximately 10 meters. appliances to crush boulders. In summary, the following The energy, which is unleashed through the ignition of system characteristics can be put on record: the loading unit, is prevented to be directed to outside, due to the weight and elasticity of the rubber mat. Instead it Drop Ball: The drop ball with a weight of 3 to 9 tons is is mostly directed inside the boulder through the medium being dropped on a boulder by a loading device from a water in form of a hydrodynamic impulse and can crush the height of approximately 4 to 5 meters, and crushes the boulder. Furthermore the safety mat significantly reduced boulder through the impulse of the clash. This method is noise and flying rocks. cost-effective and almost maintenance-free, however it For types of rocks which have high water permeability requires a high degree of precision, because the boulder or boulders with clifts it is obviously difficult to keep the has to be exactly hit for an effective crushing. With a drop water inserted into the bore hole. In order to tackle this ball it is possible to achieve 3 to 6 strokes per minute. problem, a gel can be used instead of water as a conducting medium. The types of rocks and their characteristics have Hydraulic breaker: A hydraulic breaker is a hydraulic an influence on the required amount of charge. While accessory equipment for a hydraulic dredger. The support the blast wave is better conducted in hard and stable frame supplies the hammer with hydraulic energy through rock, it can be mostly absorbed in plastic rocks. Here the high pressure tubes. The technological development of application of a multiplyer charge is necessary. the hydraulic breakers has lead to very high application The boulder buster can crush rocks that are bigger than weights of up to 10 tons and high impact energy of up to 2 m in diameter, and is therefore an alternative to blasting 16 kJ, as well as to a rate of strokes of several hundreds methods for boulders. Thanks to its safety there is no need per minute. As a result the performance of the devices for a blasting license, and there is almost no danger for has greatly increased and the areas of application vastly transport and storage. It is for this reason that it can be been expanded. A significant advantage of the hydraulic applied in versatile ways, in cases where blasting is not breakers results from their application possibilities on possible or can only be done with high effort. This method operational extraction equipment. can even be applied in closed rooms and in canalization. Buster: The working principle of a buster can be compared with a directed drop ball. A drop weight of up to 10 t hits the boulder to be crushed in a tube-like conduct in free fall. Contrary to the drop ball the stroke can be directed to an inch. Like the hydraulic breaker, the buster is accessory equipment, which due to its weight of up to 10 t requires a hydraulic dredger of a weight of a minimum of 40t. Contrary to the hydraulic breaker, the hydraulic energy is only needed to elevate the drop weight, therefore the energy Pic. 13: consumption is significantly lower. The rate of strokes is Dimensions of the crushable boulder with boulder buster comparatively low at up to 7 strokes per minute. Due to the very high impact energy of up to 100 kJ these devices are suitable for extremely big and hard boulders.

Boulder blasting: In classical boulder blasting the explosive is applied on the boulder or is applied in bore holes which were previously drilled. The blasting method is universally applicable and almost unbound to application borders. Disadvantages are the high noise emissions, the personnel and time expenses and the danger of flying rocks, which cannot be excluded. Therefore this method is increasingly loosing importance.

Issue 03 | 2009 www.advanced-mining.com 59 TRANSFER OF TECHNOLOGY

In conclusion the four introduced methods are compared Boulder Buster: Besides blasting, this technique is in a table with the help of significant decision criteria: another method that works with bore holes. In this method the bore hole is filled with water and consecutively a specific cartridge and boosters are applied with the help of boulder busters. The energy, which is unleashed through the ignition of the loading unit, is conducted in form of a hydrodynamic impulse through the water to the body to be crushed. Thanks to its safety mat almost no flying rocks appear in application of this method and the noise is also reduced. In fact no blasting license is needed for this. However, the preparation work and drilling of the bore hole still require a high expenditure of time.

Abb. 14: Vergleich der Knäpperverfahren

Boulder Technical Data Drop ball Hydraulic breaker Buster Boulder Buster Up to medium Size of boulder Up to very big big unlimited big size

Limitation of use Rock hardness limited big big unlimited unlimited

Location of the Almost Almost Highly limited Partly limited limited boulder unlimited unlimited

Noise emission low medium medium Very high low

Vibrationof equip- Very low high low - - ment Environmental Commotion in the None up to very none none low none pollution surroundings low low low low Danger of flying (onky splinters (onky splinters (onky splinters im high Almost none rocks im suround- im suroundings) suroundings) ings)

Investition low high high medium medium Costs medium to mittel bis Personnel medium medium medium high hoch

Suport frame required yes yes yes no no

Crushing performance low high moderate Very high low

Suitability for extraction nein yes no yes no

bibliography [1] Road Building International Internetinformation: www.boulderbuster.co.za; 05/2009 [2] TEREX GmbH Internetinformation: www.ok-mining.com; 04/2009 [3] ROCKTEC Ltd. Internetinformation: www.rocktec.co.nz; 04/2009 [4] Atlas Copco Internetinformation: www.atlascopco.com; 04/2009 [5] Fractum GmbH Internetinformation: www.fractum.com; 04/2009 [6] Volvo Internetinformation: www.volvo.com; 04/2009 [7] Atlas Copco Construction Tools GmbH Bautechnik Report Spezial: Einsatzmöglichkeiten in der Gewinnung; 2003 [8] H. Tudeshki; L. Kaup: Terminator- Der Aufprallbrecher für den Steinbruch; in: World of surface mining; 0472005; S.244-248 [9] STBG Steinbruch-Berufsgesnossenschaft Schriftenreihe: Steinbrüche, Kies- und Sandgruben, 1989

Issue 03 | 2009 www.advanced-mining.com 60 TRANSFER OF TECHNOLOGY

Development of the Oil-shale-project El Lajjun in Jordan by Dr. Eike von der Linden Linden Advisory | Dreieich | Germany JJordan Energy & Mining Ltd (JEML) is developing the oil-shale deposit Al Lajjun in Jordan. Syncrude from oil-shale will contribute to the global supply of oil supported by a long term oil price forecast of USD 90/bbl. The project has gone through a full FS with 80,000 engineering hours and including infill drilling, trial mining and processing of 500t representative samples in the ATP pilot plant in Calgary. The expenditures were born by a private placement which raised funds of USD 32m. The project will be in compliance with environmental thresholds related to carbon emissions, water consumption and other relevant criteria. The key findings of the bankable FS are:

• based on NI 43.101 certified 2p reserves 29year mine life in the northern Al Lajjun concession field • Total oil-shale mined 210m t containing 140-150m extractable barrels • Barrels per stream day approx 15,800 • Net carbon emission 210 kg CO2/bbl • Water used (predominantly brackish water) about 0.5 m³/bbl • 70 MW power generated partly for power export • Engineering and construction 42 months • Total initial capex before financial costs USD 1,500 million • Cash unit costs approx. USD 22/bbl, full costs approx. USD 55/bbl

Dependence of global Supply on unconventional Oil

Serious forecasts on future energy markets like the example of the Cambridge Energy Research Associates (CERA) presented below are predicting the dependence of oil supply on unconventional oil, i.e. syncrude from oil-sands and oil-shale. While oil- sands have seen already a remarkable development during the last three decades, in the first instance in the Athabaska Region in Canada, the development of an oil-shale industry is on the threshold of realization.

Pic. 1: Development of unconventional oil

Issue 03 | 2009 www.advanced-mining.com 61 TRANSFER OF TECHNOLOGY Oil Price Outlook

In the long term the oil supply costs of newly developed conventional and unconventional oil fields will have a determining influence on future oil prices superimposing short term effects of supply demand balances and hedging. Current 2009 finding and development costs to generate 2p reserves are in the order of USD 23/bbl. This is before production, processing for transportation and transport. Current full marginal cost of production reach USD 80/bbl. Average full costs of worldwide new sources of supply are in the order of USD 60-80/bbl. These data are supporting the following oil price outlook:

Tab. 1: Oil Price Outlook

Year 2008 2009 2010 2011 2012 long term

Brent USD/bbl 98,52 45,00 55,00 80,00 85,00 90,00

WTI USD/bbl 99,65 45,00 55,00 80,00 85,00 90,00

Global Oil-shale Resources

Oil-shale, amongst others, was used during World War II in Germany. Since the 1950-ies oil-shale mining is the basis of power and syncrude generation in Estonia. Recent pilot and demonstration size developments on oil-shale are taking place in the US (Colorado, Utah), in Russia, in China and Australia. In Jordan a number of international companies like Shell, BP, Total, Petrobras, Energia Estonia are pursuing projects in addition to JEML, which may be farthest advanced in project development.

Tab. 2: Major Oil-shale Resources/ Reserves and Oil-sand Resources by Countries

Demonstrated Oilshale Proven Oilshale Reserves Heavy Oil & Tar Resources [Billion bbls] Sands [Billion bbls]

USA 1539 560

China 500

Russia 147 2 800

Australia 145 12

Jordan 102 28

Marocco 100 10

Brazil 80 11

Canada 1700

Venezuela 1300

Issue 03 | 2009 www.advanced-mining.com 62 TRANSFER OF TECHNOLOGY

Environmental Aspects merely no other GHG (methane, etc.) a full GHG emission comparison shows even a more favourable picture for Al A major criterion for the development and the funding of Lajjun. unconventional oil projects is environmental compliance with international and national regulations. While oil-sands are confronted with high water consumption for pipeline transportation of r.o.m. sands, for hot or cold water oil extraction and with discharge of water contaminated with Water Consumption hydrocarbons, oil-shale processing is mainly confronted with CO2 emissions. In addition to carbon emissions the water consumption of Al Lajjun was benchmarked with comparable sources of supply.

The retorting process selected for Al Lajjun is the Carbon Emissions Alberta-Taciuk-Process (ATP). The scheme of the process is shown in picture 8. The major component of the retort JJEML retained DMT/TÜV Nord for a study on carbon is a rotary kiln with an inner pipe. Water is used for emissions and benchmark operations. The independent quenching of spent shale for cooling and for the avoidance consultant was ask to compare the CO2 footprint of “Al of dust emission when the spent shale is disposed on the Lajjun net” with other potential oil sources for the supply dump side of the open pit. For the purpose of quenching, of Jordan. Al Lajjun net was derived from “gross” by brackish water can be used which can be extracted from deducting offsets for the sale of spent shale to the cement a water table with salty water. industry, for mining of rock phosphate underlying the oilshale without further waste stripping, for the sale of The total water consumption including cooling water for sulphur to the phosphate industry in Jordan and for the oil up-grader and power plant cooling is 0.5 m³/bbl. sale of excess power to the grid.

As being demonstrated in the following graph, Al Lajjun produces a net carbon emission of 209 kg CO2/BOE and lies in a comparable range with alternative sources of supply for Jordan. Since oil-shale mining and processing emits

Pic. 2: Carbon Footprint JEML and Benchmark Operations

Issue 03 | 2009 www.advanced-mining.com 63 TRANSFER OF TECHNOLOGY

Environmental Guidlines The shareholding of JEML subsequent to a private placement for funding of a full bankable FS is: Environmental design criteria for the project were developed based on Jordanian standards, International • RAB Capital (London) – 28% Finance Corporation (IFC) Performance Standards and • The Sentient Group – 25% EHS Guidelines with: • Founders – 25%% • JP Morgan – 7% • air emissions that meet Jordanian regulatory requirements and that has one of the lower emissions rates • Others (each less than 5%) – 15% • zero water discharge from the site, maximizing water recycle and reducing makeup water requirements • noise reduction and attenuation, as required • set backs and methods of operation to minimize the impact Milestone on local communities and historical sites • re-establishment of local olive groves that exist at the pro- A development plan put forward by JEML in its Proposal posed site to the Jordan Government in April 2006 was divided into • community interface planning, information sessions and four phases as follows: community information centre • establishment of a research chair at the university of Karak • Phase 1: complete conceptual / Pre-Feasibility stu- dies and framework commercial agreements allowing • consideration and minimization of the impact on traffic in the JEML to scope and budget a Bankable Feasibility Stu- area dy (BFS) and raise additional funds either by listing JEML on the AIM market in London or seek additional funding through Private equity or other sources of Pre Initial Public Offering (Pre- IPO) funds. • Phase 2: Complete a Bankable Feasibility Study (initi- ally July 07 to June 08 but now formally extended to Jordan Energy & Mining Ltd July 09) The Company • Phase 3: Construct an initial Commercial Plant produ- cing ~15,000 BD shale oil (January 2010 to June 2012) JEML operates from offices in Tunbridge Wells and • Phase 4: Following successful operations of initial London in the United Kingdom and Amman, Jordan. The plant construct a full scale commercial plant producing board and senior management of JEML consists of the 50-100,000 BD shale oil for +30 years following experienced staff:

• Dr. Peter Klaus – non-ex. Chairman • Mr. Christopher Morgan – Managing Director • Mr. David Pedley – Finance Director • Eng. Munter Akroush – Director Jordan Operations • Mr. Chris Nurse – Legal Advisor/Government Relations • Dr. Eike von der Linden – Technical Director • Dr. Peter Cassidy – Non-Executive Director • Ben McKeown – Alternate Non-Executive Director

Issue 03 | 2009 www.advanced-mining.com 64 TRANSFER OF TECHNOLOGY Projekt Al Lajjun

Pic. 3: The complete Al Lajjun project

The Al Lajjun Project Feasibility Study For the FS some 80,000 engineering hours have been consumed so far with ongoing activities for optimizations. The Concept Study/ Pre-FS (amongst others with DMT The FS documentation consists of 11 volumes, 24 binders and Lahmeyer) was prepared during 2007/08 resulting in for drawings, all together containing some 7000 pages. encouraging results enabling JEML to raise some $ 32m by a private placement and initiating a full FS including infill drilling, trial mining and processing of a 500 t oilshale sample in the ATP pilot plant in Calgary.

The FS has been compiled by using not only in house JEML staff but also a range of internationally recognised consultants and contractors, namely:

• Hatch Limited – overall study coordination (Canada) • UMATAC / ATP Systems - oil shale processing and oil up- grading (Canada) • Krupp Polysius - engineering and cost estimating of retorts and support systems (Germany) • DMT Montan and Marston International – geology, oil shale reserves and resources, mining and materials handling as- pects (Germany and Canada) • Lahmeyer International – power generation (Germany) • Citrus Partners – environmental, health, safety and social / community assessments (UK)

Issue 03 | 2009 www.advanced-mining.com 65 TRANSFER OF TECHNOLOGY Concession Area

Pic. 4: map of concession area with map section enlarged

Issue 03 | 2009 www.advanced-mining.com 66 TRANSFER OF TECHNOLOGY

Pic. 5: detail map of concession area Resourcen und Reserves It is noteworthy that the costs for generation of 2p The oil-shale resource and reserve assessment has oil-shale reserves were in the order of USD 0.3/bbl. been certified by an independent qualified person to be in For comparison reason the actual 2009 finding costs to compliance with the NI 43.101 of the TSX. establish new conventional 2p oil reserves are reported to be USD 23/bbl. Out of these resources a tonnage of some 210 mt 2p reserves shall be mined at an average kerogene grade of 11.6%. The waste to shale ratio is 1.3:1.

Issue 03 | 2009 www.advanced-mining.com 67 TRANSFER OF TECHNOLOGY

Tab. 3: Oil-shale Resources Mining

Drill hole Mining is a shallow flat lying open pit stripping Catergory Million t spacing operation with a r.o.m. production rate of some 7.5 m t of oil-shale. Both conventional truck and Oil-shale gemessen 218 0 - 500 m shovel operation and inpit crushing belt conveying have been investigated in dependence of the oil Oil-shale indiziert 11 500 - 1000 m respectively Diesel price.

Total m + i 228 Processing Overburden 300 The following graphs present the principle process flow diagram and the plant layout.

Pic. 6: Process Flow Chart

Issue 03 | 2009 www.advanced-mining.com 68 TRANSFER OF TECHNOLOGY

Pic. 7: Plant schematic

Retorting

The initial commercial capacity of the project is 2 x 500 t/h processed in two parallel trains with an ATP Processor each. The ATP Processor is a horizontal rotary kiln consisting of four internal zones as shown in the following picture.

Pic. 7: ATP Processor Flow Schematic

Issue 03 | 2009 www.advanced-mining.com 69 TRANSFER OF TECHNOLOGY Oil Upgrading Key findings

JEML intends to start with a production rates with 2 ATP The key findings of the bankable FS are: retorts of 500 TPH capacity each, producing approximately • based on NI 43.101 certified 2p reserves 29year mine life in 15,800 BPSD of raw crude shale oil. The different fractions the northern Al Lajjun concession field can be hydro-treated separately under different reactor conditions of temperature and pressures. • Total oil-shale mined 210m t containing 140-150m extractable The initial intent of the hydro-processing unit is to barrels develop a synthetic crude oil (SCO) blend that can be sent • Barrels per stream day approx 15,800 to refinery (Zarqa in Jordan) for processing to finished • Net carbon emission 210 kg CO2/bbl products. At some higher capital investment, it is also • Water used (predominantly brackish water) about 0.5 m³/bbl possible to go directly for the finished products. • 70 MW power generated partly for power export The hydrogen will be produced on the basis of natural gas delivered by the Egypt-Amman pipeline. • Engineering and construction 42 months • Total initial capex before financial costs USD 1,500 million • Cash unit costs approx. USD 22/bbl, full costs approx. Power Generation USD 55/bbl Fuel gas with a calorific value of approx. 50% of NG and Sources of Information: excess steam from processing will be used as energy for a • Bankable FS and internal supporting documents 70 MW gas turbine. The internal power requirement is up to 60 MW. The excess power shall be sold to the grid. • DB Ressearch: Commodities Outlook, Jan. 2009

Infrastructure Dr. Eike von der Linden: Al Lajjun is located in a favourable infrastructure close to the main highway Amman-Aqaba. A connection highway Objective: runs through the concession area to Karak, a city in 15 km Senior Executive with engineering and financial back- distance with 37,000 inhabitants and a university. ground with board level functions in international ope- Parallel to the highway Amman-Aqaba runs a high rating companies voltage power line and a gas pipeline importing gas from Current positions: Managing Director of Linden Ad- Egypt to Amman. visory; Director and Member of the Board of Zhaik- munai LP; Director Jordan Energy and Mining Ltd; Member of the Board GLR Resources, Canada; Mem- ber of the Board of Schüllermann AG; Independent financial advisor to national and Capex international companies and financial institutions in the field of natural resources, utilities and extractive industries The initial capital cost is some US$ 1,500 million before Education: financial costs. The major lump sum turnkey packages Technical University of Clausthal (Mining engineering); Technical University of Mu- have a total value of up to US$ 775 million. Most of the nich (Economics) supplies can and may be delivered from Germany. Qualifications: Dipl.-Ing., Dr.-Ing. ; Bergassessor (Senior Government Mine Supervisor) Work experience: Opex 1985 – present: More than 35 years experience in senior management, more than 20 years experience in board functions, Project funding with particular focus on national (German) and international guarantee instruments and subsidies; Indepen- Cash unit opex are in the order of USD 22/ bbl. Full opex dent Advisor to financial institutions and companies in the fields of natural resour- are in the order of USD 55/bbl. ces, utilities and extractive industries for equity investment, mezzanine and debt funding (Project Finance), Feasibility Studies, independent auditing, market value and risk assessments; 1972 – 1984 Metallgesellschaft AG; 1982-84: Member of the supervisory board of Metallgesellschaft AG; 1980-84: Branch manager with Lurgi’s natural resources branch; 1972-80: Various appointments with Metallgesellschaft’s domestic and international mining division; 1970 – 1972 University of Clausthal Post- graduate Study and Scientific Fellow; 1968 – 1970 Bavarian Bureau of Mines Trainee (Senior Government Mine Supervisor)

Issue 03 | 2009 www.advanced-mining.com 70 TRANSFER OF TECHNOLOGY >>The most intelligent chapter in mining history was written by German Engineering<< he German Brown Coal industry is not only contributing heavily to the national energy supply, Ton which our economic prosperity is based, but during the past one hundred years it has also lead to a globally unparalleled and valued place of expertisefor mining technologies, which also needs to be preserved.

We observe in all European industrial nations that the systems, which do not fit into the world view of the respective importance of raw material production, as the basis of the speaker. At the same time there are high expectations; The value chain and energy production is increasingly being responsibility towards future generations need to be met, repressed from the consciousness of all people. Although international law obligations need to be observed, and the mineral material is indispensable for the production of living standards need to be kept. All these demands are almost all commodities, and access to raw material is justified, however, it should be noted that it is exactly our geo-politically becoming increasingly important, they established energy mix, on which our economic prosperity are seen as sources of irritation which impede access to is based, and on which such demands can be formulated goals of climate and landscape, even in industrial regions. in the first place. However, the trend in global increase of requirements is irreversible and its political and economic waves have long reached us. The search for new deposits is in full In such debates the complementary meaning of energy swing, even in regions of Europe, where mining already and raw material production for the location of Germany was an attraction in museums. is very often disregarded. Investment in international mining The innovation potential in companies, the establishment of our mining technology is new mining enterprises, as well unparalleled. As an example, as the obtaining of licenses for the technology for continuous raw material are on the agenda surface mining, which was of many companies. developed at the beginning of the last century in the German brown coal districts, has lead to In Germany the extraction of enormous efficiency increases and the power generation by in extraction, production and brown coal is particularly at the dumping processes, which center of the conflict between again is also ecologically secure and cost-effective energy relevant. A mass movement supply and ecology. In no other of more than 30,000 m³ could country the question of the be achieved already in the „right“ energy-mix is discussed year 1930. Nowadays we have as vehemently as in this country. extraction and mining chains Hereby the debates often carry that allow for daily outputs of a tone of rejection of energy 240.000m³. This is the reason

>>The German Surface mining technology has an enormous innovation potential.<<

Issue 03 | 2009 www.advanced-mining.com 71 TRANSFER OF TECHNOLOGY why the large open cast pits of the Rhenish, Lausitz and central German brown coal districts achieve the by far highest delivery rates and mass movements in the global brown coal mining.

The fact that open cast mining technology is no isolated application for the German brown coal districts only, but also has international market potential, has been proven by manufacturers having Innovation, flexibility and the ability to adapt to the various circumstances in mining. It was already in the sixties that the bucket wheel excavator and other solutions of the excavation technique was applied first in the US, and later in various open cast mining operations in almost all parts of the world. This development was made possible mainly because of the internationally strong relevant branches of German Universities. The engineering services of the numerous show that both the industry and science have actively and renowned consulting firms are also much in demand. taken up the challenges of energy supply - from energy They have also contributed to the knowledge transfer for efficient mining technology up to climate-friendly power optimum application of the giant equipment technology. generation through coal.

>>The brown coal industry has long outgrown its role as a supplier.<< Hence, the importance of the brown coal industry has long Within the context of the often prognosed fast growth surpassed the role of a national energy supplier. In over in the world‘s energy consumption, innovation impulses 100 years, a globally acknowledged place of expertise, for an ecologically and economically and ecologically which combines practical and scientific know-how, has balanced energy supply, which is according to needs, are developed. The advancement of technological innovation indispensable. In the future almost no political economy on the basis of the achieved standards remains a national, with coal deposits can and will do without this affordable European and international contribution to growth and energy feedstock. Some promising development projects prosperity.

Issue 03 | 2009 www.advanced-mining.com 72 TECHNOLOGIETRANSFER Innovative and Efficient Solutions for challenging tasks in extraction, surface mining and surface forming.

T1255 Terrain Leveler

Vermeer has transcribed its long-standing The machine has been designed to ablate all experience in the area of rock mills into its new kinds of rocks, gypsum, coal and other ma- surface mill. terial (e.g. concrete). This is done using a big, The T1255 is characterized by protected tech- hydrostatically steered milling drum, which nology, intelligent design, excellent produc- ablates the rock in a more efficient way and tion and system stability. with a higher cutting depth. Meanwhile the Terrain Leveler can process an The result: area of up to 3.7 m width and 61 cm depth in More coarse material with a low proportion of one single run. fine fraction.

www.vermeer.de

Deutschland GmbH Puscherstr. 9 90411 Nuremberg, Germany

Tel.: +49 (0) 911 5 40 14 0 ADVERTISEMENT Fax: +49 (0) 911 5 40 14 99 Ausgabe 03 | 2009 www.advanced-mining.com 73 NEWS & REPORTS

HOT SUCCESS! Steelworks « Dillinger Hütte » & « Saarstahl » Since 1953, the company BACKES is doing the preparation of slag in order of the steelworks “Dillinger Hütte” in Dillingen (close to Saarbrücken). BACKES recycles the slag to gravel, which is Dused as material for street construction. Still, a converter lime is produced from the steelworks slag, which is used for fertilizer for the agriculture. BACKES is a Customer’s of ESCO’s dealer Peter KESSLER GmbH &Co. During their visits ESCO District Manager and Kessler Dealer proposed that the company try to equipped their Machines with ESCO products solutions parts. BACKES uses several machines in the steelworks. For solving and loading of the hot slag the company BACKES use 3 LIEBHERR Excavators R984 Litronic.

Steelwork « Dillinger Hütte »

The temperature of the hot slag is up to 1100°C. At this high temperature, bucket must be well protected by products with optimum performance. SUPER V® is the best choice to meet this challenge! Mr X, manager of the Subcontractor Backes needs the top Systems for Today’s performance demands:

• Reliability • Longer Wear life • Lower Maintenance Costs (Faster and Easier change-out) • Better Penetration

Against this background, BACKES, ESCO and KESSLER agreed to use the esco wearparts on two LIEBHERR R984 Litronic to protect their buckets.

Issue 03 | 2009 www.advanced-mining.com 74 NEWS & REPORTS

The V71 ADHL is a specially designed point shape when digging Hot Slag operation. The ADHL has a heavier wear shoe, as well as beefier ears and box section to stand up to the most punishing applications. In addition, ESCO engineering with TSG designed a special V69/71HPNA pin, a little bit longer than the standard version which provides a very good locking. SUPER V® V71ADHL points worn out after only 70-100 hours on average. Because of the self sharpening effect, the teeth keep a perfect penetration until the end. TOPLOK® & KWIK-LOK® Runners are ideally suited for fighting abrasion in hot slag so that buckets must be repaired after approximately 12 months instead of 3 months with previous Systems..

VIDAPLATE 17 on 10

KWIK®-LOK KLR02MB

TOPLOK 90x320-5 TOPLOK 90x320-6L TOPLOK 90x320-6R

WING-SHROUDS ES4410SA

SUPER V® points V71 ADHL

Steelwork « Saarstahl »

The both steelworks SAARSTAHL and DILLINGER HÜTTE are operating many telescope excavators in the two steel mills. These special machines removes the hot-slag from the ladles. The temperature of the ladles is between 600°C and 800°C. The excavators also remove the unusable refractory liners form the ladles.

This application is one of the most demanding metallurgical expertise on the market. ESCO alloy and SUPER V® System can meet that challenge. Together with the ESCO Dealer KESSLER in Völklingen, ESCO could convince the two steelworks to

Issue 03 | 2009 www.advanced-mining.com 75 NEWS & REPORTS

convert the shanks of the telescope excavators to SUPER V® system V51SD and V51SDX. The shanks of the telescope excavators are now equipped with SUPER V® weld-on noses as well as the both different tooth shapes V51SD and V51SDX. For this hot application, of course ESCO offers a special hot-slag locking device. The alloy and the design of the both tooth shapes maximize the heat dissipation capabilities of the SUPER V® system to minimize the affects of hot- slag material. This points are a very good alternative when impact is causing breakage in longer style points. With the SUPER V® tooth, the hot-slag can be removed from around 25 - 30 ladles. The wear time of the teeth is approx. 30 hrs. The refractory liners of the ladles can be used for approximately 45 - 50 cast fillings. The refractory liner is also removed with the telescope excavators afterwards.

The Operators likes the performance, the high wear time as well as the save and easy handling of the SUPER V® System. They have explained with V51SD V51SD(X) and with V51SDX they have a better penetration and a better power transmission. Thanks to the long lasting experience of ESCO in the steel technology, Saarstahl and Dillinger Hütte can believe in SUPER V® tooth system. It has improved their profitability by extending wear protection products. Following this HOT successful story ESCO has offered this solution to many other German steelworks.

ESCO corporation Tel.: +49 (0)2166 - 9684-0 Fax:+49 (0)2166 - 9684-22 eMail: [email protected] Internet: www.escoeurope.com

Issue 03 | 2009 www.advanced-mining.com 76 NEWS & REPORTS

Kl e e m a n n Gm b H Stationary plants now become mobile thanks to interlinked plants! Kleemann demonstrates what is possible today with process know-how and high- performance plants: t/h feed capacity, up to seven final fractions of which five comply with the strict standards for 500asphalt and concrete production - and all this is possible using mobile plants? Using the plant combination at Kelly’s of Fantane in Ireland, Kleemann demonstrated what can be achieved today using mobile plants. Mobile crusher and screen plants are advancing more and more into output ranges that up to a few years ago were only possible using stationary plants. Examples such as the one quoted above are guiding the way for the future.

Kleemann Kelly´s of Fantane Kelly’s of Fantane, Ireland: Three crushing and screening stages, up to seven final fractions, total capacity of over 500 t/h

What exactly are “interlinked plants“?

“Interlinked mobile plants are crusher and screen plants, which are coordinated to work together in terms of output and operation“. Two, three or several plants can be combined for use in both natural stone quarrying and recycling. The potential output of such plant combinations currently ranges from 100 t/h up to 500 t/h, whereby the upper limit has not yet been reached:

Issue 03 | 2009 www.advanced-mining.com 77 NEWS & REPORTS Why are interlinked mobile plants becoming more popular?

Experience shows that the licensing procedure for operators of stationary plants who are about to make new mobile plants is, for the most part, considerably shorter investments in machinery. This is also a feasible concept for and less complicated than that for stationary plants. In larger infrastructure projects as such projects are mostly addition, the flexible use of the plants in spacious areas limited in terms of time or in scope and are often located in and in technical applications reduces the investment risk. sparsely populated areas. A suitable combination of mobile The plants can also be resold, thus further lowering the plants could also be used for newly opened quarries, as risk. An equally important contributory factor is the fact well as recycling projects which demand top-quality end that manufacturers such as Kleemann have been able to products. offer plants for such large tonnage in various crushing and screening stages.

Kleemann Lauchhammer Reconstruction company Lauchhammer, Germany: Concrete and rubble processed in final fractions of 0 - 32 mm and 32 - 45 mm

What are the potential areas of Requirements and expectations application? Of course, the requirements are high: On the one hand, there must be a guarantee that top-quality end products, Due to the development of these plants in recent with regard to cubicity and output, can be manufactured. years, the mobile plant is increasingly becoming a real On the other hand, the process must be reliable and alternative to the stationary version in a great number of economically worthwhile, which, of course, also applies projects. For this reason, it is now examined more often largely to the machines used. whether an original stationary concept with mobile units is more economical. This is of particular benefit to existing

Issue 03 | 2009 www.advanced-mining.com 78 NEWS & REPORTS

Kleemann LSR Zement LSR Zement, Russia: Two-stage crushing process for achieving four final fractions

Kleemann Maxwell Maxwell, England: Two crushing and three screening stages allowing up to seven final fractions

Issue 03 | 2009 www.advanced-mining.com 79 NEWS & REPORTS

There must be cost advantages, which are not ideal for interlinked plant concepts. In addition, optimally necessarily noticed in the procurement stage, but mainly coordinated mobile screening units, available in double or during the operation of the plant. For example, in quarries triple deck design, provide reliable end classification. which cover a large geographical area, it is often possible to load the crusher directly at the wall. Thus the use of heavy duty vehicles is partially or completely avoided. This leads to considerable savings not only in vehicles and machines, but also personnel costs. In the example at Kelly’s of Fantane, Martin Flynn, Operation Manager, explains that all machines are linked through a computer- supported system. „The bottom line is we produce 500 tonnes per hour with only one man“, he added. He went on to say that since they have been using Kleemann plants, their costs have dropped significantly. „We now produce more during a single shift compared to the previous two- shift operation“, he explained.

What does Kleemann specifically offer?

Kleemann not only offers the required plants but also the relevant process know-how. Decade-long experience in the construction of stationary plants combined with over FOR MORE INFORMATION AND CONTACT: 25 years‘ experience in the construction of track-mounted crushing and screening plants means Kleemann can offer its customers a comprehensive service. Therefore, Kleemann GmbH is a member company of the not only does Kleemann assess and design the required Wirtgen Group, an expanding and international technical process safely and reliably, but it also ensures group of companies doing business in the const- its successful implementation by providing support for ruction equipment industry. This Group includes the the customer during the difficult transition stage from four well-known brands, Wirtgen, Vögele, Hamm stationary to mobile plants. and Kleemann, with their headquarters in Germa- The decisive factor is, however, the plants themselves. ny and local production sites in the United States Kleemann plants offer, on the one hand, the relevant of America, Brazil and China. Worldwide customer operations in the plant design, and, on the other, robust, support is provided by its 55 own sales and service sophisticated, high-performance machine technology. companies. Jaw, impact or cone crushers have split feeding for optimal loading (no blockades), large primary screens for optimal final fraction quality, stable control voltage and separate monitoring of the individual machines. They also have ideal access, easy maintenance and, last but not least, diesel-electric drives with the option of external power supply (quarry machines) which also make feed capacities of up to 700 t/h possible. All these characteristics are Kleemann corporation Mark Hezinger Hildebrandstr. 18 73035 Göppingen | gERMANY Tel.: +49 (0) 7161 20 62 09 Fax: +49 (0) 7161 20 61 00 eMail: [email protected] Internet: www.kleemann.info

Issue 03 | 2009 www.advanced-mining.com 80 NEWS & REPORTS

Wi r t g e n Gm b H New 4200 SM surface miner from Wirtgen:

Maximum performance in large-scale opencast mining!

he new 4200 SM is a high-performance machine for mine operators and customers in large-scale Topencast mining whose goal is to achieve an annual mining capacity in soft rock of up to 12 million tons with a single machine while wanting to make full use of the benefits offered by Wirtgen’s selective mining technology that enables cutting, crushing and loading in a single working pass. The surface miner is available to customers in two different designs: as a powerful mining expert for hard rock, such as iron ore, bauxite or phosphate, or for use in various types of soft rock including, for example, coal or lignite. The miner has a cutting width of 4.20 m and is capable of working at a maximum cutting depth of 83 cm in soft rock.

offering capacities of 2,900 l for diesel and 10,000 l for The 4200 SM is synonymous with water additionally increase the miner’s uptime. tremendous power A two-stage conveyor system with 1,800 mm wide primary and discharge conveyors and a discharge The heavy-duty machine is equipped with a 16-cylinder conveyor length of 12,000 mm or 16,000 mm respectively, diesel engine from Cummins, making it the ideal candidate supports the miner’s impressive cutting performance of for a wide range of applications as its power of 1,194 kW up to 3,000 tons per hour. The discharge conveyor’s large / 1,623 PS offers tremendous reserve capacity. Being the slewing angle of 180 degrees, flexible height adjustment most powerful machine in the surface miner division, the and variable belt speed ensure smooth loading of large 4200 SM complements Wirtgen’s product portfolio in the transport trucks even in space-restricted conditions. upper performance class. Generously dimensioned tanks

Issue 03 | 2009 www.advanced-mining.com 81 NEWS & REPORTS The right cutting technology – whether Fully equipped for long and tough mining in hard rock or soft rock operations

Customized components manufactured to the high Ergonomic design of the operator’s workplace was quality standards of Wirtgen’s cutting technology have been another major point in the machine’s development as long precisely adapted to the miner and the rock to be mined, uptimes or even continuous operation are required in the enabling the 4200 SM to achieve maximum production deposits to increase productivity and to ensure maximum rates at low cutting tool wear and tear. Depending on the utilization for an economical operation of the large operation and the material to be mined, the cutting drums machines. are fitted with different numbers of cutting tools at different The 4200 SM’s cabin has undergone a complete redesign: tool spacings. It is located above the front, left-hand crawler track unit For applications in soft rock with unconfined compressive and is isolated from the vibrations and noise emissions of strengths of up to 50 MPa, the 4200 SM is equipped with a the engine and cutting drum by a parallelogram-type height 4.20 m wide cutting drum unit with larger cutting diameter, adjustment system. The fully glazed operator’s platform permitting cutting depths of up to 83 cm. In soft rock, the offers the machine driver an exceptionally good view of operation focuses on the throughput of large quantities of all areas relevant for cutting and loading of the mined the material to be mined. material. The cabin can additionally be swivelled about The largest Wirtgen miner can alternatively be equipped 45 degrees to either side, thus also permitting an optimum with a drum assembly offering a cutting width of 4.20 m view of the loading operation and steering of the crawler and a cutting depth of 65 cm for applications in hard rock tracks. The driver’s seat with all major controls installed with unconfined compressive strengths ranging from 30 in the armrests can be swivelled about 135 degrees to MPa to 80 MPa. It aims at achieving maximum cutting the left and right. The controls, which are integrated into performance in hard materials at reduced cutting depths. both armrests in a clearly structured fashion, comprise all Both cutting drums can optionally be equipped with the functions of the work process. tried and tested HT14 quick-change toolholder system for The operator’s cabin is soundproof and is supported the fast replacement of cutting tools. on special anti-vibration buffers to protect the machine

Wirtgen 4200 SM Hallmarks of the new 4200 SM include high cutting per- formance, unmatched economic efficiency and project- specific customization to on-site operating conditions and local safety regulations

Wirtgen 4200 SM The cutting drum unit with a cutting diameter of 1,500 mm is ideally suited to the mining of medium-hard to hard rock, such as iron ore. The number of cutting tools depends on the operating conditions

Issue 03 | 2009 www.advanced-mining.com 82 NEWS & REPORTS operator during the mining operation. To ensure pleasant in the operator’s cabin. The cabin’s location on that side working conditions, the cabin is equipped with a powerful of the machine opposite the embankment wall is yet air-conditioning unit for cooling or heating. These are all another safety criterion offering maximum protection to factors to improve the machine operator’s performance the machine operator. and power of concentration. The large machine’s user-friendliness is complemented by wide opening service panels offering excellent access to all points of maintenance.

Wirtgen 4200 SM The panorama cabin of the 4200 SM offers not only an excellent view for permanent monitoring of the work processes from the operator’s platform but also a high degree of comfort for the operator in 24-hour shifts

Comprehensive safety package for country-specific requirements

Safety regulations are tightened in mineral deposits around the world. The new design of the 4200 SM takes account both of the stricter safety requirements and of new mining regulations. The miner’s comprehensive safety package includes, among other things, a FOPS roof to protect the operator from falling objects, a second emergency exit in addition to the hydraulically operated Wirtgen corporation access ladders installed on both sides of the machine, Press Relations fire extinguishers, and covers on all rotating parts. The Reinhardt-Wirtgen-Str. 2 access ladders and walkways are illuminated and consist 53578 Windhagen | Germany of anti-skid grating. Several emergency stop switches can Tel.: +49 (0) 2645 1 31 0 be actuated from the ground and are additionally installed Fax: +49 (0) 2645 1 31 4 99 in the engine compartment, at the electrical cabinet and eMail: [email protected] Internet: www.wirtgen.de

Issue 03 | 2009 www.advanced-mining.com 83 NEWS & REPORTS Improved performance out in the open! Substitution of screen panels to help hard rock quarry achieve increased production n Groß-Bieberau, the Odenwälder IHartstein-Industrie AG – a holding I n d u s t r i e subsidiary of the Mitteldeutsche (OHI) has been Hartstein-Industrie AG – operates producing railway a gabbro quarry which is well ballast which known in particular to originally benefited railway fans. For well the local railway between over a century now, Reinheim and Groß the Odenwälder Bieberau. Today its range of Hartstein- production is very much more widely spread: apart from ballast, there are chippings, grit, crushed sand, filler, armourstone, mineral mixtures, asphalt aggregates and many other products besides. Hand in hand with the increased scope of the product range there are the more exacting demands of an optimization of the output performance. The aims of the operators make it clear that the technical principles for processing are once again under the microscope. Up to now it was always assumed that the proven combination of crushing and screening equipment was able to deliver 250 t/h of material. Closer inspection has however shown that this target is seldom actually attained.

Trellexscreens Rubber and plastic screening panels are much more resistant to wear than wire screening panels

Issue 03 | 2009 www.advanced-mining.com 84 NEWS & REPORTS arl-Heinz Rossmann, responsible for product support of screen media at Metso Minerals, Ksummarizes the present situation in the following terms: „When crusher and screening machines at least together fail to achieve the necessary productivity, closer examination is absolutely essential.“ Rossmann got the ball rolling by suggesting an impartial analysis of the technical situation at the site. The initial condition was not to consider exchanging the screening machines for the time being to restrict replacement investment costs to an absolute minimum.

stucking grain New investments remain Clogging is often a problem where no rubber screening panels are used. Specially when wire screen panels within reason are used, a supposedly open area may remain up to 80% unproductive With the aim of achieving the throughput of 250 t/h originally quo- ted or to increase this in the short or medium term to 300 to 350 t/h, the first task was to take a look above all at the screening machines. It was very soon clear that optimization could only be carried out in the field of the screen panels, as no invest- ment provisions had been made for replacement of the screening machi- nes themselves. An initial examination on sight brought to light the fact that all the screens were fitted with different panels to different designs in terms of length, breadth, thickness and perforations. „This in not necessarily a fault“, says Karl-Heinz Rossmann, „because the tasks for which the machines were specified were dif- ferent right from the start. What we have to do now is establish the ex- tent to which optimization is required in each individual case“. The investigations started on the grit side – where the grains are al- ways broken twice, if not three times. Metso had to examine four scree- ning machines in this area to find out what the optimization requirement of the screening panels was. At the moment, there are 250 t/h scree- ning machines by Krupp in service. Upstream of these machines there are one conical crusher After it became clear that investment in new machinery and one vertical impacter. Initially, the solution was con- was not the operator‘s first priority, sidered, to save a crushing stage, of replacing both crus- Karl-Heinz Rossmann devoted his attention to a fully- hers by the Metso HP 4 and to configure a new screening detailed investigation of the effective screening areas ac- machine. For the sake of simplicity, the latter would have tually available. been fitted with wire screens to give a bigger screening The result was two slightly different pictures with one surface and thus to increase the throughput. This first idea common denominator: partly, proper utilization of the open was however revised after further consideration. screening areas was just not possible with the screening

Issue 03 | 2009 www.advanced-mining.com 85 NEWS & REPORTS media in use, partly right from the start there were insuffi- um with a large open screening area, to meet the demand cient perforations in any case. for a higher throughput. It would have been easy enough With the use of more effective screening media, the to solve the situation existing by replacing all screening question of service life arises. Does an extended service panels by wire panels. life of the screens have priority, or is a heavier screen gau- However, in the fundamental decision-making the appli- ge with less holes more important? This inevitably means cation itself plays a critical role: gabbro, a hard, igneous that that a larger number of „blind spots“ in the screens rock, is capable of wearing out a wire screening panel (areas without holes) mean a longer service life. But how within two to four weeks. „You can stand by and watch is that then reconciled with demands for a higher through- the steel wire getting thinner and thinner and finally dis- put? „Here it wasn‘t a matter of choosing between service appearing altogether“, says Karl-Heinz Rossmann. In the life and performance – both aspects are equally important fines area, where wear is not the decisive criterion, mois- in the final analysis“. ture frequently gets into the screen. In the case of wire screens, this leads to undesirable caking and can cause complete blockage. Clearing it with a hammer or some other tool is useless, because deformation of the screens would be unavoidable. There would be similar difficulties with wire rod screens too. A further disadvantage of the Wire screen panels under conditions of wire screening panels: An overlapping of wire meshs, such wear as Metso found in some places in Bieberau, also leads to slower material conveyance which can only be compen- The most important requirement was to reach a fun- sated by the screens being tilted by 2° more in comparison damental decision regarding the basic material: whether with synthetic screens. synthetic screening panels or wire panels – at first glance, Requirements for an increased throughput cannot ade- the observer would be inclined towards a screening medi- quately be met in this way. Since on site we want to ensure that the performance capacity of the screening machines

wide guide rail Large areas of the screen panels remain effectively unused due to excessively-wide edges and large blind spots

Issue 03 | 2009 www.advanced-mining.com 86 NEWS & REPORTS

blind area keeps up with that Here there are possibilities for augmenting of the crushers, in the rows of holes: Metso Minerals can the final analysis optimize the design or the perforation there are further individually for the respective application considerations mi- litating against the use of wire scree- ning panels: their comparatively short service lives lead to higher setting- up times, which in turn has the con- sequence of longer standstill times. Productivity of the plant as a whole would suffer con- siderably, and inc- reased personnel and material costs would be unavo- idable. The fact that immediately after installation a wire screening panel can under certain circumstances temporarily provide up to about 20% more screening surface, even after allowing for the unused surfaces taken up by the traverses, is not really a great help. There is no question that effective screening area can be increased, even with synthetic screening panels. In the con- text of the areas available, Karl- Heinz Rossmann took great pains to establish ex- actly how the ef- fective proportion of open surfaces can be increased to improve per- formance: screen by screen, he analyzed precis- ely where ma- terial should be changed and / or the number of holes should be increased, the holes enlarged, to make use of spars or to break up blind zones. Screen areas wire screen cloth which demonst- With wire screen panels, moisture can cause undesirable clogging which may even result in complete blockage in places

Issue 03 | 2009 www.advanced-mining.com 87 NEWS & REPORTS rate a high rate of grain clogging are to be exchanged in the future for rubber screen panels. Rossmann is recko- ning that only by the elimination from plugging material, an increased throughput of around 20% can be achieved. In addition, he can demonstrate that by using rectangular mesh in blind zones a further 10% increase in performance is more than likely. The sum total of the examination in Bieberau works covered about 100 m² of screening area. Metso Minerals Germany corporation The design of the screening media it will be necessary Kantstrasse 22 – 24 to replace can be carried out flexibly by Metso Minerals. 44867 Bochum | Germany Karl-Heinz Rossmann will be giving the manufacturer his Tel.: +49 (0) 2327 54 44 43 individual recommendations. Fax: +49 (0) 2327 54 44 91 A works analysis is planned to determine the increased eMail: [email protected] proportion of correctly-sized grains at a later date and to Internet: www.metso.com give information on the quality and quantity of saleable gra- Adservice, press relations nulate in accordance with DIN and on the extent to which Ralf Goffin the situation has actually altered since the installation of An der Wolfskaul 42 a the new screens. 41812 Erkelenz | Germany Tel.: +49 (0) 2423 89 08 09 0 Fax: +49 (0) 2423 89 04 42 9 eMail: [email protected]

Best results lead to the breakthrough

If crusher technology by Metso looks after anything, then it’s your purse: the Barmac vertical impact crusher protects the rotor which controls the process in an autogenous layer of feed material in crushing. The mobile Lokotrack LT1415 protects the nerves, as its large intake opening prevents bridging. As a primary crusher, the LT140 saves time – in conjunction with the flexible Lokolink conveyor system it makes such progress in opencast quarrying that you can save a large proportion of your dumpers. Talk to us about the possibilities of staying successful even in difficult times. Metso Lindemann GmbH Business sector Construction Obere Riedstr. 111-115 68309 Mannheim Tel. ++49 (0) 621 72700 611 E-Mail: [email protected] www.metso.com

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Issue 03 | 2009 www.advanced-mining.com 88 NEWS & REPORTS

THE NEW bucket crusher BF:

MB ANSWER TO CUSTOMERS’ NEEDS! MB S.p.A. presented the new version of the bucket crusher at the Paris trade fair Intermat.

Issue 03 | 2009 www.advanced-mining.com 89 NEWS & REPORTS

MB S.p.A., a Vicenza company and worldwide leader crushers. Also, company participation in major national in the production and sales of bucket crushers, was at and international events in this sector has enabled MB the Intermat 2009 trade fair in Paris to present its latest to establish and strengthen relationships and loyalty with product, clients, who always receive special attention. – a new bucket crusher, the result of ongoing investments in technological research and the continuous attention to its customers’ needs. The company has decided to present this new product during one of the most important At the Intermat fair, MB S.P.A. was presenting a historical international trade fairs in the sector of construction, to product of the MB house, in a modernised version, once highlight the importance of this event. again demonstrating that the investments in research and technology offered to clients ensure that the company achieves the maximum levels of quality and satisfaction.

The historical model has been transformed to offer an even more revolutionary product on the market, thanks to the in- depth research of the MB team and technical engineers.

The company is committed to the constant satisfaction of customers’ requirements, ever attentive to their needs, carefully listening to all problems faced every day on construction sites, finding solutions most suited to the various international situations in which MB S.p.A. operates. It is also thanks to the long-lasting relationships and loyalty of clients that MB can produce bucket crushers that represent a valid work tool. The new version of the bucket crusher is in fact more resistant in work, featuring a more compact size and improved structural layout to facilitate operator manoeuvres on the excavator.

Despite the world crisis affecting all sectors, MB confirms its success and keeps on investing in research and development, giving priority to vertical specialisation in the production of a single product that enables the guarantee of high quality and top performing bucket

Issue 03 | 2009 www.advanced-mining.com 90 NEWS & REPORTS

MB S.p.A. set up in Breganze in 2001, now exports to 100 countries and is acclaimed for innovation and technology of its products and quality of its service. The ability to respond to market demands and technical assistance on offer to their numerous clients have contributed to the growth of the MB brand worldwide.

MB S.p.A.

eMail: [email protected] Internet: www.mbcrusher.com

Issue 03 | 2009 www.advanced-mining.com 91 NEWS & REPORTS Solving many Problems at Once!

was to show machines in action. This led many visitors to The AVANT TECNO Concept of Multi- the big booth, and evoked a lot of interest in the machines Functional Loaders Wins and their approach. With regard to the 40 (out of more than 100) accessory equipment, which could be tested, Sterkel Transporting sand from A to B is easy. For this, only the balanced a good exhibition result. “one-dimensional” output of the loader is important. However, in GaLa Construction, demolition, commune, channel construction, industry, etc., very often various Opening up New Areas of the Industry demands have to be met within very short timeframes Many enterprises in the industry take new directions and on narrow construction sites. Such demands can and open up to new branches. In order to do this, there only be met by an efficient, high-performance, robust is a demand for multifunctionally applicable and compact and multi-functional loader. In addition, the good quality machines that at the same time are very powerful. In such of accessory equipment (AVANT is delivering over 100) a case the multifunctional loaders of AVANT provide the is very important and of significant advantage. This fact right solution. With their five series and ten machines of is increasingly being acknowledged and used by the an application weight of 0.6 to 1.75 t and more than 100 costumers. “We are very happy to note that up to now, the available accessories of best quality, they are efficient and current business year has not brought us a total collapse; profitable helpers. “Furthermore, our customers appreciate on the contrary, it has brought about a turnover, which is the quality of our area-wide network of dealers, which almost at the same level as last year. The reason for this provides consulting, sales, renting and services. Besides fact can surely also be seen in the innovation of AVANT. At the quality of the machines, this is also a guarantor for our the beginning of this year, we created a new and expanded leading position in the market in this year and beyond.” application horizon with our 700 Series (up to 1.75 t of Sterkel says. You can verify these advantages locally with usage weight; 36 kW/49 PS motor)”, said Thomas Sterkel, the relevant regional dealer (information can be obtained managing director of AVANT TECNO, Germany. The high from www.avanttecno.de). Or visit at Agritechnica, 8. – 14. interest of visitors of the industry exhibition in demopark 11. 2009 in Hannover. in Eisenach in multifunctional loaders was clearly felt. AVANT had taken the exhibition concept seriously, which

AVANT TECNO Germany corporation Max-Planck-Straße 3 64859 Eppertshausen | Germany Tel.: +49 (0) 60 71 98 06 55 Fax: +49 (0) 60 71 98 04 53 eMail: [email protected] Internet: www.avanttecno.com

AVANT multifunctional loader Manifold tasks can efficiently be tackled with the AVANT multifunctional loaders of 0.6 to 1.75 t application weight

Issue 03 | 2009 www.advanced-mining.com 92 NEWS & REPORTS Atlas Copco launches ROC T35M - a robust surface drill rig!

he new ROC T35M combines the straightforward design concept of Atlas Copco’s former CM line Twith the well-tested features of the ROC family, in a new modular design developed for the next generation of Atlas Copco‘s surface crawler drill rigs. All with focus on productivity, cost-efficiency and hole quality for our customers.

ROC T35M is a fuel efficient drill rig equipped with a highly productive rock drill. The well-proven COP 1840 rock drill with 18kW drilling power provides high penetration rate. It gives more drilling power for less input energy, resulting in less fuel consumption. The hydraulic based control system COP Logic adjusts the feed speed, feed pressure and impact pressure in realtime according to the rock condition.

Bo-Göran Johansson, Vice President, Marketing, at Atlas Copco SDE adds: “Every contractor dreams of higher penetration rates, straighter holes and better accessory life. The ROC T35M drill rig employs a cylinder-driven aluminum feed system that fulfills this dream by providing optimal penetration rates and drill steel life. Its rod handling system, with a streamlined number of parts, ensures easy adjustment and maintenance. The well proven aluminum feed profile is sturdy and highly resistant to bending.”

Issue 03 | 2009 www.advanced-mining.com 93 NEWS & REPORTS

ROC T35M RROC T35M is equipped with the well-proven COP 1840 rock drill

ROC T35M is built of modules and parts common to Atlas Copco Surface crawler portfolio. This makes training easy and parts stocking requirement reduced for contractors with different Atlas Copco rig models. Maintenance is simplified thanks to all around access to service points and good hose management with bulk heads. Maintenance- friendly design together with ROC Care and COP Care service agreements mean less breakdowns, increased availability and reduced service costs.

ROC T35M Maintenance on ROC T35M is simplified thanks to all around access to service points and good hose management with bulk heads

Issue 03 | 2009 www.advanced-mining.com 94 NEWS & REPORTS The Atlas Copco Simba W6 C rig available for new markets!

fter having proven itself at LKAB, in Sweden, one of the world’s leading producers of iron ore products, AAtlas Copco is now releasing the production drilling rig Simba W6 C to the market. Patrik Ericsson, Product Manager Simba rigs, Atlas Copco, says:“Our commitment to the customer is to provide the best possible tool for their application. Working together with a leading mining company such as LKAB has proven that high demands create great solutions.”

Focusing on high productivity, reliability and hole The Simba W6 C rigs have now been in production for accuracy, Atlas Copco and LKAB have a common history more than two years in LKAB’s Kiruna and Malmberget in developing production drilling rigs for successively mines and the results have so far lived up to the company’s longer holes with a minimum of hole deviation. This focus high expectations. has paved the way for increasing the distance between the sub levels. The Simba W469 rigs, introduced in 1995, have The Simba W6 C rigs are equipped with a rig control been working successfully in both Kiruna and Malmberget. system which optimizes the performance for in-the-hole In 2006/2007 these rigs were complemented by the Simba hammer (ITH) applications. The Simba W6 C rigs offer W6 C rigs. The Simba W6 C rig is specially adapted to the unattended drilling in full fan automation, enabling the Wassara water driven in-the-hole hammer and gives long, operator to supervise several drill rigs at the same time. In straight holes with a minimum hole deviation of less than cases where manual operation is preferred, the rig’s cabin 1 percent. Besides long hole drilling, the Simba W6 C can offers a good working environment with air conditioning, also be modified for slot hole drilling, a method that is used vibration dampening and noise insulation. in LKAB’s Malmberget mine.

Issue 03 | 2009 www.advanced-mining.com 95 NEWS & REPORTS

An important feature is the water pump system which gives high efficiency, low water spillage and low overall cost. An air venting system ensures long pump life, and the pump pressure control optimizes hammer efficiency and life length.

Simba W6 C The Simba W6 C rigs are equipped with a rig control system specially designed for in-the- hole hammer (ITH) applications

Surface Drilling Equipment is a division of the Atlas Copco Underground Rock Excavation is a Construction and Mining Technique business area of division within Atlas Copco’s Construction and Mining the Atlas Copco Group, with its main manufacturing Technique business area. It develops, manufactures, center at Örebro, Sweden. The division develops, and markets a wide range of tunneling and mining manufactures and globally markets rock drilling equipment for various underground applications equipment for various applications in civil engineering, worldwide. The division focuses strongly on innovative quarrying and open pit mining. A strong focus on product design and aftermarket support systems, innovative product design and aftermarket support which give added customer value. The divisional systems provides added customer value. headquarters and main production center is in Örebro, Sweden.

More information can be found at http://www.atlascopco.com Surface Drilling Equipment Simba Bohrgeräte Bo-Göran Johansson (VP Marketing) Patrik Ericsson (Product Manager) Tel.: +46 (0) 19 670 72 59 Tel.: +46 (0) 19 670 74 10 Mobil: +46 (0) 70 321 21 11 Mobil: +46 (0) 70 347 87 28 eMail: [email protected] eMail: [email protected] Internet: www.atlascopco.com Internet: www.atlascopco.com Surface Drilling Equipment Tunnelling & Mining Equipment Sandra Lagerqvist, (Com. Professional) Anna Dahlman Herrgård, (Com. Professional) Tel.: +46 (0) 19 503 1240 Tel.: +46 (0) 19 670 73 82 Mobil: +46 (0) 73 337 8028 Mobil: +46 (0) 733 26 73 82 eMail: [email protected] eMail: [email protected] Internet: www.atlascopco.com Internet: www.atlascopco.com

Issue 03 | 2009 www.advanced-mining.com 96 NEWS & REPORTS

Diamond scrap heap Cat-machines process one of the world’s largest scrap metal stock piles in Namibia!

First discovered by German prospectors during the early 1900s, major diamond finds along Namibia’s Skeleton Coast in regions like Lüderitz subsequently led to the rise of thriving mining communities at the turn of the 20th century. Attracting fortune hunters from around the world, many of these centres later became ghost towns as deposits were exhausted and have now subsequently been reclaimed by the mountainous sand dunes of the Namib.

Up until 1994, the largest player in this country was Consolidated Diamond Mines (CDM), which at the time was a wholly owned subsidiary of De Beers. In that year a new agreement was concluded with the Republic of Namibia, resulting in the formation of the Namdeb Diamond Corporation. The latter is jointly owned by the Namibian government and De Beers Centenary AG.

Given the high intrinsic value that diamonds hold, all Namdeb mining operations are governed by strict security protocols concerning how processed diamonds are transported to market. This means that all equipment going into any diamond mining area – whether it’s a dozer, a pick-up truck or an excavator - never comes out again.

However, given the scale of Namdeb’s operation (and CDM’s before it), this has meant that a large stockpile of redundant equipment has steadily gathered at Namdeb’s various mining sites. Recently, both for environmental and practical reasons, Namdeb took the decision to clear these waste dumps, with Cape Town, South Africa, based company SA Metal, securing the contract to systematically recycle and process the materials on site prior to their release from these secured areas.

Issue 03 | 2009 www.advanced-mining.com 97 NEWS & REPORTS

The task of cutting up these redundant machines and other materials is being tackled by two Cat 330DL hydraulic excavators fitted with boom mounted S340 shears, sold and supported by Barloworld Equipment Namibia, the local Caterpillar® dealer. A Caterpillar Work Tools team flew out from the factory in Holland to help install the shears, as well as to provide training for SA Metal’s operators.

Issue 03 | 2009 www.advanced-mining.com 98 NEWS & REPORTS

Uubvlei

According to SA Metal’s Xavier Fazakerley the contract, which commenced in July 2008, is open-ended and expected to be ongoing for around three years. During this period, SA Metal expects to commercially process around 250 000t of saleable material.

“This is one of the world’s most corrosive regions and metal items don’t last long in this environment,” explains Fazakerley. “This means that any scrapped metal items prior to the mid-1960s will have in most instances turned to dust long ago.”

The largest sizeable scrap metal source is located at Namdeb’s Uubvlei operation, situated some 10km north of the Orange River and stretching approximately 1km inland.

“This represents one of the world’s largest scrap metal stockpiles,” says Fazakerley. “In fact the scale of the operation is so big that the footprint of the site is clearly visible from Space - a final resting place for worked out earthmoving machines, commercial vehicles and just about anything else no longer usable. During dumping operations, everything was mixed in together. This means we have to separate metal and non-metal materials in sourcing items such as copper, steel, lead and zinc. Currently we are processing around 5 000t per month.”

At Uubvlei, SA Metal expects to process around 100 000t of steel, with the balance sourced from an estimated 15 satellite mines spread over a distance of some 110km up and down the coastline.

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Press Inquiries Europe, Africa and Middle East Mia Karlsson Tel.: +41 (0) 22 849 46 62 Fax: +41 (0) 22 849 99 93 eMail: [email protected] Internet: www.cat.com

Issue 03 | 2009 www.advanced-mining.com 99 EVENTS

2009THE AMS-EVENT CALENDER

October 2009 03 - 04 Oct 2009 2009 Toronto Resource Investment Conference Toronto ON, Canada www.cambridgehouse.ca www.nupus.uni-stuttgart.de/index.p 05 - 07 Oct 2009 International Conference on Non-linearities and Upscaling in Porous Media Stuttgart hp?module=events&file=stuttgart 06 - 08 Oct 2009 MiningWorld Uzbekistan 2009 Tashkent, Uzbekistan www.miningworld-events.com 06 - 09 Oct 2009 2009 APCOM Symposium Vancouver BC, Canada www.cim.org/apcom2009 08 - 09 Oct 2009 Bergbau- und Steine- und Erden-Tag 2009 Neuburg a. d. Donau www.abbm-bayern.de 08 - 09 Oct 2009 Mining Magazine Congress Ontario, Canada www.miningcongress.com 12 - 14 Oct 2009 NEXT 2009 Shanghai, China www.next2009.com www.ausimm.com/content/wsc. 12 - 14 Oct 2009 Tenth Mill Operators Conference Adelaide, Australien aspx?ID=17 13 - 15 Oct 2009 FILTECH 2009 Wiesbaden www.filtech.de 14 - 17 Oct 2009 Mining Indonesia 2009 Jakarta, Java, Indonesia www.pamerindo.com GDMB-Arbeitskreis Tagebautechnik im Fachausschuss "Steine, Erden, 15 - 16 Oct 2009 Walzbachtal-Wössingen www.gdmb.de Industrieminerale" www.geo.tu-berlin.de/steine-in- 16 - 18 Oct 2009 Tag der Steine in der Stadt Berlin der-stadt/tag_der_steine_in_der_ stadt www.wisa.org.za/minewater2009. 19 - 23 Oct 2009 IMWC — International Mine Water Conference Pretoria, Südafrika htm 21 Oct 2009 MIRO-Ausschuss "Rohstoffsicherung, Umweltschutz, Folgenutzung" www.bv-miro.org IFAC MMM 2009 IFAC Workshiop on Automation in Mining, Mineral and Metals 20 - 22 Oct 2009 Vina del Mar, Chile www.ifacmmm2009.com Industry 20 - 22 Oct 2009 CHINA MINING Congress & Expo 2009 Tianjin, China www.china-mining.com 21 - 23 Oct 2009 TZMI Asia in Focus Congress 2009 Singapore, Singapur www.tzmi.com 21 - 23 Oct 2009 WCSB4 — The 4th World Conference on Sampling and Blending Kapstadt, Südafrika www.wcsb4.com 26 - 30 Oct 2009 World Gold 2009 — SAIMM World Gold 2009 Processing Workshop Kapstadt, Südafrika www.worldgold2009.com 27 - 29 Oct 2009 China Coal and Mining Expo 2009 Beijing, China www.chinaminingcoal.com/2009 Adelaide, South Australia, 27 - 29 Oct 2009 Mining & Energy SA Australien www.miningandenergysa.com.au 28 - 29 Oct 2009 Forum MIRO 2009 Kolloquium und Ausstellung Würzburg, Maritim Hotel www.bv-miro.org 27 - 30 Oct 2009 ENTSORGA-ENTECO 2009 Köln www.entsorga-enteco.com

Issue 03 | 2009 www.advanced-mining.com 100 EVENTS

2009THE AMS-EVENT CALENDER November 2009 Johannesburg, South 02 - 04 Nov 2009 MINE-TECH International www.MineTechExpo.com Africa 04 - 06 Nov 2009 Valuation of Mineral Projects Vancouver BC, Canada www.edumine.com/pd/valuation 09 - 12 Nov 2009 Flotation 09 — 4th International Flotation Conference Kapstadt, Südafrika www.min-eng.com/flotation09 Los Andes, Santiago, 09 - 11 Nov 2009 Slope Stability 2009 www.slopestability.cl Metropolitana, China 10 Nov 2009 Steinkohlentag 2009 Essen www.gvst.de 10 - 12 Nov 2009 Stainless Steel World Conference & Exhibition 2009 Maastricht (Netherlands) www.stainless-steel-world.net 10 - 13 Nov 2009 Metal-Expo 2009 Moscow (Russia) www.metal-expo.com 11 - 12 Nov 2009 Hochschul-Kupfersymposium 2009 Duisburg www.kupferinstitut.de/symposium 10 - 12 Nov 2009 China Mining 2009 Beijing, China www.china-mining.com 13 Nov 2009 Fachtagung Asphalt in Freiburg Nano Petroleum, Gas and Petro-Chemical Industries Conference: “Providing www.npg.sabrycorp.com/conf/ 15 - 19 Nov 2009 Kairo, Ägypten Nano-Powered Solutions” npg/09 SWEMP 2009 — 11th International Symposium on Environmental Issues and 16 - 19 Nov 2009 Banff, Alberta, Kanada ww.mpes-cami-swemp.com Waste Management 17 - 19 Nov 2009 Geothermiekongress 2009 Bochum www.geothermie.de 16. Internationale IFF-Fachtagung: „Verfahren und Ausrüstungen für die 18 - 19 Nov 2009 Leonardo Hotel Weimar www.iff-weimar.de Herstellung von Betonwaren und Betonfertigteilen“ San Francisco CA, 21 - 22 Nov 2009 San Francisco Hard Assets Conference www.hardassetssf.com Australia 23 - 24 Nov 2009 CoalMine Methane London, UK www.smi-online.co.uk 23 - 24 Nov 2009 Comparative Decision Analysis in Mining Vancouver BC, Canada www.edumine.com/pd/analysis December 2009 01 - 03 Dec 2009 FEM 2009 — 7th Fennoscandian Exploration and Mining Rovaniemi, Finnland www.lapinliitto.fi/fem2009 01 - 03 Dec 2009 STUVA Tagung 2009 Hamburg www.stuva.de 02 - 04 Dec 2009 PROCEMIN 2009 VI International Mineral Precessing Seminar Santiago, Chile www.procemin2009.com 02 - 05 Dec 2009 EuroMold 2009 Frankfurt www.euromold.com Nature's Treasures: Minerals and Gems (MSGBI Joint meeting with the Gem- 07 Dec 2009 London, Großbritannien www.minsoc.ru mological Association of Great Britain and The Russell Society) 10 - 13 Dec 2009 ENERGY INDIA, MDA INDIA, CeMAT INDIA, Industrial Automation INDIA Mumbai (India) www.cemat-india.com

Issue 03 | 2009 www.advanced-mining.com 101 EVENTS

IV International Conference on Mining Innovation

first announcement and call for papers

23 ---> 25 june 2010, Sheraton Santiago Hotel & Convention Center, Chile. Planning for Sustainable Mining

participants The Department of Mining Engineering of the Universidad de Chile and the Mining Centre of the Pontificia Universidad Católica de Chile, are pleased to invite executives, academics, professionals and technical experts to participate in the iv international conference on mining innovation - minin 2010, to be held on 23 – 25 June 2010, in Santiago, Chile.

objectives areas of interest

MININ 2010 is organised to provide an international forum where — Mine Planning experts may analyse and discuss innovations and recent developments — Sampling and Geostatistics in mine planning, operations optimisation, equipment development and management of the mining business. The Conference aims to: — Geomechanics and Geotechnics • Promote the exchange of best practices and — Mine Unit Operations experiences applied to mining processes — Optimisation of Mining Processes • Discuss emerging trends and developments and — Expansions and New Projects identify best practices in the mining industry — Integrated Mine Management

• Promote the development of an interdisciplinary — Mineral Economics international network for technical collaboration and exchange among professionals engaged in the — Innovation Management planning and development of mining processes

abstract submission deadlines

Prospective authors are invited to submit a 300 word abstract abstract submission 11 october 2009 in English, until 11 October 2009, to [email protected] The notification to authors 23 october 2009 abstract must be in MS Word, including a 100 character title, full paper submission 23 november 2009 full author’s name, position, company, business address, phone comments to authors 30 december 2009 number and email. If accepted, a full article up to 10 pages long final paper submission 29 january 2010 will be required by 23 November 2009. All final papers accepted early registration 23 march 2010 for publication will be included in the Conference Proceedings. The technical program will be comprised of oral and poster presentations; the form of presentation for each paper will be executive committee decided upon the receipt of its final version. English–Spanish Diego Hernández Carlos Barahona Romke Kuyvenhoven simultaneous translation will be provided during the Conference, chairman executive director technical coordinator thus, the oral presentation may be made in either language. minin 2010 minin 2010 minin 2010 BHP Billiton, Chile Gecamin, Chile Gecamin, Chile

Organised by enquiries

Isis Galeno Telephone (+56-2) 652 1514 minin 2010 Fax: (+56-2) 652 1570 event coordinator E-mail: [email protected] Gecamin, Chile www.minin2010.com

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Fax: +49 (0) 241 - 401 78 28 Stationary plants now become mobile thanks to interlinked plants! Kleemann demonstrates what is KLEEMANN GMBH eMail: [email protected] possible today with process know-how and high-performance plants New SURFACE MINER 4200 SM from Wirtgen: Maximum performance in large-scale opencast WIRTGEN GMBH mining! Internet: METSO MINERALS Germany GmbH www.graumann-design.de Improved performance out in the open! MB Crusher S.p.A The new bucket crusher BF AVANT TECNO Germany GmbH Solving many Problems at Once! ATLAS COPCO Atlas Copco launches ROC T35M a robust surface drill rig! Surface Drilling Equipment, Tunnelling & PROGRAMMING INTERNET SITE The Atlas Copco Simba W6 C rig available for new markets! Mining Equipment

Diamond scrap heap - Cat-machines process one of the world’s largest scrap metal stock piles in CATERPILLAR INC. 79pixel Namibia! Steffen Ottow, B.Sc. Scharenbergstr. 24 EVENTS The AMS Event Calendar 2009 38667 Bad Harzburg | Germany Tel.: +49 (0) 53 22 - 8 19 38 THIS MAGAZINE IS SUPPORTED BY: eMail: [email protected] Bell Equipment Sandvik Mining & Construction Internet: www.79pixel.de Continental/ContiTech Vermeer Metso Minerals Zeppelin ISSUE DATES Online-Journal Format: DIN A4 as Print optimised PDF in German and Englich Language | 4 Issues per Year HOW TO SUBSCRIBE TO AMS:

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