Small hydropower; another source of renewables for Australian underground mining?

Amir B. Tabrizi^a, Robert Markoski^b

^a Mechanical Engineer, International Mining Engineering Consultants (IMEC), Perth, WA, Australia

^b Engineering Manager, International Mining Engineering Consultants (IMEC), Perth, WA, Australia

Abstract

The mining sector in Australia consumes approximately 500 petajoules per year, which is 10% of Australia’s total energy usage. It is predicted that the Australian mining sector’s long-term energy intensity will see a year-on-year increase in usage due to the trending decline (on average) of ore grades, which requires mines to remove more waste (overburden) for sustained mineral output. Wind and solar are primarily considered the main renewable resources which can be effectively utilized by the mining sector to generate power, However, given the use of water systems within underground mines another source of renewables in the form of small hydropower may provide a ‘green generation method’ not typically considered and is discussed in this paper.

Common practice for underground mines is to utilise ‘Break Tanks’ in the supply water system from surface to the network underground which is utilized throughout the mine operation. The Break Tanks control the piping system pressure that continues to increase with depth due to gravity. The Break Tank do this by simply ‘breaking’ the pipework distribution system back to atmospheric pressure. Instead of ‘losing’ this energy generated by gravity, it has been estimated that by installing a pump as a Turbine (PaT) at the inlet of the Break Tank, up to 300 kW of energy could be recovered (in a typical Australian underground mine operation), which annually generates up to 2.5 GWh electricity which translates to savings of up to AU$ 0.7 million of mine site annual electricity costs and reduces CO₂ emissions (assuming the mine power is hydrocarbon generated). In addition to several hydraulic advantages of utilizing Break Tanks in an underground mine water supply system, energy recovery is another benefit which should be considered as well.

Keywords: Underground Mining, Renewable Energy, Break Tank, Pump as Turbine (PaT)

1. Introduction

The mining sector in Australian consumes around 500 petajoules per year which is 10% of Australia’s total energy usage.  As mining volumes increase in Australia, the mining sectors electricity consumption has risen approximately 6.0% per annum over the last decade [1,2].

Diesel (41%), natural gas (33%), and grid electricity (22%), are the main energy sources which generate electricity for Australia’s mining sector while a mixture of other refined fuels, biofuels, renewables, LPG and coal contribute the remaining energy sources for electrical power generation in the mining sector [3]. Over the past decade, diesel contribution has reduced from 49% to 41%, and has been significantly replaced by grid electricity and natural gas due to infrastructure developments and volatility of the oil prices [2].

It is predicted that the Australian mining sector’s long-term energy intensity will continue to increase due to the average falling ore grades (close to surface) and overburden increasing (over the last 30 years, the average grade has halved, and overburden doubled) [4].

Development of batteries and electric equipment has enabled diesel consumed on mine sites to be reduced and increasingly be swapped for a combination of electricity generation and energy storage. It is expected that electricity generation and storage in the mining sector will be more important due to the transition to ‘all electric’ mining. Historically, the “favored fuel source” of Australian mining sector was diesel along with natural gas, however the concept of an ‘all-electric mining’ integrating renewables, batteries and traditional energy is now rapidly building momentum [2].

Logistics and fossil fuel price volatility are outside the control of most mine owners but have a remarkable impact on the economic ability of the mining sector. The mining sector in Australia and the Australian Government have acknowledged the environmental impacts and risk of the fossil fuels and are encouraging the renewable electricity adoption and energy efficiency measures [2]. The Australian mining sector has recently discovered that there is a cleaner, cheaper, and smarter way to power their operations, and the mining industry is now appearing as the source of the next boom in renewables investment [5].

In general, energy storage is currently uncompetitive with fossil fuels for most energy shifting applications. However, the electric vehicles and global attention of renewable energies has led to remarkable research and development in the storage field. It is forecasted that the capital costs of most storage technologies will fall by around 25%–50% over the next 5 years due to improvements of design and chemistry, manufacturing scale and reduction of material costs [2].

As mentioned, wind and solar have been considered as main renewable resources which can be utilized by the mining sector in Australia to generate power. This work discuses another source of renewables, small hydropower, which could be an alternative renewable source for hybrid electricity systems at underground mines in Australia.

 

2. Water supply system of underground mines and available hydro-energy

The water supply system within underground mines is generally very similar throughout Australia. In general, the reticulation of raw water from surface to underground is distributed via a gravity fed system. The layout of the system typically is;

• A Supply System, often in the form of a header tank above ground, which functions either via gravity or is pumped into the mine.
• An Underground Bulk Storage System, to store water in the event of upstream supply problems as well as manage peak demand spikes, and
• A Distribution system, often just standard HDPE pipelines, throughout the mine, with “Break Tanks” and/or pressure reduction valves strategically placed to manage both the pressure the system produces (due to differential static heads), as well as manage localised supply demands (in the case of a break tank).

Given the water is transferred via gravity, the deeper it travels into a mine the more the pressure increases within the pipe system. For the safety of workers and equipment that utilize the water, in addition to the capacity of the piping components, pressure must be maintained within a set range.

For this reason (control of pressure), pressure reduction valves (PRVs) are installed in various locations throughout the mine, with Break Tanks serving a similar purpose (system break back to atmospheric pressure).

As the main supply HDPE lines are extended down the decline, take-offs to the various levels within the mine then tee off. Generally, the system is depicted as per the schematic below:

Figure 1 – Generalised Water Supply Schematic of an Underground Mine

  Figure 2 – Isometric View of Water Supply System Model at Underground Mine, Western Australia

It is commonly recommended by professionals that open to atmosphere ‘Break Tanks’ be utilized as pressure reduction equipment for water supply systems at underground mines.  These tanks serve as pressure reset devices, as they ‘break’ the pipelines into individual segments and allow the piping network to be exposed to the atmosphere. Further, they provide localized surge capacity within their proximity, allowing for short bursts of high demand to be managed by the tank itself. Installing level-controlled break tanks, every 80-120m vertically, connected via 100mm diameter HDPE lines, is common and generally good practice for water supply systems.

Figure 3 – Typical Break Tank Isometric View (designed by IMEC)

If we assume that the Break Tanks are connected via OD 110 PN 12.5 HDPE pipe, which is very common in underground mining owing to it being manageable size to handle (and comes in large 100m rolls), then based upon the pipe working pressure, the Break Tanks can be located every 120m vertically.

As the pipe route at an underground mine usually follows the haulages, the pipe physical length between every two tanks will be much longer than the 120m vertical height and could be expanded up to 800m (for a typical 1:7 gradient). The level of the water inside each tank usually is controlled using float-level control valves.

Figure 4 shows the pressure loss through a OD110 PN 12.5 HDPE line (100m pipe) across various flowrates which are calculated using the Darcy-Weisbach equation, where Darcy friction factors are obtained from the Colebrook equation approximations suggested by Cheng [9]. If the example static differential head of 120m is assumed between two break tanks, in excess of 40 L/s can be delivered to the downstream break tank during filling time.

Figure 4 – Pressure Loss through OD110 PN 12.5 HDPE Lines

Typically the break tanks will continue to recharge with water once the low set-point on the float valve is reached, and so flow through the valve will generally be lower than the rates shown above. But in essence, the valve will ‘throttle flow’ into the tank and therefore lose energy via water movement, noise, heat or other means as water fills into the tank and pressure reduces back to atmosphere. Therefore, part of the available head at the tank inlet ccould be exploited as energy via deploying energy recovery devices at the inlet of each Break Tank.

The available energy at the inlet of each tank is calculated from below equation:

E = p x g x Q x h

Where,

 

 

 

Table 1 presents the available energy at the inlet of the downstream tank for different flowrates (using the 120m and 110 OD pipe sizing).

By deploying an energy recovery device at the inlet of each Break Tank, with a duty point of approximately 25 L/s and 79 m Head, the maximum energy can be exploited during filling time, whilst also delivering 25 L/s of water to the tank.

       3. Hydro Turbines Vs. Pump as Turbine (PaT) for hydro-energy recovery

As discussed in the previous section, an energy recovery device with duty point around 25 L/s and 79 m Head is required at the inlet of each Break Tank to recover maximum energy.

Figure 5 shows the general operational range of different types of hydro-turbines, Pelton, Francis and Kaplan turbines, for small and mini hydropower solutions.

Figure 5 – Operational Range of Different Types of Hydro-Turbine for Small and Mini Hydropower Solutions [10]

In general, the Pelton turbine is utilized for high-head, low-flow application. As the hydro-turbine chart at Figure 5 shows, the Pelton turbine cannot meet the duty point which is required at the inlet of the Break Tank (flowrate=25 L/s and Head=79m).

Pump as Turbine (PaT) technology is taking the field in different small-hydro energy recovery solutions [11]. Williams [12] discussed economic and practical advantages of utilizing PaTs instead of micro hydro turbines in medium-head sites. Due to the possibility of PaTs application in different situations and to its lower cost than turbines, this technology has been rapidly improved in the recent decade [11].

Larger operation range of heads and flowrates, low investment costs, variable installation possibilities, extensive range of products and materials, easier availability of spare parts like seals, bearings and easier installation can be summarized as some advantages of using PaTs instead of micro hydropower turbines [13,14].

In most cases, it is possible for PaT systems to achieve the same high level of pump efficiency in conventional operations. The efficiency of a double-entry volute casing pump is approximately 85 %.  At Best Efficiency Point (BEP), the PaT runs as smoothly as a pump in conventional mode. The outgoing flow is almost vortex-free, and noise, wear and pipe vibration are very low [15].

Figure 6 presents a range of different pumps for PaT applications. According to the required operational range at the inlet of the Break Tank (flowrate=25 L/s and Head=79m) Radial Flow PaT or Multistage Radial Flow PaT may be used.

Figure 6 – Choice of pumps for PaT applications [16]

4. Economical Evaluation

As explained in section 2, the maximum available capacity of hydropower at inlet of a Break Tank is around 19.5 kW. By taking into account the PaT efficiency (70%) and generator efficiency (95%), the maximum achievable capacity is around 12.95 kW.

The PaT utilized at the inlet of the Break Tank only generates electricity during tank filling. Most of the underground mines, especially the gold mines, in Australia operates 24 hours per day, 365 days per year. However, filling duration of a Break Tank during a day can be varied and depend on activities at different parts of the mine.  Figure 7 shows the possible annual generated electricity (365 days of mine operation) by a PaT at the inlet of a Break Tank for different tank filling durations per day.

Figure 7 – Possible Annual Generated Electricity by a PaT at Inlet of a Break Tank

The potential saving of electricity costs by using PaT at the inlet of a Break Tank is totally dependent on the electricity price being paid by the mine. The price ranges of <$0.10/kWh for grid electricity, $0.10/kWh–$0.30/kWh for electricity derived from pipeline gas, and $0.15/kWh–$0.30/kWh (after rebates) for electricity generated by off-grid diesel or gas, have been reported as the electricity prices in Australia by the Australian Renewable Energy Agency(ARENA) [2]. Maximum annual saving of mine electricity costs can be achieved by using PaT at the inlet of a Break Tank for the mines which are powered by different sources has been reported at Figure 8.

Figure 8 – Maximum Annual Saving of Mine Electricity Cost by Using PaT at Inlet of a Break Tank

Figure 7 and Figure 8 show the annual generated electricity and annual cost saving which is achievable by a single (1) Break Tank. It is common for a mine to utilize multiple tanks, and in some cases upto 15 to 25 Break Tanks for larger/deeper mines. Therefore, by using PaT at the inlet of all Break Tanks, the maximum available capacity of hydropower in an underground mine could range between 195 kW to 325 kW. Annual generated electricity by small hydropower and maximum annual saving on electricity costs in an underground mine would then be increased up to 2.5 GWh and AU$0.7 million, respectively.

Hydropower at the inlet of the break tank is the intermittent source.  This limitation can be overcome by utilizing a hybrid system or energy storage. To calculate the payback ratio (period) for utilizing PaT at the inlet of a Break Tank, the cost of battery storage to store the generated electricity for one day with 80% depth of discharge and 1.05 inefficiency factor, has been considered as upfront investment costs as well.

In 2019, battery prices have fallen 87% in real terms to US$156/kWh, while they were above US$1,100 per kilowatt-hour in 2010. According to the latest forecast from research company BloombergNEF (BNEF), average prices will be close to US$100/kWh by 2023. It looks very promising that the price will be reduced even further, from US$100/kWh down to US$61/kWh by 2030 [17].

Table 2 represents the investment cost for utilizing a proper PaT, which was explained in section 2, at the inlet of a single Break Tank.

Table 2 – Investment Cost for Utilizing PaT at Inlet of Single Break Tank

Figure 9 shows the minimum payback ratio for utilizing the PaT system including the battery bank at the inlet of a single Break Tank versus different tank filling durations per day for the mines which are powered by different sources.

Figure 9 – Minimum Payback Ratio for Utilizing PaT System at Inlet of Single Break Tank Vs. Different Tank Filling Durations Per Day

While the payback ratio is around 2 years for the mines powered by pipeline gas or off-grid diesel/gas, it is around 6.5 years for the mines connected to the grids. However, in future years by dropping the battery price, the payback ratio should be much less than the values reported in figure 9.

5. Environmental Advantages

Figure 10 shows the specific carbon dioxide emissions of various fuels and Table 3 represents emission factors for consumption of purchased electricity or loss of electricity from the different grids across Australia.

Figure 10 – Specific Carbon Dioxide Emissions of Various Fuels [18]

Table 3 – Indirect Emission Factors for Consumption of Purchased Electricity from Different Grids across Australia [19]

Based on the reported values at Figure 7 and Table 3, Figure 8 represents that the annual CO₂ emission reduction can be achieved by recovering hydro-energy at the inlet of a single Break Tank at mines which are powered by different grids across Australia or other off-grid systems.

It is notable that Figure 8 reports CO₂ emission reduction just for single Break Tank and as explained previously, water supply system of an underground mine usually includes 15 to 25 of Break Tanks.

Figure 11 – Annual CO₂ Emission Reduction by Recovering Hydro-Energy at Inlet of Single Break Tank

6. Conclusion

Wind and solar have been considered as the main renewable resources which can be utilized by the mining sector in Australia. However, small hydropower is another source of renewable energy that can generate electricity for underground mines in Australia.

Utilization of Break Tanks at water supply systems of underground mines is a recommended practice. Installing PaT systems at the inlet of the Break Tanks require low upfront investment costs, can recover more than 300 kW energy, annually generates up to 2.5 GWh electricity and save up to AU$ 0.7 million in annual electricity costs for an underground mine in Australia.

In addition to several hydraulic advantages of utilizing Break Tanks in an underground mine water supply system, energy recovery is another benefit which should be considered as well. As electricity generation and storage in the mining sector is going to be more important due to the transition to ‘all electric’ mining, all available sources to power the mining sector are getting more valuable. Utilizing the Break Tanks as part of an underground mine water supply system, provides an extra source of energy for underground mines. In the close future, by rapid development of battery storage and hybrid power system technologies, utilizing a PaT at the inlet of the Break Tank may be a common practice in underground mining.

References

[1] Australian Government Department of Industry, Innovation and Science, 2016, Australian Energy Update 2016, Canberra, September.

[2] Australian Renewable Energy Agency (ARENA), 2017, Renewable Energy in the Australian Mining Sector White Paper (20062017 Rev. 2).

[3] Australian Bureau of Statistics, 2017, Energy Account Australia 2014-2015 (4604.0).

[4] Bye, A. R., 2011, Case Studies Demonstrating Value from Geo-metallurgy Initiatives, 1^st AusIMM International Geo-metallurgy Conference (GeoMet 2011).

[5] https://reneweconomy.com.au/miners-see-50-renewables-as-standard-but-are-aiming-for-100-100/ (Visited on 31/08/2020)

[6] https://www.australianmining.com.au/features/renewables-are-a-no-brainer-for-the-australian-mining-sector/ (Visited on 31/08/2020)

[7] Lazard, 2016, Levelized cost of energy analysis – version 10.0.

[8] Liebreich, M., 2016, Bloomberg New Energy Finance Summit – In search of the miraculous, 5/4/2016.

[9] Cheng N., Formulas for Friction Factor in Transitional Regimes, Journal of Hydraulic Engineering 134 (2008) 1357–1362.

[10] ANDRITZ HYDRO Gmbh, Small and Mini Hydropower Solutions Booklet (available from: https://www.andritz.com/resource/blob/33446/d2118386d6a8dbbec556c6e159391c64/hy-small-and-mini-hydropower-solutions-en-data.pdf)

[11] Rossi M., Righetti M., Renzi M., Pump-as-Turbine for Energy Recovery Applications: The Case Study of An Aqueduct, Energy Procedia 101 (2016) 1207 – 1214.

[12] Williams A., Pumps as Turbines for Low Cost Micro Hydro Power, Renewable Energy 9 (1996) 1227-1234.

[13] Agarwal T., Review of Pump as Turbine (PaT) for Micro-Hydropower, International Journal of Emerging Technology and Advanced Engineering 2 (2012) issue 11.

[14] ANDRITZ Gmbh, Pumps Used as Turbines Booklet ( available from: https://www.andritz.com/resource/blob/238812/7dbb1b203bbd97d0e3740faf76f40f25/pumps-as-turbines-en-data.pdf)

[15] https://www.ksb.com/centrifugal-pump-lexicon/turbine-mode/328156/(Visited on 10/09/2020).

[16] Teuteberg B., Design of a Pump-As-Turbine Microhydro System for an Abalone Farm, Final Report for Mechanical Project 878, Department of Mechanical and Mechatronic Engineering, Stellenbosch University, March 2010’

 

[17] https://about.bnef.com/blog/battery-pack-prices-fall-as-market-ramps-up-with-market-average-at-156-kwh-in-2019/?sf113554299=1 (Visited on 14/09/2020)

[18] https://www.volker-quaschning.de/datserv/CO2-spez/index_e.php (Visited on 08/09/2020)

[19] Commonwealth of Australia, Department of the Environment and Energy, 2017, National Greenhouse Accounts Factors.

Completed: 2018

Location: Philippines

Key Points:

• The engineering and design of a 340m³ concrete plug for a 9 megalitre vertical dam to support 60m of head pressure
• Detailed construction methodology
• Collaboration with site geotechnical engineers
• Design of concrete plug steel reinforcement
• Design of cast in spooling
• Design of shotcrete formwork
• Procurement support
• Onsite construction management

The Brief

IMEC were engaged as a direct contractor to provide full EPCM services for the installation of a 9 megalitre dam concrete plug for a Life of Mine Primary Dewatering System.

The Challenge

Accessibility to the plug location was a key constraint and to fill a 9 megalitre vertical damn meant there was a large volume of concrete required.

Recommendation

IMEC were able to propose the use of SCC (Self Compacting Concrete) delivered directly to the plug location via a surface borehole. This enabled a high volume concrete pour without the need for vibration. To ensure final concrete strength was achieved, IMEC provided cast in thermocouples and data logger to monitor and record concrete curing temperatures.

In the run up to christmas, it can be hectic with last minute project deliverables and deadlines to be met before the festive fun begins. Whilst it can be a time of indulgence, there are some that are less fortunate and can struggle to make ends meet.

This year IMEC’s Perth office are trying to make a difference by donating food to OZ Harvest’s Festive Food Drive.

OZ Harvest is Australia’s leading food rescue charity helping to feed Australians in need.

We’re calling all our clients, suppliers and friends!!! If you’re passing our office at 51 King Street, Perth, please get involved, donate and help make someones christmas special.

All dry goods (cereals, pasta, biscuits, crackers, tinned) welcome!!!!

Liam Jones joins IMEC’s Australian office in Perth. His design experience covers many disciplines with notable achievements in Water & Waste Water Infrastructure at GHD to more recently working with Lycopodium on a Central American mining project.

Great to have you on board Liam!

We had the privilege of having Year 11 graduate, Ethan Berryman from John Tonkin College, Mandurah in the office last week for work experience during his school break.

Ethan’s flare to learn was evident from the get go. Even when put in the deep end presenting his weeks work to the team, his passion and drive to learn was clear for all to see.

We wish Ethan all the best with his studies and future endeavour’s.

[one_full last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]There’s no hiding the fact that effective mine dewatering is key to an efficient mining operation.

As we delve deeper into the Earth’s crust and the ingress of water into the operating mine increases, is it enough to just add more pumps to the system to get the water out? This reactive approach is all too common. With a ‘daisy chain’ of pump stations of different makes, sizes and duties desperately trying to keep our feet dry.

How can we improve our approach to mine dewatering and what are the benefits?

[/fusion_text][/one_full][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””]

System Flexibility

[fusion_text]There should be a push for mine owners who are setting up a mine or implementing a new Primary System to push for ‘flexible’ systems that include monitoring systems where practical. In this day and age of big data and where costs for instruments are continuously reducing and becoming more affordable, such instruments can provide a significant amount of information as to the performance and status of a system and enable its users to determine its efficiency, utilisation and how it is serving the original design criteria. If set up in a flexible manner, it will enable the operator to make quick and effective changes and ensure the system can be constantly adjusted to suit the ever-changing conditions of the site.[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”zoomin” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””]

Operating Costs

[fusion_text]Dewatering accounts for a significant power consumption cost in a lot of UG mines globally, and also in operating maintenance and service costs. A lot of sites develop a Life of Mine (LOM) plan as part of the Definitive Feasibility Study phase or at least early within the commencement of the mine life. Whilst it is not always practical to completely change a primary dewatering system in an operating mine for obvious reasons (and some not so obvious), there are many ways in which operating systems can be improved/modified/upgraded etc. to be optimised and suit the ever changing mine. Particularly where we now see a trend for mine life extensions and resources being expanded as a result of buoyant metal prices – it’s these mine sites that will really benefit from reviews of their dewatering & operating systems.[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”zoomin” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””]

Attack the source not the symptom.

[fusion_text]Rather than passively dewatering, careful consideration should also be made in investigating whether there are methods to actively stop water from entering the mine (or at the very least diverting water to areas away from working heading). One method that we have found to be successful is via the installation of dewatering bores underground to achieve localised lowering of the water table. These bores can be localised around the periphery of active developments so as not to interact with equipment, and can be installed in advance of development, ensuring water ingress will not be an issue.

Other methods include the use of high pressure grouting (if ground conditions allow) to create impermeable “screens” which divert water away from active underground developments. By using pre-excavation grouting, risks of water inrush can be eliminated and poor and unstable ground conditions can all be approved, whilst sealing developments off from water ingress.[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”zoomin” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_full last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]

“the importance of regularly and periodically revaluating a mines dewatering system to ensure optimum performance and efficiency can’t be ignored”

[/fusion_text][/one_full][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””]

Investigate Recycling

[fusion_text]As mines get deeper, the use of recycling systems underground has become more pronounced. By recycling the water underground, the amount of water that needs to be evacuated from the mine is reduced. Recycling system technology has reached a point where the creation of ‘raw’ and even potable water can be produced underground at costs much lower than if the water had to be removed completely. Modern modular systems similar to the IMEC designed recycling plant pictured, can be designed to suit the mines parameters and simply plugged into the system minimising disruption to operations.[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”zoomin” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””]

Use Automation

[fusion_text]Given advances in UG communication bandwidth and the increase in competition of vendors supplying connected devices, automation of dewatering systems has become incredibly cost effective. By including an automation philosophy as part of their design criteria, dewatering systems can be developed so they can not only accurately track and trend system performance, but also allow for automated redundancy operations. By automating redundancy in the system, down time in operations due to flooding, or pump failures can be reduced, leading to overall savings for the mine.[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”zoomin” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half]

[fusion_text]IMEC’s European office is delighted to announce their engagement to provide engineering support to Trafigura Mining Group’s, Aguas Tenidas (MATSA) mining operation at the new Magdalena mine in Spain’s Andalusia region.

The project comprises of design and construction management support of an UG Refuelling System, which IMEC will utilise its extensive experience in underground mining to develop a fit for purpose facility.[/fusion_text]

[fusion_text][fusion_text]In order to complete my Bachelors in Mechanical Engineering all students are required to complete 12 weeks of work experience with an engineering firm or degree related industry.

I was lucky enough to be given the opportunity to complete my internship with IMEC in their head office in Perth. (Although placement in their European office would have been cool too!)[/fusion_text][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]

Getting the opportunity to work along side IMEC’s experienced design and projects teams was a great experience. Under the guidance of team leaders, IMEC immersed me in all facets of project & design engineering. From initial client engagement to project meetings & on site data collection, I was given a great insight into what it takes to deliver projects successfully.

[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”none” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_full last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]Putting my university learnings into practice with IMEC not only reinforced my engineering capabilities but reaffirmed my aspiration for a career in engineering.[/fusion_text][/one_full]

[one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]Never before have people been more connected to the physical things around them. Giving us data and insights that were previously unknown or unattainable.

IoT connects mining companies with their valuable assets, whether it’s people at the rock face, mobile equipment or fixed plant. The captured data empowers the decision making process, enabling preemptive action to be taken for improved optimisation, operability and most importantly worker safety.

 

[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”none” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_half last=”no” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]IoT is here to stay and that’s why IMEC mine equipment is designed to be connected.

With purpose built IoT enabled ports, our equipment is specifically designed to connect with Newtrax, a global leader in underground mine productivity & safety solutions. Knowing where your mobile plant is and how its performing has never been easier!

[/fusion_text][/one_half][one_half last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][imageframe lightbox=”no” lightbox_image=”” style_type=”none” hover_type=”none” bordercolor=”” bordersize=”0px” borderradius=”0″ stylecolor=”” align=”none” link=”” linktarget=”_self” animation_type=”0″ animation_direction=”down” animation_speed=”0.1″ animation_offset=”” hide_on_mobile=”no” class=”” id=””] [/imageframe][/one_half][one_full last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]So whether you want to actuate an underground pump or increase ventilation with our louvred ventilation regulator, IMEC’s connected equipment and infrastructure gives you the control without having to leave your desk.[/fusion_text][/one_full]

[one_full last=”yes” spacing=”yes” center_content=”no” hide_on_mobile=”no” background_color=”” background_image=”” background_repeat=”no-repeat” background_position=”left top” hover_type=”none” link=”” border_position=”all” border_size=”0px” border_color=”” border_style=”” padding=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”” animation_speed=”0.1″ animation_offset=”” class=”” id=””][fusion_text]IMEC is delighted to welcome Chris Law onto the design team in Perth. Having worked in the mining industry with the likes of Lycopodium & GR Engineering, Chris brings with him many years of design experience. Welcome aboard Chris![/fusion_text][/one_full]

[fusion_text]IMEC’s Perth office is delighted to be working with Murray Engineering for the design and fabrication of a pedestrian Bridge south of Perth. The design is in the early stages of concept approval and is the second bridge design for IMEC in as many years.

IMEC’s Senior Structural Engineer, Edward Sutoro has been driving the project and has called upon his years of experience in structural design to produce a bridge ideal for the site parameters.[/fusion_text]

Introducing Spencer Cutler as IME Consultants Gosowong Site Project Manager. IMEC is pleased to welcome Spencer Cutler as its Gosowong Site Project Manager. With over 30 years experience in the mining industry and project management expertise in shaft development and surface/underground infrastructure projects, we feel Spencer will be a valued asset to IMEC. Welcome aboard Spencer!

IMEC recently completed the design and certification of a bespoke EWP to be used on South 32′s Boddington Bauxite mine. The EWP would be subject to thousands of hours of repetitive work so the design had to be robust as well as user friendly. The platform for the design was a 4WD Mercedes Sprinter selected by the client.

---

The EWP’s design was based on the relevant Australian Standards and has personnel safety as the basis of all design decisions. The mid-walkway controls remove risk to personnel as they are safely removed from any crush zone during inclination.

---

---

Inclinometers with audible alarm for safe working angles and non-slip FRP grating for walkways, are just some of the safety aspects designed into the EWP.

---

This truly was a unique project and one that challenged and inspired the IMEC design team and further emphasised that personnel safety needs to be the number 1 design consideration for all mine equipment designs.