Innovation is at the heart of the company’s ability to develop custom-made solutions that are sustainable in the long term.

Erizon’s unique approach pulls together a wealth of talent and experience in the areas of science, engineering, project management and technology.

Its experienced team of agronomists, horticulturalists and soil scientists take the time to fully understand the variables in each project to develop effective solutions based on scientific analysis of the environmental issues at play.

The Australian Mining Review spoke to Erizon Operations Manager Tom Corkhill about the dust control solutions the company provided at one of Australia’s biggest gold mines, and how this has led to the development of innovative equipment that will revolutionise the industry.

Case Study

Erizon won a major contract to devise a solution for a 700ha tailings storage facility (TSF) at a large gold mine in Orange, NSW.

The client had experienced several failures in dust suppression from alternative products and companies, which offered solutions that had no functional longevity.

Erizon took part in a trial alongside other market leaders in dust management to allow the client to determine the best fit for the site.

At the conclusion of this trial, Erizon’s innovative solution had the long-term desired effect, meeting project requirements and exceeding longevity targets.

Previously at the site, a polymer solution was being dissolved within three months, due to the high salinity level of the TSF.

Rather than continuously apply a polymer solution every three months, Erizon tailored a solution that involved growing specific vegetation to provide greater dust suppression results, while adhering to EPA and community requirements.

The solution took into account the results of scientific trials and testing, which confirmed it would be difficult to grow numerous types of vegetation in the hostile environment created by this particular TSF.

Furthermore, the mulch needed to be hydraulically applied via the use of customised HydroRigs, which would face a high chance of getting bogged or sinking if they were mounted on standard trucks.

‘’There are tailings dams in the world which have trucks and equipment stuck at the bottom of them, so to avoid that we have developed some innovative technology to reduce the pound-per-square-inch (PSI) on our equipment,’’ Tom said.

With Erizon, a HydroRig is mounted on a purpose-built truck with low bearing capacity (LBC) capabilities, which is then towed by a mine-spec, wide-tracked tractor.

The new PSI of just 5.8, thanks to the clever distribution of the weight over a larger surface area, is smaller than the PSI of a human footprint, which is about 11.

Erizon has an engineering department and devotes significant resources to research and development.

The company is developing exciting new equipment with a PSI of less than one, which would be a game changer in the mining industry.

Erizon’s equipment can access areas that other providers simply can’t.

‘’With our LBC HydroRigs, we have direct access to areas that other equipment can’t,’’ Tom said.

‘’It allows us to have more control over application. When accessing TSF’s directly there are numerous safety concerns. Our equipment addresses these concerns.

‘’Aerial options are always an option, but this comes at a greater cost, due to the need for pilots, helicopters, fixed wing planes and increased safety requirements.

‘’It can cost up to $2500 an hour to hire a plane, so if we are on-site applying solutions directly, there is an opportunity for cost savings.

‘’It also allows us to apply a better product because we are not applying it aerially, we are applying from our trucks and we can monitor the quality of the application in real time.

‘’The other problem with aerial is availability; they are not always available, and they are unable to fly in heavy fog or high winds.’’

Other availability issues with using aircrafts arise in emergency situations, such as when many of Australia’s planes and helicopters were diverted to the bushfires that ravaged the entire country.

FibreLoc is a heavy-duty dust suppressant that has been scientifically engineered for extreme conditions, such as substrates with high salinity levels like tailings dams.

On-site Solution

Envizo is a real time, on-site performance monitoring system that provides updates and alerts for unexpected weather events.

Monitoring stations and a live feed give Erizon and the client 24/7 access to a full range of performance indicators, including PM levels, Wind speed and direction, temperature, humidity, soil moisture levels and rainfall.

‘’We can pinpoint where the dust is coming from through the tactical placement of sensors; we will know if there are going to be possible dust issues before impacting the local community,’’ Tom said.

‘’Many sites have this sort of equipment and EPA monitors, but what you will find is, a lot of them monitor dust from outside the perimeter of the mine.

‘’The point of difference with Envizo is we are monitoring at the source in real time, which triggers an alert so action can be taken.

“Envizo is enabling us to take full ownership of our dust management solutions for our partners. ‘’

When coupled with scientifically developed solutions and expert application methods, Erizon is able to develop an end-to-end solution which allows Erizon to provide a Supply, Apply Guarantee.

‘’We have created our own product range, solutions, monitoring systems and applications which allows us to take full ownership – and that is something that a lot of our competitors can’t do.’’

Each project comes with a tailored Quality Management Plan and Inspection and Test plan (ITP) to identify and record project specifications and requirements.

HydroRigs

With hydraulic cannons mounted on state-of-the-art HydroRigs, Erizon can apply their dust suppression product to areas in a fast and efficient manner.

Erizon’s HydroRigs feature in-built agitators to maintain solution uniformity and homogeneity and are also fitted with hydraulic hoses with an extended hose capacity over 500m.

The power, speed and design of its machines optimise efficiency and effectiveness by providing unparalleled coverage of extensive areas and difficult terrain such as steep slopes.

All of Erizon’s HydroRigs have the ability to apply product to upwards of 50,000m2 per day.

Every HydroRig is mine-spec compliant, equipped with rollover protection systems, edge protection and harness attachment points, interlocks and emergency stops, firefighting equipment, spill containment kits and first aid equipment to protect the safety of its operators.

Erizon also uses advanced drone technology for spraying, seeding and the application of fertiliser in hard-to-reach places or where the terrain is uneven.

With more innovation in this space in the works, progressing the use of drones for this industry is something Erizon is investing into heavily.

Pushing the Envelope

Erizon is not only an expert in dust suppression.

With more than 25 years of experience, Erizon is also an industry leader in large-scale mining and civil environmental solutions including revegetation, rehabilitation, and erosion control.

The mining industry is known for sticking to old-school, traditional methods because that is the way it has always been done.

Erizon is all about innovation and pushing the boundaries to come up with better ways of tackling problems.

The company researches and develops cutting edge solutions that are tailored to Australia’s climate and individual project requirements.

‘’We work closely with our partners to develop custom-made solutions for their sites, and we are moving away from the one-solution-fits-all approach by developing exciting equipment that should revolutionise the industry,” Tom said.

‘’We also place a big emphasis on working with local suppliers wherever possible, such as sourcing seed locally.’’

With an Australia-wide footprint and more than 50 staff and contractors, Erizon has the ability to take on the big projects.

The company has worked with the likes of Newcrest, Rio Tinto, Ventia, AGL and GHD, providing tailored solutions for all.

SOURCE

Erizon
P 1300 182 182
E info@erizon.com.au
W www.erizon.com.au

The post Custom-Made Solutions appeared first on The Australian Mining Review.

Breathing the silica dust can result in irreversible, untreatable diseases, including silicosis and lung cancer.

Some dust particles can be so small that they are not visible: these are referred to as respirable particles.

Respirable silica dust particles are those that are small enough to breathe in and penetrate deep into the lungs causing permanent damage that can lead to serious illness or death.

Dust-related diseases caused by respirable crystalline silica, such as silicosis, is on the rise. There is no known treatment to stop the progression. Silicosis is permanent and untreatable.

In Australia, there are more than 350 cases associated with silica dust. Annually, about 600,000 Australian workers are at risk of inhaling silica dust at their workplace.

Occupational exposure is high for workers in industries including mining and quarry, constructions, agriculture and stonemasonry.

Safe Work Australia publishes exposure standards for airborne contaminants in the workplace.

The exposure standard for crystalline silica dust, listed under quartz (respirable dust), is 0.05mg/m3 as a TWA (time-weighted average) airborne concentration over eight hours.

An eight-hour time-weighted average exposure standard is the average airborne concentration of a particular substance permitted over an eight-hour working day and five-day working week.

The workplace exposure standard for respirable crystalline silica is based on the levels found in a person’s breathing zone, outside of any respiratory protective equipment that may be in use.

WorkSafe Victoria has gone above the national standard and recommends that employees are not exposed to levels above

0.02mg/m3 as a TWA. This is a precautionary measure to prevent silicosis and to minimise the risk of lung cancer.

Employers are required to ensure employee exposure does not exceed this standard.

Managing risk and worker exposures to silica can be achieved by selecting and implementing measures using the hierarchy of controls:

• Substitution such as sourcing composite stone benchtops with a lower percentage of silica
• Isolation of the hazard – using principles of safe work design to designate areas for tasks that generate dust and appropriate worker positioning during these tasks, using enclosures and automation to conduct dust generating tasks
• Engineering controls that minimise the risk of exposure to generated dust, for example, local exhaust ventilation, water suppression (wet cutting) or using tools with dust collection attachments
• Should a risk still remain: administrative controls, including good housekeeping policies, shift rotations and modifying cutting sequences, personal protective equipment including appropriate respiratory equipment (generally a minimum of a P2 efficiency half face respirator) and work clothing that does not collect dust.

Respirable crystalline silica is harmful toxic dust. It is preventable with precautions to minimise exposure and maintain a safe work environment.

It is highly recommended that workplaces provide adequate respiratory protective equipment (RPE) specifically designed and certified to protect workers from inhaling hazardous airborne contaminants.

With regards to respiratory protection, PAPRs (Powered Air Purifying Systems) with at least a P2 filter are the new benchmark across most industries.

Australian-made CleanSpace Respirators meet and exceed the minimum requirements for respiratory protection, with a P3 filter.

Unlike other Powered Air Purifying Respirators (PAPRs), CleanSpace Respirators are easy to put on (in under 10 seconds) and do not have heavy belts or hoses.

They also deliver cool fresh air to the wearer via a tightly sealed silicon mask that will eliminate moisture and fogging.

CleanSpace Respirators are AS/NZS 1716 Respiratory Protective Devices certified.

According to CleanSpace Technology CEO Alex Birrell, one of the main reasons people go unprotected is because of low compliance.

“If masks are uncomfortable or not quick and easy to put on then it simply doesn’t get used,” he said.

CleanSpace Respirators are a revolution in respiratory protection.

They are lightweight, offer the highest level of protection and have no belts or hoses.

Being reusable, they reduce costs and reliance on supply chains and stockpiling.

CleanSpace Technology, established in 2009 by world-class biomedical engineers, has designed and developed several respirators for various industries.

CleanSpace ULTRA is IP Rated 66 and water-tolerant, making it perfect for anyone wetcutting stone or concrete.

CleanSpace EX is intrinsically safe, certified for use in potentially explosive environments, and CleanSpace2 is for use where water tolerance or intrinsic safety is not required.

“As Australia’s only respirator company, we are proud to be supporting all those on the frontline in industry and healthcare stay protected from airborne contaminants,” Dr Birrell said.

CleanSpace Technology believes employees are an essential part of a business and the workplace environment must be safe for them.

The company hosts online presentations to share information on effective risk control, industry best practice and experiences to case studies from people in the industry.

There are two upcoming opportunities to join live sessions to learn more about CleanSpace Respirators and how they can protect you and your workers.

CleanSpace Technology supports on-going learning, product training, fit testing to provide instructions on maintenance and care with attentive customer support.

Respirable Crystalline silica is preventable.

SOURCE
CleanSpace Technology
sales@cleanspacetechnology.com
www.cleanspacetechnology.com

The post Breathe Easy appeared first on The Australian Mining Review.

At its most extreme, long-term exposure to coal dust can produce coal worker’s pneumoconiosis, or ‘black lung’, a respiratory condition in which a worker’s lung degrade and turn black from coal dust exposure. Though black lung is perhaps the most extreme example of the hazardous effects of dust exposure, respiratory ailments such as asthma and bronchitis brought on by long-term exposure can also have debilitating effects of a worker’s health and productivity.

Only preventative dust monitoring and suppression methods can hope to block the emergence of these types of corrosive health conditions. Importantly, every stage of mineral extraction and processing has the potential to generate dangerous forms and levels of dust. Everything from blast crew and dragline operations to crushing and topsoil stripping generate suspended particulate matter, and pose a health hazard to the workforce.

Dust particles fall into two categories, according to their size: inhalable dust is particulate matter measuring approximately 0.1mm in diameter, and respirable dust is particulate matter measuring approximately 0.005mm in diameter. The size of a dust particle determines how far it can travel into the lungs.

Though regulations shift depending on a range of factors, the general standard is that exposure to inhalable dust must fall below 10mg/m³, over an eight-hour time-weighted average, and exposure to respirable dust must fall below 5mg/m³ for the same time-weighted average. For coal mining, the regulations are more stringent.

An immediate problem that confronts companies working under these regulations is one of measurement and precision. How can operators precisely and effectively measure and monitor the amount of particulate matter in the air, at all times and in all areas of a mine site?

To solve this problem, TecPro offers operators the DustRoid monitoring system. It’s an elegant and effective example of smart technology that promises to refine dust monitoring to a new height of precision. In conjunction with TecPro’s suite of dust suppression equipment, companies can build a comprehensive and detailed dust monitoring and suppression blanket over the mine site.

To begin with, let’s examine the DustRoid system.

The DustRoid System

DustRoid is a pole-mounted real-time and online dust monitoring station that fulfills two basic functions.

Firstly, it offers companies a detailed information stream measuring the concentration of dust particles in ambient air. It is capable of monitoring various particulate sizes ranging from 1 micron (u) to 100 u such as Ultrafine Suspended Particulate Matter (UFPM), Suspended Particulate Matter (SPM), Respiratory Particulate Matter (RSPM) and Total Suspended Particulates (TSP). It works on an active sampling method to count particulate matters using a highly accurate laser beam.

More specifically, once the device is powered on, the device intakes air samples at a predefined frequency through the sampling system. The sensor uses a light scattering method and emits a laser beam to diffract through the air sample. The intensity of the beam scattered from the particles at an angle of 45-90^o informs about the particle size distribution and particle concentration.

This quantitative function is the most refined on the market. A sweep of detailed parameters are measured by this system. Namely, PM1, or UFPMs with a size less than 1u, PM2.5, or SPMs with a size less than 2.5u, and PM10, or SPMs with a size less than 10u, are measured to a range of 0-1000 ug/m³ to a resolution of 0.3 ug/m³ with a minimum detection of 1 ug/m³.

The sample rate of PM1, PM2.5 and PM 10 is 1 l/min. For PM100, or TSP, DustRoid measures to a range of 0-30,000 ug/m³ at a resolution of 1 ug/m³ with a minimum detection of 1ug/m³. The sample rate is 325ml per sample.

Secondly, the DustRoid system works as an alarm and trigger system. Perhaps the most impressive feature of DustRoid is the way in which it integrates with and amplifies a pre-existing dust suppression system. Particular thresholds, set by mine regulators across Australia, are keyed into the monitoring station, and when these thresholds are met or breached, DustRoid will automatically trigger an alarm to the site’s dust suppression crew, or activate dust suppressants such as mist cannons, sprinklers, mechanical barriers, dust collectors or dust filters built into the site, to begin the work of dust suppression.

Dust is suppressed effectively when the size of the mist droplets generated by a dust suppressant system matches the size of the dust particles emitted during the mining process. The dust particle and mist droplet combine, and then fall to the ground.

As a piece of smart technology, the data gathered by DustRoid is collected in real-time and communicated at a configurable data interval of 2-30 minutes. The data can be transmitted by a range of wireless or wired connectivity options such as GSM, GPRS, WiFi, LoRa, NbloT and Ethernet. This means the DustRoid system can integrate itself immediately into whatever IT system a site has established, just the kind of versatility demanded by diverse and complex operations.

The scope and detail of information gathered by DustRoid coupled with its real-time data transmission means operators are never in the dark about dust levels across their site. Dust crews can react and respond to problems with precision and intelligence, knowing exactly where and when dust levels are breaching acceptable levels.

One immediate benefit of this refined measurement system is that companies know where to direct resources to best achieve its dust suppression goals. As each part of the site is covered by a particular monitoring station, the total site can be broken down and analysed in parts. If a particular part is breaching thresholds, the dust management team can focus resources and attention to that particular problem, as opposed to clumsily trying to reduce dust across the board. This means sharpened allocation of capital, and a leaner, more productive operation.

Once the dust suppressant mechanisms are triggered by the alarms set off by DustRoid, they can begin to immediately go to work to keep dust levels within regulated limits, ensuring that companies can swiftly and properly adhere to environmental regulations and protect the safety and productivity of their workforce at all times throughout operations.

Installation

An attractive feature of DustRoid is the non-intrusive simplicity of its design.

It is a light-weight and compact system, weighing just 6.5kg and measuring 147mm in height, 314mm in width, and 261mm in depth. It is mounted to a pole at an elevation of 4-5m. This is done to ensure a free-flow of air for the sensor. It can also be mounted to a wall-face.

And because it is compact and easily to set-up, it can be positioned effectively any place where dust generation is a concern. The diagram below demonstrates where the system can be positioned. Whether it is at the entry points of a site or near diggers and haul trucks, DustRoid is designed to cover every part and process of the site, and record dust levels at each of the mineral extraction and processing stages.

It is powered by a lithium-ion battery with a backup battery time of 48 hours, giving companies the security of stable and undisrupted monitoring.

Furthermore, it is designed to function in harsh conditions, a necessity for any piece of equipment shipped out to Australian mine sites. DustRoid has an operating temperature of -20^oC to 60^oC, with an optimum operating temperature between 25 ^oC and 35 ^oC. It also has operating humidity levels of 0-90%, and IP65 weather protection. So whether it’s a coal mine in Central Queensland, or a gold mine in WA, DustRoid can withstand the harshest operating environments Australia has to offer.

Dust Suppressants

In addition to DustRoid, TecPro cooperates with a number of suppliers to offer operators an extensive and comprehensive array of dust suppression systems. From large-scale equipment such as cannons all the way down to smaller fixed systems on transfer points, TecPro offers everything a company needs to build and maintain a comprehensive dust suppression blanket over its mine site.

Specifically, TecPro offers wide range of spray nozzles, hose guns and foaming units, hose reels, CIP tank cleaning products, misting systems, large-scale dust controllers, filter nozzles and valves, filters and other accessories.

These products, in conjunction with DustRoid, offer operators the best way to erect an effective dust monitoring and suppression regime, across all areas of a site and in all working conditions.

Consulting

More than this, TecPro is a widely respected consultant in the field of dust suppression, with years of deep knowledge and experience in the field.

Each mine site is different, and there is no such thing as a ‘one size fits all’ system that can accommodate the diverse needs of operators. More than that, each part of the mine will demand a different technique to adequately control and suppress dust emanating from that particular source.

Which system is best suited for a particular situation depends of a variety of factors, such as the type and concentration of dust being generated and the availability of water supply. TecPro offers operators specialist advice on how to formulate the best dust suppression systems for haul roads, ROM bins and dump hoppers, conveyors, crushers, stockpiles, rail cars and longwall mining.

Case Study

Its work with Centennial Coal’s Mandalong mine is a case in point. The Mandalong mine is an underground mine that produces a considerable amount of dust. Specifically, a dangerous amount of dust was being generated at the point where the coal drops from the crusher into the underground bin.

Centennial Coal tried a number of approaches to suppress the dust, but none were as successful as hoped, and so the company turned to TecPro to design a more effective dust suppression system.

TecPro, in conjunction with Wollongong University, designed a custom crusher dust suppression system and ROM bin dust suppression system to meet the specific needs of a complex situation. The design was a success, and following the installation of these systems, respirable dust emissions were reduced by some 68%. What’s more, with a full load of spray nozzles in operation, the TecPro system can reduce dust by more than 90%, a fantastic solution to a vexing problem.

The Future

With DustRoid, TecPro is elevating dust monitoring and suppression to a new height of precision and intelligence. Combined with its extensive experience in consulting and specialist design, TecPro can offer operators across Australia the kind of premium technology and service demanded by a world-class industry.

Tecpro Australia 
Ph: +61 (02) 9634 3370
Email: sales@tecpro.com.au 
Online: www.tecpro.com.au

The post Dust Suppression Experts appeared first on The Australian Mining Review.

Headquartered in Singleton, in the heart of the Hunter Valley mining scene, Rapid Spray recently launched the PolyMax range: a dedicated range of trailers and skid units dedicated to applying liquid polymer emulsions.

Polymer emulsions are high-tech bonding agents specifically engineered to bond soil particles together and maintain control over dust for long periods of time.

Many mine sites are beginning to see the benefits and water savings of using polymer-based dust control agents for applications from haul roads to stockpiles.

The requirement to conserve onsite water due to drought conditions has continued to drive the adoption of this technology.

Issues such as the sticky polymer clogging the pumps and the nozzles occur when equipment hasn’t been designed specifically for polymer spraying, making it a constant struggle for many companies to find a way to reliably and efficiently apply the products.

It is for this reason that Rapid Spray has designed the dedicated PolyMax range: a full polymer emulsion spraying solution that is reliable, efficient and  removes the worry of clogged pumps or nozzles.

Rapid Spray general manager Russell Firth  said many operators had tried using standard water delivery equipment in the past with disappointing and unreliable results.

“That’s why we have developed the PolyMax range; to give teams who don’t have time to waste, equipment that won’t waste time,” he said.

The PolyMax range utilises oil-backed diaphragm pumps and tank agitation systems to ensure consistent product delivery through either handheld nozzles, batter sprayers or pressure bars when needed for larger area coverage.

A customised 1100 Puma PolyMax trailer recently delivered to a large Tier 1 contracting firm also featured an on-board safety hand wash system and dedicated 70L flush tank to make cleaning pumps and nozzles incredibly easy between material changes.

Flushing the tank and lines so there is no leftover residue ensures ongoing reliability and safety.

Working from a base of proven tough chassis and tank designs, the Rapid Spray team can build any polymer spraying solution in capacities from 800L to 15,000L to suit any site’s needs and specifications.

With a dedicated mining solutions team, ISO9001 certified and capable of delivering to MDG15 specifications, Rapid Spray can offer complete confidence to its clients in their next investment in dust control.

For more information about Rapid Spray’s PolyMax range, email Stephen.thompson@rapidspray.net or phone 1300 901 504.

The post Specialist equipment you can trust appeared first on The Australian Mining Review.