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AGG1 Academy

Tuesday, March 13

7:30 AM - 9:00 AM

T41 - Recent Automation Trends in the Aggregate Industry
Jay Wise and Doug Coulter, Kruse Controls, Inc.

Aggregate producers are increasingly recognizing that automation system integrators can help them get the most out of their current equipment. Automated production and downtime reporting systems can increase facility efficiency without physical or capital upgrades. This presentation will discuss the reasons behind the growing shift to automated reporting, the benefits of introducing reporting tools to aggregate plants, and some user-friendly ways that operators can generate real-time or historical trends and reports.

T42 - Overcoming Community Opposition
Christopher Hopkins, The Saint Consulting Group

This session provides guidelines for gaining community acceptance through dialog, community relations programs, community involvement at various governmental and non-governmental levels and the local media. The material is based on NSSGA's best-selling Community Relations Handbook: A Guide to Building Trust and Credibility in the Community. Overcoming community opposition is never easy, but can be done if you understand that it is an ongoing and political process. Learn how to develop relationships with local and state elected officials to assist in developing the “reservoir of good will” essential when the road gets rocky.

T43 - Everything You Always Wanted to Know About Crushing but Were Afraid to Ask
Mark Krause, Lafarge

This session provides an overview of crushing including the different types of primary and secondary crushers, pros and cons associated with the different types, what site conditions to consider when choosing crushers and how to optimize the process given a particular crusher. Topics covered will be types of crushers available, the features and benefits of each along with expected production capabilities end products and costs associated with using the various methods. This session will provide some understanding of the key cost drivers and how they can be managed for processing equipment (like mobile equipment), including factors involved in determining the optimal point of ownership and disposal.

T44 - The Frac Sand Process
Scott O'Brien, McLanahan Corporation

In the business of making the U.S. more energy independent, huge resources have been turned to exploration and exploitation of both established and newly discovered reserves of gas and oil. To make these sources more productive, an extraction method that fractures the host rock is employed. One of the main requirements in this process is frac sand. Much interest in production and supply of frac sand has been generated with the large sums of money being spent on these special sands. The American Petroleum Institute (API) has set our specifications for frac sand that include size consist, roundness, sphericity, compressive strength and others. While Mother Nature controls many of these specifications, size consist and agglomerates can be influenced through wet and dry processing. Familiar to many aggregate producers, washing with cyclones and rising current classifiers to prepare feeds for finishing on dry screens is the most prevalent style plant now being used to produce these tight specification sands.

T45 - Stockpile Management
Jeff Steiner, Superior Industries

Known simply as a process to storing bulk materials, the short definition of stockpiling makes the job sound easy. On the other hand, when you consider diverse building techniques, pile configurations, reclaim methods and quality control, development of a stockpile intensifies. In Stockpile Management, audience members will discover new pile construction methods and the reasons behind each procedure, do-it-yourself volume calculations, maintaining control over quality and reclaiming techniques based on demand. No longer simply piling material, this course will help convert stockpile managers into stockpile experts.

T46 - The Remarkable Value of Telescopic Stackers
Michael Hall, Thor Global Enterprises Limited

When the Telescopic Stacker came on the scene in 1992, many producers thought it was a novelty product and couldn't see a future for the unit in their operations. Most operators at that time were not very automated, not as cost conscious, nor did they have to contend with the high cost of fuel and the strict EPA rules that are currently in place. This presentation will show how operators have reduced their operating costs significantly through the use of Telescopic Stackers, how Telescopic Stacker offer a "greener" way of stockpiling vs. trucks, dozers, or loaders. It will also show how increasingly, Telescopic Stackers are being accepted as one of the best ways of easily obtaining an in-spec product at the lowest possible cost for municipal and state D.O.T. projects.

T47 - Knife River's Journey to Safety Excellence
Mike Williamsen, Caterpillar Safety Services and Zach Knoop, Knife River Corporation

With a recordable-incident rate 50 percent lower than the national average in 2010, it is apparent Knife River Corporation is fully dedicated to a culture of zero-incident performance. This case study presentation explains Knife River's journey on their road to safety excellence. Part of this journey includes support and guidance from Caterpillar Safety Services. Knife River utilized the Caterpillar Safety Services Zero-Incident Performance (ZIP) Process, which engaged everyone from executive leadership to front-line employees and resulted in a true shift in the company's culture, beliefs, behaviors and safety metrics. Together, Knife River and Caterpillar Safety Services will present the processes, tools and techniques used in the ZIP Process to elevate Knife River to the next level of safety. These processes, tools and techniques helped Knife River in more ways than one; employees started applying these principles to solve problems in areas other than safety. They proudly took ownership of the principles and made it part of their culture and how they work. Implementing safety excellence at a company is about more than improving safety metrics; it is about doing the right thing to save lives. But having solid safety metrics can do a lot for a company. As a result of the solutions provided by Caterpillar Safety Services and the dedication of Knife River employees, safety metrics have been significantly improved. Safety milestones have been hit year after year. Learn what it takes to make this type of initiative a reality.

9:30 AM - 11:00 AM

T51 - Maximizing Plant Productivity by Benchmarking & Evaluation Performance
Bob Bartok, Paschal Associate Sales, Inc., in conjunction with George Fox, Luck Stone Corporation; Phillip Gosnell, Rogers Group, Inc. and Dan Humpal, Martin Marietta Materials

The presentation will demonstrate how to establish plant performance benchmarks, then evaluate and improve overall productivity. Real-life plants will be reviewed showing before and after operating results. Elements include benchmarking new and existing plants, reviewing performance through field samples, evaluating process equipment performance, identifying bottlenecks and inefficiencies and maximizing plant productivity and profitability. Attendees will learn how to benchmark a plant using process simulation software, discover how to evaluate productivity and performance of equipment, and understand how to develop plant optimization and identify process bottlenecks.

T52 - Monitoring and Advanced Evaluation Techniques for Aggregate Mining in Urban Settings
Jeffrey A. Straw, GeoSonics, Inc. and Douglas Rudenko, PG, Vibra-Tech Engineers, Inc.

Permitted operations within urban environments are affected by politics and the neighbors. Demonstration of the actual effects is necessary along with technical evaluation. Data presentation using Iso-Seis presentation may be the ultimate demonstration device. Vibration contouring uses over 175 seismographs surrounding an urban mining operation showing reduction of vibration with distance and identifying geologic features that affect off-property vibration. Results give a better understanding of what residents actually feel in their homes. Combination with the Vibra-Map program provides computer simulation of thousands of potential blast designs. It is possible to synthesize the frequency spectrum from hundreds of potential blast designs and identify the blast patterns least likely to affect houses. All of the evaluation may be used and presented for successful zoning results.

T53 - Production Automation: The Future of Aggregate Dredging
Bill Wetta, Dredging Supply Company

With energy costs soaring and permitted sand and gravel sites decreasing, transporting dredged aggregate at the optimum flow rate and concentration is paramount. In years past, dredge operators would vary the dredge pump speed, cutter speed, and swing speed to achieve acceptable dredge production with little risk of pipeline plugging or equipment over-loading. Seldom was the deposit actually surveyed to check on the material characteristics or to ensure that all of the material was being removed. Additionally, maintenance and operating crews usually performed only critical repairs to the equipment, not routine service to maintain a high production rate. Today, many dredges employ flow control systems that vary the dredge pump speed based on the slurry flow rate and density. This type of automaton can greatly reduce energy usage while insuring a fairly consistent production rate. Often slurry dilution automation is combined with pump speed control to allow the dredge operator the ability to maximize the dredge excavating system. Cutter/swing speed control systems are also installed to try to optimize the excavation rate. GPS positioning and digital pre, current, and post survey maps are used to assist the operator and survey engineers to control the excavator position and spoil area throughout the dredging project. Control systems also log equipment faults, alarms, and hours to assist maintenance personnel keep the machine operating at peak efficiency. However, this type of automation is only the beginning of what is currently under development. With addition of a few sensors, cameras, software, and the integration of current pump speed, swing and cutter speed, GPS positioning and predictive maintenance, the dredge is being re-created as an intelligent machine that can "learn" from its environment and assist the crew in making decisions that further optimize production and reduce operating costs.

T54 - Reducing Struck-By/Blind Spot Accidents
Michael Hitchcock, Preco Electronics

The environment in which aggregate equipment works in each day is full of potential dangers: Maneuvering around different sizes of equipment. Complacent pedestrians. Subcontractors unaware of safety procedures. Reducing struck-by accidents, the industry's #1 cause of injury and downtime, is a top priority. In this presentation you will learn how some of the industry's top aggregate companies have combined technology and training to reduce their backing accidents, reduce on-site injuries, and save lives.

T55 - How Production Changes Can Affect Quality
William Sheftick, Bowser-Morner Testing Laboratories

In today's markets, it is vital that the aggregate source supply the contractor with consistent aggregate products meeting the more stringent aggregate characteristics being demanded by End Acceptance or PWL contracts currently being used by many agencies to avoid major penalties to the contractor. It is important to remember that these penalties will be passed on to the aggregate source if the aggregate supplied to the contractor did not meet the contract use requirements. One area that many aggregate sources are not fully aware of is the potential for change in aggregate product quality due to changes initiated in the production process. In most cases, production changes are made to the production process without consideration to quality changes in the aggregate products due to lack of understanding or knowledge about potential problems that may be created. The products produced after a production change may normally just be placed on approved stockpiles and shipped out under the impression that the products still meet specifications, which may not be the case. This presentation is primarily directed at aggregate sources which have to beneficiate their raw feed streams through the production process to produce high quality aggregate products. The presentation will discuss the effect of production changes on product quality. The presentation will also emphasize the need for Production and Quality Control sections at an aggregate source to establish a working interface to identify/correct any production changes that unacceptably alter the product quality.

T56 - Optimizing Screen Performance Before You Buy the Screen
Ron Kuehl, Polydeck Screen Corporation

In a traditional screen application review, flow sheet programs are combined with industry experience to predict both screening capacity and efficiency. In many cases, the actual feed curves and rock characteristics are not accurately accounted for when completing the sizing calculations. Therefore, producers would have to install the screen and media to determine if they selected a suitable combination for their application. If problems are encountered, they typically solicit help from the screen manufacturer, the media company, or both. This process can be costly and time consuming. A more effective solution to this problem is to use a test lab with adjustable screening equipment that allows the accurate prediction of any type of screen and media combination. Prior to a screen purchase, evaluating actual performance data on the most effective screening angle, the most effective speed and stroke, and the optimum travel rate helps make the right screen choice. In the cases where the screen has already been selected, the test equipment should be set up to match the OEM's parameters. Once the most effective screen set up is established, evaluating panel performance data side by side will help determine which panel to choose. Some factors that can be reviewed are listed as follows; the highest capacity, the best wear, secondary motion benefits, surface features improvements, and drainage rates. The primary focus of the presentation will be to show examples of different material tests and how to use the results. We will also demonstrate how these tests can be incorporated into a sizing program.

T57 - Is Your Company Ready for Tier 4?
Terry Oftedal, John Deere

OEMs are working to deliver mobile equipment with cleaner engines that meet your uptime needs to support production. Join us to discuss Tier 4 timeline, fleet planning insights, maintenance and operator expectations with these new engine forms.

2:00 PM - 3:30 PM

T61 - An Aggregate Producer's Experience Implementing Photoanalysis Equipment and Software for Optimization of Crushing Equipment
James Cox, CEMEX

Discussion of one aggregate producer's experience in acquiring and implementing a portable photoanalysis system for optimization of crushers. In 2010, CEMEX evaluated systems for portable use in automating the measurement of crusher input and output. This presentation presents the results of our efforts to find and implement a program to utilize photoanalysis equipment for evaluating efficiencies of crushing equipment and optimization to critical product needs.

T62 - The Value of Diligent Land Management
Richard Tyler and Steven T. Brown, Lafarge

Companies with multiple land holdings may often overlook the value to be derived or maintained through the diligent management of their sites and properties for the entire life-cycle from sound acquisition, prudent leasing, attention to real property taxes, development of and adherence to mining and reclamation plans, and periodic review of financial aspects including depletion and reclamation accrual. Following certain guidelines and best practices can yield significant financial and operational benefits for ongoing operations, acquisitions as well as divestments.

T63 - Creating a Safety Culture
Mike Williamsen, Caterpillar Inc.

Employee safety is top priority for any company, including those employees who work in the aggregate business. Having a positive safety culture as an integral part of the organization is key to the success of keeping people injury free. Learn more on how you can create positive attitudes and increase the value of safety. The Caterpillar Inc. website "SAFETY.CAT.COM" provides a wide variety of tools that will help engage employees and educate all levels of the workforce. New for Caterpillar Inc. are the safety consulting services offerings that will help guide your employees to their best safety performance. This presentation will touch on creating a safety culture in the workplace, providing tips and techniques to help everyone arrive “Safely home. Everyone. Every day.TM”

T64 - Evolution of Crushing
Andy Bartram, FL Smidth, Inc.

This presentation will key on the history of crushing, description of the founders, the crushing process and a glimpse of equipment from the turn of the century. Learn about the challenges and changes in maintenance and operation through today and discover how technology has gradually addressed keeping up with market demands. Attendees will learn what role new designs and technology have played to improve quality and efficiency in the production of aggregates.

T65 - Lean Material Processing
Paul Smith, KPI-JCI, Inc.

A typical aggregate producer is essentially a manufacturer of aggregate products. Under this mindset, they are faced with many of the same issues as all types of other manufacturers: absorbing work-in-process (WIP) as well as finished goods inventory, reacting to process flow interruptions, relieving production bottlenecks, absorbing process inefficiencies, etc. When one truly analyzes the total cost of most typical operations, they will find that the majority of the actual total cost can be defined as “non-value added” cost, which is to say that these costs do not add any value to their customer. Examples of non-value-added costs include energy consumption, operating and maintaining material handling equipment, inventorying and replacing consumable wear parts, etc. This thought-provoking presentation will apply Japanese “Lean Manufacturing” principles to a typical aggregate operation. The intent is to provide a simple, logical, hands-on approach to show how an organization can form internal "focus groups" comprised of multi-departmental personnel to implement “5-S” programs to organize and improve the quality of workstations so that the right parts and the right tools are at the right place at the right time. Additionally, it will provide a proven process as to how these “value stream teams” can identify non-value-added processes that create additional costs as well as identify and address interruptions in process flow. Finally, this presentation will provide some real-life examples of how simple adjustments to crusher and screening equipment configurations can improve productivity and quality.

T66 - Conveyor Starting Methods
Robert Schultz, Baldor Electric Company

The presentation will cover the different methods available to start a conveyor. Across the line motor starter, electronic soft starter, variable frequency drives, fluid couplings and clutches will be discussed. Each method will be reviewed with advantages and disadvantages listed.

T67 - Inverted Base: Turning Pavement Design Upside Down
Randy Weingart, PE, Luck Stone Corporation

The concept of using a graded aggregate base as an interlayer between a stabilized base and a riding surface has been considered for some time. The use of an "inverted pavement" on medium- to high-volume roads is an opportunity for the aggregate industry to optimize (best yield to product mix) the use of aggregate materials and provide a lower cost, high-performing road section. Not only is this concept 20 to 25% less expensive than a conventional pavement design, but it complements the green highways initiative, as it uses materials that would be considered more sustainable while representing a diminished CO2 footprint. In Georgia, an inverted pavement section was installed in 2000 as an entrance road to an aggregate quarry. After a decade of heavy duty service, the inverted section is still in excellent condition. As a result of this performance, the Georgia DOT installed a .7 mile inverted test section on a bypass in LaGrange, Georgia in 2008. At their Northern Virginia Bull Run Quarry, Luck Stone is currently reconstructing a new alignment of Route 659 for future quarry expansion. This bypass includes an inverted test section. The Federal Highway at Turner-Fairbank labs has been a key partner and is fully instrumenting several sections. Attendees will discover opportunities to consider alternative pavement designs for use in your market area and gain a general design understanding of inverted bases from a layman's perspective. Additionally, this presentation will discuss leading edge pavement design concepts for the non-pavement designer and give a summary of cost savings and base utilization as a green product.

Wednesday, March 14

7:30 AM - 9:00 AM

W41 - What is cloud-computing, software as a service, integrated web applications and what can they do for your business operations?
Liz Haight, Placer Online.biz and Brent Tardif, Continental Placer Inc.

The cloud, online-data, software as a service, integrated web applications, these buzz words all mean about the same thing; pretty soon most of your operations will soon place valuable documents and data on the internet . What are the pros and cons of adapting your operational and data processes to an online system? What are the different types of services available and what does it cost to implement them? Who is ultimately responsible for updating and maintaining the changing technology of an online system? What kind of security and back-up do you really need? This presentation will answer these questions and then provide a brief example of  PlacerOnline.biz, a current, web-based data management system specifically designed for your industry. Examples will show how to create a standardized system to manage operational data flow; upload and organize existing documents, permits and maps making them available to all sites; develop a customized system of e-mail notifications mailed to field personnel and management reminding them of important inspections or dues dates. PlacerOnline.biz was developed by Continental Placer Inc., geologic and environmental consultants to aggregate and construction material producers. Continental Placer's professional geologists saw the need for a central depository to securely organize and store very important maps, reports and regulatory documents. Continental Placer Inc. hosts PlacerOnline.biz, a custom web-based data management subscription service.

W42 - The Accidental Boss
Brian Gareau, Caterpillar

Effective leaders, now more than ever, must wear many hats. Yes, your hard hat is very important. But you also need to wear your business, company advocate and employee advocate hats too. Come and explore tactical and practical leadership reminders on "blind spots," signs and hazards. Rediscover how some basic techniques can significantly improve the commitment, effort and the loyalty of your workforce.

W43 - Improving the Quality of Natural Sand with Manufactured Sand
Mark Krause, Lafarge; David Morrow, Metso Minerals Ind.; and Scott O’Brien, McLanahan Corporation

As natural sand is being depleted and new sources are difficult to permit, the need for quality manufactured sand is more important than ever. We will investigate, based upon case studies, various methods of reduction both compression and impact and wet and dry processing. Reasons why certain equipment or process choices were made including cost considerations will be discussed. The demands and specs will differ for asphalt and concrete applications. We will look at costs, shape, yield and potential blending with natural sands.

W44 - Where is the money? Practical cost reduction in your quarry operations
Gary Atkinson, Volvo Construction Equipment

In the prevailing difficult market, every penny matters whether for competitive advantage or business viability. This talk will discuss the basic principles of mobile equipment operating costs and relate examples of a few simple but effective means to reduce them.

W45 - The Andreas Impactor: Technology - Helping You Achieve More
Jeff Sikora, HAZEMAG USA, Inc. and Chris Upp, Conco Quarries

The presentation includes a brief history of the Andreas Impactor along with its development over the last 25 years. The emphasis is put on today's machine and how it can bring about operational benefits in an aggregate quarry. The presentation will review today's technology and the benefits that are realized in the form of higher reliability, increased machine control, reduced operating costs and a higher level of safety. We will review a couple of typical case installations including customer feedback.

W46 - How to Control Dust
Mark Kestner, NESCO

Dust emissions from mining and material handling operations arise from four major sources: unpaved roads, paved roads, material processing and stockpiles. Dust emissions are a regulated pollutant and must be controlled to comply with federal, state, and local air quality standards. This paper describes a method for developing a dust control plan that relies upon a combination of good operating and engineering practices coupled with wet suppression and dry collection systems. Based on the philosophy that good dust control is good process control, this method is designed to comply with regulation without sacrificing productivity. By treating dust control as a problem of process control rather than a regulatory issue plants are shown how to employ low-cost, low-efficiency controls first in order to reduce reliance upon more expensive and efficient control measures. As a result, affected facilities are able to comply with air quality standards at the lowest possible cost.

W47 - Getting the Most from Your Equipment Dealer
Magnus Dahlgren, Mellott Company

The importance of the equipment dealer in the “equipment supply chain” is often overlooked. This presentation outlines how many ways a good equipment dealer can add value to your operation and help improve the bottom line. The selection of the right equipment dealer is just as important as selecting the brand of equipment. Although the dealer is an agent of the manufacturer, an equipment dealership is usually an independent business and it operates under its own values. If you find a dealer with values similar to your own business and build a mutual trust-based relationship, it could be financially rewarding to both of you. This presentation points out the many ways an equipment dealer can add value to your organization and defines what to expect from your dealer. You'll come away with a checklist to evaluate the dealers of the competitive brands you deal with and realize the importance of considering the combination of brand and dealership.

9:30 AM - 11:00 AM

W51 - Unattended Scale House: Does it Fit?
Scott Killough, JWS a Div of Command Alkon, Inc.

This presentation will discuss what some quarry operations have done to reduce costs with attended scale houses. Going unattended requires some planning, government approval, connectivity and training. This discussion will focus on how to accomplish this and what are the options, and will include photos of some actual sites and how they accomplished what they were trying to do. Connectivity is a big issue and is getting easier with current technologies and new devices.

W52 - Recovery of Ultra-Fines - How to Eliminate or Extend Your Pond Life
Cory Jenson, McLanahan Corporation

Pond maintenance and permitting are becoming growing issues for producers around the country due to increased environmental regulation and the lack of space for future ponds. This presentation will discuss methods for eliminating or reducing the solids reporting to settling ponds and how to analyze the material reporting to your pond in order to determine the most cost effective method for reducing or eliminating the need for a pond. After properly defining the material reporting to the pond, the implications on equipment selection will be discussed. Types of fines recovery systems discussed will include:  Cyclones over a dewatering screen for recovery of fine sand down to 400 or 500 Mesh, thickeners to thicken material and reduce the volume of slurry going to the pond as well as recover process water, and recessed plate filter presses to completely eliminate the need for settling ponds by dewatering the -400 Mesh material into stackable, conveyable cakes. Due to the recent trend towards using recessed plate filter presses which have become very common in Europe, plate presses will discussed in greater detail to help potential users understand the implications of different styles of filter presses such as Overhead Beam presses versus SideBeam Presses, impacts of operating pressures, recessed plates versus membrane plates, opening and closing systems and their impact on production rates and maintenance, as well as the impact cake thickness has on production with less permeable materials or when variations in feed gradation or density are expected.

W53 - Safety & Health Management Programs for Aggregate Operations
Adele L. Abrams, Esq., CMSP, Law Office of Adele L. Abrams PC

Both OSHA and MSHA are conducting rulemakings to mandate safety and health management programs for all businesses in the U.S. This program will address the key components of such programs, state regulations currently in place, consensus standards that outline how to develop such programs, and the status of the OSHA/MSHA rulemaking initiatives. The program will also address the cost/benefits of such programs, legal issues associated with their implementation and enforcement, and the role of such programs in MSHA's Pattern of Violations rule.

W54 - Broadband Alarms: A Tangible Part of an Effective Noise Reduction Strategy
Alan Parks, Memphis Stone & Gravel Company

Not unlike many aggregate mining companies, Memphis Stone & Gravel Company operates within close proximity to residential dwellings. It is not unusual to operate within three hundred feet of a house or other occupied structure. Noise or "the potential to cause noise" is frequently cited by stakeholders as a major (negative) issue associated with mining operations. Stakeholders include neighbors who live or work near operations and the property owners who lease land to the company. The Census Bureau reports that noise is Americans' top complaint about their neighborhoods, and the major reason they wish to move (NFA, 2007). Memphis Stone & Gravel Company follows a three phase strategy to reduce noise at its operations, including: 1) site planning, 2) effective use of noise barriers, and 3) noise source reduction. The information presented in this paper will describe practices Memphis Stone and Gravel Company use to control noise at the mine with particular emphasis on its use of broadband sound technology for its mobile equipment and conveyor systems.

W55 - Screening 101
Joe Schlabach, Deister Machine Company

This session covers basic concepts for novice plant design personnel to understand screening options. Screening is the critical "cashbox" of each operation. This overview will cover items like stratification, separation, bed depth, and the effects of stroke, amplitude and speed. You will glean nuggets on to help your existing screening operations while gaining an understanding for future plant expansions. Different types of media and their application will also be covered.

W56 - New Technology in Synthetic Wear Linings
Louis Ondrias, TEMA Isenmann Inc.

In early 2010 TEMA Isenmann partnered in research and development on what is promising to be one of the most innovative products developed for the mining industry in a number of years. This new technology uses a patented method of molding high strength magnets into wear liners. These liners are able to be installed on all types of vibrating equipment, in chutes, and any wear areas where steel backing is present for the magnets to attach to. These liners are made of the highest quality mine duty urethane that has been proven in screen media applications for years. This new system of installing liners has far reaching effects on plant operation. In terms of safety there is no cutting or welding required to install modular parts make them much safer in terms of handling. In terms of labor they can be installed in minutes compared to hours on conventional liners. The presentation will give information on existing installations and technical data on wear-life, labor reduction, increased safety issues, and bottom line plant savings.

W57 - Crusher Maintenance Best Practices
Erik Schmidt, JCI Inc.

This topic will present the three types of maintenance: preventative, predictive and reactive as they apply to crushing equipment. Specific examples for typical crushing equipment are given in problematic areas as “do's and don'ts” and keying in on the top 10 improper best practices.

2:00 PM - 3:30 PM

W61 - Pond Elimination - Use of Centrifuge Technology
Donald J. Ruppert, Derrick Corporation and Steve Brooks, Tilcon New York

With settling ponds continuing to be a major negative to the wash plant operations; highly problematic belt press technology has been the only options in close looping the settling ponds, until now. As technological advancements move forward, centrifuge technology can now be deployed to replace the cumbersome belt press technology.

W62 - Modeling Vibration and Fragmentation with Electronic Detonators
John Babcock, South Technical Services

For the last several decades, the eight millisecond rule has been considered the industry standard in limiting the vibration at nearby structures through the Scaled Distance formula and vibration predictions. With the increase in computing power along with improved vibration and blast modeling programs, the use of digital or electronic detonators has eliminated the need to abide by the 8ms and Scaled Distance rule. The four case studies included in this presentation will follow the execution and application of the well designed blasting program in producing lower vibration, better fragmentation, and improved cast through several different types of geology. The resulting timings used have totally negated the 8ms rule and in fact have shown that proper blasting with hole detonations at 1 or 0ms (based on correct modeling) separations can lower vibrations and increase frequencies.

W63 - Maximize Your Sustainable Outcomes through an Engaged Workforce
Margie Flynn, BrownFlynn

When it comes to sustainability, where does your company rank on the employee engagement barometer? Many companies begin their sustainability journeys focused on the “quick wins” or “low-hanging fruit”—those activities that are most easily understood and embraced by employees. However, as you strive to take sustainability to the next level and make it core to your operations, how do you keep your employees actively engaged and contributing to meaningful top- and bottom-line results? In this workshop, you will learn why and how employee engagement can help generate sustainable returns for your company as well as some best-practice strategies to help strengthen your employee engagement initiatives.

W64 - Managing Your Mine: Traveling with Inspectors, Dollars and Sense, and Pattern of Violations
Jason Nutzman, Dinsmore & Shohl LLP

This presentation will present three very important areas on MSHA regulatory enforcement: traveling with an inspector who comes onto your mine property; managing your mine history for purposes of civil penalties; and understanding MSHA's plan for pattern of violations. The presentation will offer best practices and procedures to consider and implement when faced with an MSHA inspection, including how to train your front-line supervisors in note-taking and fact gathering. Oftentimes, the information these individuals gather walking with an inspector provide the basis for the defense of citations and orders issued by MSHA. Next, ideas will be discussed regarding conferencing citations and orders as well as the initial stages of litigation. The purpose of this section is to provide information on how a simple change in from one box to another on the citation or order may significantly increase a civil penalty issued to the operator. This section will provide suggested areas of focus for those front-line supervisors to discuss with the inspector during the inspection, including the criteria for a finding of significant and substantial ("S&S") and unwarrantable failure. Finally, the presentation will discuss MSHA's pattern of violation program and how that could impact an operator for many years. Part of this section will also focus on recent MSHA initiatives and similar initiatives by the industry.

W65 - Building Relationships with Elected Officials: Strategies for Getting to Know Your Elected Officials
Darrell Shull, BIPAC

Sometimes the most effective and efficient way to gain a policymaker's attention is to simply show them the benefits your operation brings to your community. This advocacy training session will explore the best ways to introduce your operation to a range of elected officials. It will look at options for putting together site visits, attending town hall meetings, engaging town boards and city councils, and working with local Congressional staff. We'll also discuss strategies for getting elected officials involved and engaged in your operation's activities.

W66 - Replace that VSI and Roll Crusher with a Cone
Jeff Gray and Sean Neitzel, Telsmith Inc. and Delmar Hansen and Ron Kastor, Tricon Materials

Case study of a sand and gravel application where a VSI and a roll crusher were replaced with an automated cone crusher to produce asphalt chips and manufactured sand. All aspects of the application will be reviewed from operation cost, particle shape, productivity and uptime. We will explain the importance of crusher automation in fine crushing as well as the importance of understanding your customer's expectations of the finished product.

W67 - Blended Training Program
Jon Goodney, John Deere

Learn about Training programs available from OEMs that can be tailored to your business with a deeper insight on Safety and Operator Training. You might ask… how effective are operator training simulators? Come to this session to learn about new studies that explain how you can boost your productivity and safety program. You will also learn about other programs that will complete your Safety, machine troubleshooting (light) training, and how you can track employee participation.

Thursday, March 15

7:30 AM - 9:00 AM

TH41 - Obtaining Special Use Permits for Aggregate Sources and Development Encroachments on Current and Potential Future Sites
Mark Krumenacher, GZA GeoEnvironmental, Inc.

Local zoning ordinances place the future of mining in the hands of the residents and locally elected municipal, Township and County representatives.  Mining is a unique industry that has in recent decades transitioned to one of the most heavily regulated industrial businesses with increased public exposure and public control over the permit to operate. Mining permits are now written largely by the public; specifically to incorporate input from residents, community groups, NGOs and other stakeholders which is an added burden on the mining entity due to the effort to educate all stakeholders and greatly increased cost of permitting and operation.  The strategies that have developed to obtain permits have evolved along with the local zoning ordinances, the residential development of land around urban areas, pressure brought on by the public's growing affluence, education and easy access to information; and overall emphasis placed on groundwater, protection rural lands and sustainability.  Ironically, as the population increases, and communities expand, the need for convenient aggregate and other mineral resources increases.  Existing mining operations are encroached upon and resources made unavailable for future use by the expanding new developments.  The land use management plans and local ordinances recently developed to control land use too often ignore the importance of mining and the source of all raw materials needed to develop the land that the planning and ordinances control.

TH42 - The case for comprehensive dust control
Bill Campbell, Applied Industrial Technologies

A comprehensive chemical treatment, used properly, can improve the control of fugitive dust, airborne particulates and prevent track out of mud to city streets. It will not only make your facility more environmentally friendly but will also make you be recognized as a good neighbor. Talk will discuss the three main areas of primary concern. 1. Haul roads 2. Transfer points, from conveyor to shaker screen, from screen to conveyor from conveyor to crusher and from conveyor to conveyor. 3. Static slopes and piles that experience wind corrosion.

TH43 - Save the Belt: Maintaining Your Conveyor's Costliest Conveyor Component
Jarrod Felton, Superior Industries

Not only is it your costliest conveyor system component, but belting is also the most complex element to maintain. In Save the Belt, audience members will discover the most effective installation techniques, operating procedures to maintain peak performance and problem-solving solutions to resolve maintenance-related complications. From installation and operation to daily maintenance techniques and procedures, this course is designed to communicate and demonstrate skills that will extend the performance life of conveyor belting. Topics include proper belt installation, the relationship between idlers and pulleys and conveyor belting, plus maintenance techniques to correct problem belting. Properly installing and maintaining a conveyor belt will eliminate costly downtime, reduce or eliminate the need for replacement parts and keep equipment running smoothly to its full potential.

TH44 - Washing 101
Jeff Wendte, KPI-JCI and Alan Bennetts, Weir Minerals-Linatex

This presentation overviews the basics of this easily misunderstood portion of operations. Topics include washing techniques, classifying tanks, dewatering screws versus dewatering screens, cyclones and separators. With the ever-increasing need for sand, especially manufactured sand, gaining this insight is invaluable.

TH45 - Fuel Optimization & Performance Seminars
Roger Arnett, Caterpillar

For years Caterpillar has been successfully training operators to run heavy equipment safely, efficiently and productively while protecting the health of the operator and the machine. With the soaring cost of fuel, it is imperative that operators also learn to save fuel while performing their daily work with machines. Caterpillar's Fuel Optimization and Performance Seminar covers efficiency operating tips for machine operation to ensure customers can lower fuel consumption within their companies. For some applications there can be substantial fuel savings once the different operating skills are learned and implemented. For other sites, dependent on site management and production demands, the fuel savings can still occur, but will not be as substantial. After studying these efficient operating techniques, operators will learn to safely operate their machines and maintain production while decreasing fuel consumption overall. They will learn to properly inspect their equipment and identify small maintenance issues to eliminate them before they become major issues. Site management support is crucial. It will serve no purpose for positive fuel savings if managers/owners direct operators to operate their machines differently from what they have learned from this program. This training is not a fix-all for all applications concerning fuel savings, and success will vary from application to application depending on operating policies, production demands and upper management support. By the end of this training, the operators will be learning safe and efficient operating procedures that will save money for their companies. The field portion will tie all the knowledge and theory portions of this training together as the operators actually see the fuel savings occurring. As they operate the machines differently than they have before, operators gain an understanding of how they can save fuel and still maintain production as needed.

9:30 AM - 11:00 AM

TH51 - Drive to a Greener Future: Sustainability and Energy Efficiency with Variable Speed Drives
Ken Kerns, Siemens Industry, Inc.

Participants in this session will learn how to realize cost savings with state-of the-art variable speed drives technology. Attendees will see that variable frequency drives allow for more efficient control over processes than ever before resulting in energy savings of up to 60%, thereby resulting in a considerable reduction in their facility's overall carbon footprint. In many applications, variable speed drives have the potential to return energy back to the facility power grid through regenerative in-feed technology. Returns on investment can be realized in as little as 3-6 months depending on the existing installation.

TH52 - Pros & Cons of Contract Drilling & Blasting
Edward J. Svec and Mike Osborne, Austin Powder Company; Matt Boatman, General Drilling; Billy Zimmerman, Luck Stone Corporation

This is a basic, 101-type course that discusses the positives and negatives for operators to consider whether they should drill in-house or sub contract and whether they should blast in-house or sub contract. It also pursues sub contracting both as one package. The panel consists of: (1) A producer member that has done both in-house AND sub-contracting. (2) A contract drilling company representative. (3) A contract blasting representative. This presentation is aimed at new quarry foremen and superintendents, or any person in need of knowledge of this core requirement of overall quarry operations.

TH53 - Expanding Your Market Footprint with Portable Processing
Jerry Sammons and Jerry Hall, Telsmith Inc.

With today's reduced demand for aggregates, large stationary plants are forced to run at reduced levels which can be costly and potentially non-competitive. Portable plants offer the ability to efficiently produce finish product in depressed market areas while allowing its owners to enter new markets that may only require 300,000-500,000 tons per year. We'll explore the potential pitfalls that can be avoided as fixed plant operators venture into portable production.

TH54 - Conveyor Safety: Training, Guarding, and Best Practices
Jerad Heitzler, Martin Engineering

A belt conveyor is essentially a large rubber band, stretched tightly, loaded with large tonnage of loose material, and driven at a high speed over long distances through a maze of obstacles and pinch points. These systems are a critical and common component in aggregate operations. Due to their nature and their universality, conveyors pose a number of hazards to personnel. This presentation will look at ways to improve safety and mitigate the risks for personnel who work on or around belt conveyors. The needs include improved training, to understand both the risks of conveyors and the proper procedures that allow work around conveyors, improved guarding to reduce hazards, and reduce the need for proximity to conveyor systems, and improved work practices that can reduce accidents themselves. It will review OSHA and MSHA requirements for safety equipment and guards on conveyor systems and the procedures for the personnel who operate and maintain these systems. Due to the variations in conveyors and conditions, it is impossible to make precise recommendations on specific equipment and practices needed. However, the common thread this workshop will provide is there are safety "best practices" which can be identified and applied to all situations. The adoption of these best practices will provide a double benefit for operations; they will improve safety, and as equipment is safer, it can run better and be maintained better, and so a plant can be more efficient and productive.

TH55 - Tuning and Operations of VSI Crushing
Neil R. Hise, CEMCO Inc.

The presentation will cover a brief history of CEMCO, Inc. and who Neil R. Hise is, to show the authenticity of the material presented.  It is based on 44 years of operation and service of VSI crushers. Continuing will be a showing the history of crushing from the first Blake type jaw and Gates gyro disc crushers thru the modern compression cone and jaw type crushers and other impact crushers such as HSI crushers. Comparisons will be presented showing relationships of product output of the compression crushing and impact crushing with the associated input of horsepower. Video of internal VSI crushing will be shown in the power point presentation along with in depth discussion of the physics and dynamics of the internal configurations of a VSI. All four types of VSI crushing will be explained and discussed, using actual processing photos, videos, and computer animation.  Specific types of material and how to obtain best reduction ratios of that material will be analyzed. Automation of a VSI crusher will be discussed. The opportunity to for questions to the presenter will be a very important part of this presentation. This is not a sales pitch, but rather information on how the real physics of VSI crushing is used in our industry.