Miners trapped underground in rock

fall.” Headlines such as this are all

too familiar, particularly in South

Africa where deep hard rock mines such as

those in the gold industry predominate. Booyco

Electronics’ new Trapped Miner Locator promises

to make a positive impact by facilitating and

accelerating the process of establishing the

whereabouts of miners trapped underground.

“Seismic events, gas explosions or rock falls

deep underground can be catastrophic

because of the time taken to pinpoint the

position of trapped miners,” Anton Lourens,

Managing Director of Booyco Electronics,

explains. “Previously, it was almost impossible

to penetrate the volumes of rock to find

people, so clearance had to take place

agonisingly slowly. The mining industry has

long been looking for a system that can ‘see

through’ rock so that people can be found

without wasting time.” Time, of course,

impacts not only on the possibility of saving

lives but has a dramatic impact on productivity

and thus the bottom line.

A Trapped Miner Locator, developed by

Selectronic of Germany and already

successfully implemented in Poland, is being

introduced in South Africa by Booyco

Electronics. Lourens says this has extended the

current range of VLF collision warning products

available from the company, and has been met

with positive feedback from the mining sector.

“Miners’ tags are fitted with a VLF

transmitter,” Lourens continues. “VLF has

pronounced through-rock penetration

capabilities – up to 30 m and more. Search

teams are equipped with a VLF receiver which

is much like a hand-held unit and this is used

to screen the rock falls ahead of them. The VLF

technology enables them to read a good 30 m

ahead of them and if no VLF signals are

detected from the miners’ tags, the team can

go in with heavy equipment to clear out fallen

rock speedily without fear of further injuring or

even killing those trapped.”

The device has two different antennae – one

which can scan for 30 m and a second that

scans within 10 m. “Once rock falls have been

cleared, one can use the near-range antenna

to find miners within a few metres and clear

that debris by hand.”

There are no Trapped Miner Locator systems

currently deployed in South Africa. “The

current global recession has put many mining

concerns under considerable financial strain,”

Lourens points out. “So implementation of

such a system might not take place as speedily

as one would desire, but there is little doubt of

its value and I am confident that depending on

financial constraints, all deep hard rock mines

will soon be evaluating it.”

NL Technologies recently introduced the

Northern Light® first ever MSHA approved

cordless, all in one cap lamp, the Polaris. This

Deep thinking

John Chadwick considers some breakthroughs inlocating trapped miners, undergroundcommunications and new ventilation technology

GOING DEEPER

42 International Mining SEPTEMBER 2010

“ The Mine-Phone is a VoIP telephone that can be used

with the ImPact Network whenever required. It is

basically like a mobile phone for underground mines.

Here a miner uses the MinePhone, whilst using his

lap top that is wirelessly connected to the mine’s

network. Both the phone and lap top use the ImPact

WNS when they are within range to make the

connection to the network and the rest of the mine

The low maintenance Polaris is safe for Group II

environments, while also being fully approved by

IECEx and ATEX M1, and boasts the latest in LED

optics and multiple mounting options for a person or

a vehicle. The 170 g lamp is of low profile, allowing it

to fit snugly against the mounting bracket. The

Polaris provides a stable light through a lithium-ion

battery, with an operating and charging time of 12

hours and a 500+ charge lifecycle, which retrofits

two for one on NLT GII charging racks

integrates the battery and light source in one

enclosure. The lamp is hands free and fully

cordless. Two light sources plus an emergency

flashing beacon mode are standard in Polaris

lamps with the main light output at

3,500+Lux. “The Northern Light® Polaris is

going to revolutionise personal lighting in

mines,” says Heidi Levitt, President of NLT

Global.

Better commsMine Site Technologies’ MinePhone – the Voice

over Internet Protocol (VoIP) telephone handset

for underground two-way

communications, has received

MSHA approval for use in US

coal mines. This is the latest

component of MST’s tracking

and communication system to

be approved and completes the

system’s ability to meet the

conditions of the MINER Act

2006.

The MinePhone is also

relevant to hard rock mine

operators, as MinePhones are

already deployed in metalliferous

mines. The MinePhone uses the

MSHA approved ImPact Wi-Fi network or the

standard non-IS ImPact network as the

communication backbone to provide two-way

voice and texting along the primary and

secondary escapeways underground. The

telephone handset allows private dialling

between other phones in the network and the

mine’s outside telephone system, as well as

text messaging. Additionally, it has 24

channels, Push-to-Talk functionality and

emergency calling, emulating the functionally

of many radios currently in use, but with many

other functions available.

The Wireless Network Switches (WNSs) are

the key part of the underground digital

backbone and also act as

readers for the Wi-Fi RFID Tags

that are carried by miners

underground, allowing a single

communication network to

provide both underground

communication and tracking

throughout the mine

“[This] is a breakthrough in

underground voice and

messaging communications,

offering functionality never

before available in coal mines”

said Lloyd Zenari, CEO of MST.

“The safety and productivity

benefits for mining operations have quickly

become apparent in metal mines and we

expect the acceptance to be quicker still in coal

operations”.

Lockheed Martin recently conducted an in-

mine test of its MagneLink™ Magnetic

Communication System (MCS). The work was

conducted at America’s National Institute of

Occupational Safety and Health (NIOSH) test

mine in Bruceton, Pennsylvania in June.

MagneLink MCS is a wireless, through-the-

earth communications system developed to

meet the industry’s post-accident emergency

communications requirement. The system

provides voice communication and texting to

give trapped miners fail-safe communication

during a catastrophe.

The system works by transmitting magnetic

waves through the earth without the

transmission wires and in-ground infrastructure

currently required to communicate via standard

radio transmissions. It is a portable, two-way,

voice- and text-capable emergency

communication system operating at ranges

sufficient to communicate from the surface

into deep underground mines.

“During the test, MagneLink MCS

performed superbly,” said Warren Gross,

MagneLink MCS Program Manager. “The

system interfaced with hand-held radios similar

to the Miner Emergency Radios (MERs) and

functioned as a multi-band receiver,

44 International Mining SEPTEMBER 2010

GOING DEEPER

establishing communications with multiple

MagneLink MCS units without the requirement

for the MCS units to be on the same channel

to receive transmissions.”

“Lockheed Martin has leveraged its

advanced communications and signal

processing expertise to successfully develop

this unique system in co-ordination with NIOSH

to help saver miners’ lives following a mine

accident,” said Gross.

Lockheed Martin

previously conducted

two additional

MagneLink MCS in-mine

tests. In December 2009,

the MagneLink MCS

Engineering

Development Model’s

functionality for voice

and text communications

was successfully

demonstrated at a

commercial mine in

Dilliner, Pennsylvania.

Then in March 2010, it

was tested at the

Contrary Portal of

CONSOL Energy’s Buchanan mine in Mavisdale,

Virginia. The system demonstrated successful

two-way voice communications to a depth of

almost 475 m and two-way text

communications to a depth in excess of that.

Lockheed Martin and the Mining Safety and

Health Administration (MSHA) are currently

working to certify the equipment for use in

mines. MagneLink MCS systems will be

available following MSHA certification.

The new TX2123 Ethernet adaptor from

manufacturer of sensors and sensing systems

Trolex, makes possible the connection of

almost any group I M1 RS485 MODBUS slave

device onto the mines Ethernet backbone.

Unlike many general-purpose Ethernet

adaptors, the Trolex TX2123 device is ATEX

group I M1 certified, meaning it works

effectively in mining applications and continues

to operate even when situated in a potentially

explosive atmosphere.

The robust TX2123 converts data

communications between MODBUS TCP over

Ethernet and MODBUS RTU over RS485. The

TX2123 connects to the Ethernet via industrial

standard 'ST' optical fibre connectors and to

the RS485 via copper.

Good airBucyrus says that "with a preference for diesel-

powered vehicles within the Australian

underground coal mining industry, [it] is at an

advantage as the only OEM to offer mines the

option of either wet bath or dry exhaust

systems with filtration. This allows Bucyrus to

offer its customers an independently verified

zero diesel particulate matter (DPM) emission

to mine atmosphere solution.

As a supplier and operator of its own diesel

vehicle Hire Fleet, Bucyrus Australia is suitably

placed to understand the needs of the

customer and end-user from an owner

operator perspective. All Bucyrus diesel

Recent testing of Lockheed Martin's MagneLink MCS

has been succesful

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46 International Mining SEPTEMBER 2010

equipment sold is compliant with Australian

guidelines and is designed to exceed them

wherever possible.”

DPM matter is an expensive problem that

mines need to address in order to ensure a

safe and clean working environment for

personnel. Diesel particulate matter requires

considerably more airflow to dissipate than gas

emissions. Many older established mines have

ventilation systems and designs operating close

to peak capacity and increasing ventilation

rates is not just limited to fan replacement.

New infrastructure would be required to

support increased power demands along with

the redesign of panel layouts and ventilation

doors. When the financial impact of this is

considered, the selection of underground

diesel equipment can have a serious impact on

the mine's investment budget. If not fitted

with diesel particulate filters, longwall change

outs produce a high volume of diesel

particulate matter and can pose a significant

health threat to the personnel involved, a

concern for independent longwall move

contractors.

Bucyrus has designed and configured engine

and exhaust packages specifically for the

Bucyrus diesel product range. By combining

low emission engines and its wet and dry

exhaust packages, Bucyrus can offer class

setting emissions, power and performance that

help address mine ventilation concerns in

dissipating diesel particulate emissions. These dry

and wet exhaust systems cool and clean

exhaust gas before it mixes with mine

ventilation air. Catalytic converters are used to

regenerate the exhaust gas and reduce emissions.

After going through the catalytic converter

on the dry system, the exhaust gas passes

through a water-cooled finned tube heat

exchanger. Post-catalytic converter on the wet

system, the exhaust gas passes through a

water bath which reduces the exhaust gas

temperature and assists in removing

particulates from the exhaust gasses. In both

systems, the gas passes through the particulate

filters and flame trap after the heat exchanger

and water bath. It is then mixed with the

discharge air from the cooling system before

entering into the mine atmosphere. A flame

trap is fitted on the out-by side of the

particulate filter to prevent any possible flame

path to mine air on the dry system.

Nett Technologies has received US-EPA

verification of its BlueMAX 100 Selective

Catalytic Reduction (SCR) system for

controlling NOx emissions from mobile off-road

medium and heavy duty diesel engines. The

verification is a first of its kind issued for

retrofit device under the EPA ETV program.

This SCR system uses a urea control strategy

that relies on a NOx concentration

measurement by a sensor positioned upstream

of the SCR catalyst. Based on the NOx sensor

signal, in combination with an engine mass air

flow sensor and temperature sensor, the

necessary urea dosing rate is calculated by the

control algorithm. Feed forward NOx sensor-

based control strategy makes the system ideal

The exhaust system is monitored by the Bucyrus

Diesel Control System (DCS). This is an electronic

shutdown system which prevents the machine from

being operated in unsafe conditions such as low water

level, high exhaust system temperatures or back

pressure. A gauge in the operator's compartment

indicates when the filter requires changing

GOING DEEPER

for retrofit applications. The system can be

installed on a wide range of diesel engines and

no additional engine calibration is necessary.

The Nett BlueMAX also controls DPM,

hydrocarbons (HC) and carbon monoxide (CO).

A new generation of Swedvent

underground ventilation fans and ducting

system from GIA Industries offers reduced

noise levels. Improved silencer design offers

noise reductions of at least 3 dB(A) for the full

range of fan motors rated between 10 and

500 kW to meet 75-85 dB(A) at 7m. The

improved sound damping has been achieved

with a specially designed silencer filled with

processed mineral wool to reduce high

frequency sounds.

The ventilation system features advanced

impeller design incorporating a large hub,

short blades and, accurately measured spacing

between the blades to give the fan an

enhanced ability to counteract high pressure

systems. The dynamically balanced impeller

rotates in purpose - designed guide vanes to

eliminate turbulence.

Individually adjustable aluminium blades

allow the same fan to be used for a number of

different tunnel conditions by adjusting the

blade angle. For example, a 1,250 mm

diameter fan can be set to deliver 16-44 m³/s.

The range of Swedvent fans is available with

630-2,240 mm diameters and 1.5-200 m³/s

capacities. They are built in a rugged anti-

corrosion treated design to withstand

aggressive environments. The GIA Swedvent

range of fans is particularly suited to long drifts

allowing two or more fans to be installed in

series offering increased power to counteract

the possible high pressures in the tunnel

ducting.

The Swedvent ventilation system also

features GIA’s flexible, pvc-coated polyester

fabric ducting available in diameters from 300

to 3,000 mm and lengths of 10

up to 200 m; to

ensure a

pliable, easy

to handle

duct, with a

relatively low

weight and

highly durable ducting.

Increased tear strength is also

assured with an enhanced yarn in the

base fabric every second centimetre.

The flexible ducting system is also

manufactured in two different standard

qualities and two antistatic qualities which

meet SIS650082 fire resistance.

Both duct ends are fitted with a split, heavy

duty, PVC-type zipper and made with

protective flaps on both the inside and outside

to ensure an absolutely airtight ducting. The

ducting can be used several times on different

projects, and, if it should fail, is very easy to

repair. The airflow is shut off causing the

ducting to collapse: a fabric repair sleeve is

then applied to the damaged area and closed

using its zip joint. When the airflow is returned

the sleeve stays firmly in place.

Besides dust and other particultes, air quality

is also affected by temperature. DRA Technical

Services (DRATS), the hoist specialists of South

Africa's DRA Group, has ventured into new

territory with designing and building the

prototype for a mobile heat tolerance

screening unit at the request of a client. DRATS

director Graham Du Plessis explains: “This is

SEPTEMBER 2010 International Mining 47

GOING DEEPER

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48 International Mining SEPTEMBER 2010

certainly a deviation from our normal winder

work but it does offer considerable potential

for the future.” The traditional heat tolerance

screening method is used to evaluate a

mineworker’s ability to operate in the typical

high temperature, high humidity conditions

found underground in South Africa. The miner

is required to perform 30 minutes of step

exercises at 30°C and a humidity level of 98%

while his heart rate, breathing and body

temperature are continuously monitored. The

screening system is normally housed in a

permanent facility at the mine and overseen by

a team of technicians and supervisors. The

disadvantage of the system is that each mine

must either maintain its own on site or

transport workers to another facility off site.

Says Du Plessis, “Currently DRATS is

designing both a mobile and semi-mobile

version. The semi-mobile design enables the

client to install a number of small systems

where they are needed instead of relying on a

large, centralised facility. The mobile version

can be transported and installed when and

where it is required. Either way, the results are

considerable savings in operating and transport

cost and time. In addition, as the systems are

designed to be fully automated, fewer staff are

required to operate the screening system -

typically only a clerk, a test supervisor and

maintenance technician are required. This type

of system has never been used by the industry

before and offers potential for streamlining the

evaluation process and reducing costs.”

Hydraulic drillingbreakthroughA new environmentally friendly drilling

technology, developed by two UK

entrepreneurs, may have a major

impact on underground mines using

hydraulic drilling, with

some of the world's

leading mining houses

already planning to

introduce it to their

mines. Peterstow

Aquapower has

developed a new drilling

system which could save

millions of dollars in capital

and operating costs, whilst

dramatically reducing the

industry's environmental impact.

Pumping water and providing energy

down deep mines, and removing and

disposing of it, has proved so expensive that

some mines have struggled to stay

profitable. Peterstow says its “new drilling

systems for hard rock deep mining use less

than 0.01% of the energy required by some

existing systems and 60% less water. In

addition to dramatic cost savings, it will help

mines respond to increasing regulatory and

political pressure to improve energy efficiency.

The Peterstow system also cuts capital cost

by eliminating the need for much of the

underground infrastructure needed for

traditional hard rock drilling processes, such

as compressed air reticulation columns

and high strength water piping.

The system uses Peterstow’s

patented closed-loop water

hydraulic technology and

modular powerpacks. The

closed-loop design

dramatically cuts water

usage and ensures a more

efficient transfer of power to

the drill with greater

reliability than existing

technologies. It reduces

water wastage and

flooding which allows

for the reduction of

pumping facilities,

GOING DEEPER

Peterstow Aquapower's new drill uses its patented

closed-loop water hydraulic technology and modular

powerpacks

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opening up additional opportunities for

savings.

The technology represents the life's work of

entrepreneurs Douglas and Alan Barrows.

Douglas said: “We believe this is the single

most important piece of technology to hit the

mining industry in 50 years. The interest we

have received already reflects how important

this will be for the industry.” Ian Cockerill,

former CEO of Gold Fields and an advisor to

Peterstow, commented: “This is a breakthrough

technology which can give a huge leap in

productivity. This kind of innovation means the

mines can still operate while reducing their

power requirements, and at the same time get

a much more efficient drill which gives you

more operating time at the face.”

“From work done to date, it appears there is

a real financial case to change from high

pressure water columns driving drills to

Peterstow's remote operated closed-loop water

hydraulic system. “Mines are going to come

under huge pressure as significant consumers

of power. But big business like mining has the

capability to put in place a game changing

technology, and this is a game changing

technology,” Cockerill said.

The specific benefits of Peterstow technology

include:

■ Water consumption of these drills is around

2 t per tonne of ore extracted. Existing

hydraulic technology uses 5-6 t of water per

tonne of ore. For every 1,000 Peterstow

drills the water required by the mining

industry can be reduced by over 20 Mt/y.

■ 500 Peterstow drills would use 22,500 kWh

of energy in a month, based on a six-hour

daily drilling period, compared to pneumatic

drills, which can use 3,000,000 kWh.

■ Capital costs per 1,000 drills are around

$18.5 million, compared to $40.17 million

for the equivalent in pneumatic drills,

including necessary infrastructure

■ Peterstow drills improve working conditions

by reducing dust, noxious fumes and noise

pollution, whilst virtually eliminating the risk

of electrocution and oil leaks. This provides

greater health and safety for workers, and

reduces fire and electrical hazards

■ The drills will transform the quality of life for

workers and local communities as the

environmental footprint of a typical

operation is reduced

Peterstow has built a manufacturing plant on

a site in Ngwenya, Swaziland, where it employs

more than 100 people. The location provides

strong transport links to key markets in southern

Africa, from where it can be distributed

worldwide, and offers ample opportunity for

expansion to meet increasing demand.

Coal asset managementMincom had considerable success with top US

coal producers in July. First it announced a

three year global licensing agreement with

Peabody Energy, under which it will provide

Peabody with a hosted and fully managed

implementation of Mincom LinkOne,

which provides maintenance staff with

graphically supported electronic catalogues

and maintenance manuals. This helps

companies reduce equipment downtime and

improve the efficiency of maintenance

processes. Supported by Mincom’s managed

services offering, Peabody will implement

Mincom LinkOne to streamline procurement

processes and optimise the maintenance of

key equipment across its global operations.

Peabody Energy will use SAP’s standard Open

Catalog Integration (OCI) to integrate data

between SAP Enterprise Buyer Professional

and external catalogues provided by the

company’s heavy equipment OEM vendors, of

both underground and surface mining

equipment.

Mincom LinkOne is a graphical content

delivery solution that provides correct and

timely parts information to maintenance staff,

thereby reducing equipment downtime and

improving maintenance efficiency. A world

leader in graphical content management and

SEPTEMBER 2010 International Mining 49

GOING DEEPER

distribution, Mincom LinkOne has the

unmatched power to link graphics with parts

lists and rich text to easily produce graphically

supported electronic catalogs and maintenance

manuals. To quickly achieve return on

investment, the company will use Mincom

LinkOne to enhance the on demand delivery

model and other support services provided by

Mincom. Mincom says its managed services

offering can help companies decrease total

cost of ownership by speeding time to

deployment and reducing IT overhead, and

achieve faster time to results while minimising

risk. Mincom offers customers a fully managed

solution over their entire project lifecycle,

implemented either on premise or fully hosted

from Mincom’s data center to support the unique

requirements of remote mining operations.

Then, Mincom announced a significant new

agreement with Arch Coal, the second-largest

US coal producer. Currently providing roughly

16% of North America’s entire coal supply,

Arch will optimise its nationwide mining

operations through Mincopm Ellipse 8, a

powerful new solution for enterprise work

and asset management that helps boost

return on assets and workforce performance.

Additionally, Arch will implement the Mincom

Critical Inventory Optimization (MCIO) solution

across the company’s 11 mining complexes

(underground and surface) in North America. Fully

integrated with Mincom Ellipse, MCIO

automatically adjusts inventory levels to ensure

the availability of critical parts while reducing

inventory costs.

“We selected Mincom for its industry-

leading enterprise asset management solution,

which was designed specifically around the

needs of mining, and leverages the company’s

deep domain expertise from over 30 years of

experience working with asset-intensive

companies,” said Neil Novak, Vice President of

Operation Services, Arch Coal. “We’re pleased

to sign this significant agreement with

Mincom, the best-in-class EAM provider for

mining, and implement Mincom Ellipse 8 as

our solution for enterprise asset management

across our nationwide operations.” David

Hartley, Chief Information Officer, Arch Coal,

added “With Mincom Ellipse 8, we gain a

modern platform for enterprise asset

management – with a Web-native architecture

and lightweight footprint that can help us

significantly lower IT costs and resource

requirements. Mincom’s open architecture

means we can easily integrate the best-in-

breed EAM functionality of Mincom Ellipse 8

with our choice of back-office ERP

systems. Mincom’s open-standards approach

offers us the flexibility we require, supporting

our broader IT strategy of building an

enterprise infrastructure comprised of today’s

leading enterprise solutions.”

“Arch Coal operates the largest single coal-

mining complex in the world, and is one of the

nation’s top coal producers – supplying the

fuel for approximately 8% of the electricity

generated across the US. We’re pleased to

make Mincom Ellipse 8, the most powerful

release of our asset- and work-management

solution in our company’s history, available to

such a well-recognised industry leader across

its enterprise,” said Greg Clark, CEO of

Mincom. “Currently 17 of the world’s top 20

mining companies use Mincom’s solutions to

improve the efficiency and productivity of their

operations. We look forward to further

extending our deep domain expertise on

behalf of today’s mining leaders.”

Mincom says Ellipsse 8 is the industry’s most

modern and complete Enterprise Asset

Management solution designed expressly for

asset-intensive operating environments. It

provides companies in asset-heavy industries

with a fully integrated and mobile-enabled

suite of business-critical applications that

improves return on assets and workforce

productivity, while also addressing the

challenges inherent in remote and

geographically dispersed operations. IM

GOING DEEPER

50 International Mining SEPTEMBER 2010

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