Tag Archives: Cat 3512E

NRW equips Karara magnetite mining fleet with two new Cat 6060 shovels

Equipment maintenance, Mine operation news, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , , , ,

NRW Civil & Mining has recently invested in two new Cat 6060 hydraulic mining shovels to meet some unique challenges at Karara Mining’s magnetite project in Western Australia’s Midwest region, engaging Cat dealer WesTrac in the process.

Karara is the largest mining operation and the first major magnetite mine in the Midwest region, producing a premium, high-grade concentrate product which is exported from Geraldton port.
Unlike the more commonly mined hematite, magnetite is a hard and highly abrasive ore, which meant NRW needed machines that could cope with the rigours of operating in such harsh conditions.

NRW opted for the Cat 6060 Hydraulic Mining Shovel, a 600-t unit able to load 218 t trucks and above.

According to NRW Mining Operations Manager, Adam Harper, the buying decisions for a mining contractor are very much driven by client expectations.

“We’re obviously chasing safe machines, but they have to be able to perform to our clients’ expectations and do so efficiently,” Harper said.

According to WesTrac Product Manager, Greg Wear, the Cat 6060 is a premium Caterpillar® offering when it comes to hydraulic mining shovels and has traditionally been the shovel of choice for top tier miners.

“This is the machine that we promote for highly productive loading of 240 ton (218 t) trucks and up,” Wear said. “Tier One miners have had good success with that and, now with NRW onboard, it shows that mining contractors are also seeing the value of the Cat 6060.”

Wear explains that the 600-t models have a long history, having first been released to market under previous owner Terex as the RH340 in 2004. Since being acquired by Caterpillar, the machine has been progressively “Catified” through a series of phased improvements.

“Over the past 10 years, Caterpillar has made phased improvements,” he said. “Phase one was a lot of quick wins that could be applied to make the machine more reliable. Phase two looked at structural changes designed to provide stronger, heavier frames and more reliability. Phase three continued that with modifications around sticks and booms, and a completely new superstructure and larger slew ring.

“Today with all the next generation technology, the transformation is complete with all Cat electronics and parts, and there’s been a new cab installed. Now the 6060 has the complete Caterpillar feel and functionality.”

Part of the new cab design was increased visibility, allowing the operator clear views to the digging and loading areas as well as the tracks.

Caterpillar Product Application Specialist, Dirk Tegtmeier, said the transformation of the Cat 6060 brings the same level of commonality to the large shovel that is seen across other Cat equipment.

Tegtmeier says a key efficiency gain, thanks to the 6060 now incorporating all-Cat components and improved structures, is that service intervals and the total operating life of the machine can be extended.

“The updated Cat 3512E engine, coupled with the fuel burn saving features, thanks to new hydraulic optimisation, will certainly offer a longer life than with the previous version,” he said.

That longevity, coupled with the added strength and Cat Enhanced Motion Control as part of the Operator Assist functionality of the Cat 6060, is important given the harsh terrain in which the new mining shovels are operating and the need to meet high production targets – with a minimum feed rate to the primary crusher of 3,500 t/h.

“The 6060 FS comes with an extremely productive profile that enabled us to match the client’s production schedules perfectly,” Harper said. “We also chose the Cat 793 trucks that are perfectly matched for size and passing with the 6060, so it’s a highly productive match. But we needed to ensure we had the reliability as well.”

Karara’s proximity to Geraldton and Perth – two and four-hour drives from the mine, respectively – and the fact WesTrac has parts and service centres in those locations, was another key factor in NRW’s decision to go for the Cat 6060.

According to Harper, the hardness and abrasiveness of the magnetite ore means ground engagement tools can wear up to 20 times faster than in hematite mining operations, meaning regular access to spares is vital.

“The teeth on the bucket can need replacing within 24 to 70 hours, whereas in some hematite mines, it could be anywhere from 500 to 1,000 hours,” Harper said.

“Having the customer service centre four hours away in Perth that runs 24/7 is crucial as it means we are able to get access to parts as needed. Also, WesTrac Geraldton being two hours away for support was really a deciding factor for us in choosing the Cat 6060s.”

Harper says NRW’s previous experience working with Cat equipment and existing relationship with WesTrac was one factor that helped win the contract with Karara Mining.

“Karara Mining Limited had a long association with Cat products, in particular the 6060 face shovels and the 793 dump trucks, and that played a big part in helping win the contract,” he said.

Caterpillar and the next generation of productive hauling

Automation, Communications in mining, IoT, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, , , , , , , , , , , , ,

Caterpillar says it is leading the way in the next generation of productive hauling through game-changing efficiency advancements with the Next Generation of Cat® Mining Trucks.

The 785 large mining truck was Caterpillar’s first entry into the mining industry more than three decades ago and, the company says, has been a top performer on sites around the world ever since. It is fitting, therefore, that it is the first of a new generation.

Designed by operators, for operators

“Where does the next generation of productive haulage begin? It all starts with operators, who work in an environment designed for them by other operators,” Cat says.

Truck operators provided input, worked alongside Cat’s large mining truck design team and shared feedback to help create a state-of-the-art environment on board the 785 designed for efficiency and ergonomics, and equipped with features that increase comfort, automate functions and boost confidence, from the smallest operator to largest operator around the globe, the company said.

The next generation operator experience is safer, more consistent, more predictable and more intuitive, shortening the learning curve and boosting productivity of less experienced operators, according to the company.

The new speed coaching feature gives operators real-time feedback on how to operate the truck to maximise its productivity, Cat told IM. In field trials, the new AutoHoist controls, meanwhile, have shown reductions of up to 12 seconds in the dumping cycle. “This feature can also reduce fuel burn during this portion of the haul cycle,” the company said.

Features such as Hill Start Assist, Anti Roll Back, Enhanced Traction Control, Dynamic Stability Control, Anti-lock Brake System, Machine Speed Limiting and Cruise Control improve machine responsiveness and controllability, while improving cycle times and reducing operator fatigue, the company added.

Serviceability and reliability

In addition to enhancing the operator experience and efficiency, the next generation truck platform delivers significant improvements in serviceability and reliability, according to Cat.

“We’ve worked to reduce key contributors to downtime with features like the new modular HVAC (heating, ventilation and air condition) system, which improves reliability and consolidates components so the entire system can be removed and replaced quickly,” Cat said.

Field studies have shown this modular element alone can improve physical availability by up to 0.5%.

New “Remote Flash” and Remote Troubleshooting capabilities reduce downtime and maximise machine availability, according to Cat, providing the ability to troubleshoot the machine remotely or update the software of an electronic control module on an engine or machine through cellular service.

“A manager in the back office can securely push machine software updates over the air to the truck,” Cat explained. “This feature reduces machine downtime and technician time, allows updates to be performed when most convenient, and keeps the machine up to date with the most recent software.”

Connectivity and technology integration

Mine sites have access to real-time information and analytics that improve their total cost of ownership, the company claims, with these next gen pre-production machines “quantifying the full value of new features” at multiple customer sites right now ahead of the start of manufacturing in the March quarter of 2021, Cat says.

Cat says it will be easier to integrate Caterpillar and certain third-party current and future technology solutions on the next generation platform, with offerings such as Cat MineStar™ – which includes fully autonomous haulage with Command – able to deliver a step change in productivity, efficiency and safety.

This integration can provide valuable data and analytics to enable near real-time decision making, maintenance troubleshooting, and the ability to predict and proactively prevent failures, according to the company.

Included on the truck is an improved payload monitoring system that comes with more accurate measurements, improved monitoring and an improved interface, according to Cat.

“Information is more accurate and the system provides access to more data,” the company said of this system. “The new system also provides accurate dipper counts, reduces false loading triggers and overload detection, while carryback calculations are more accurate.”

The system also provides detailed haul cycle segmentation and remote access through telematics, Cat added.

The backbone of advanced connectivity on the Next Gen truck platform is the ability to communicate through dual mode cellular 4G/LTE and Satellite, or local Wi-Fi networks – “whatever benefits the mine plan”, Cat says.

“Next generation connectivity delivers faster data transfers, better access to data, consistent and reliable data communication, more insightful and actionable data, improved data analytics and new diagnostic capabilities,” the company explained.

“The NextGen telematics systems can collect and transmit information securely into locally-hosted or cloud-hosted applications, such as Cat MineStar Fleet, MineStar Edge, and Health Equipment Insights. These applications boost productivity and improve maintenance and machine life.”

Built on a solid foundation

With nominal rated payload of 138 t or higher with optional larger tyres, the 785 has delivered lowest cost per tonne in a wide range of mining applications ranging from flat hauls to deep pits, and solid roadways to challenging underfoot conditions, the company said.

Its 3512E engine offers selectable power options so miners can either match the speed of their current fleet or speed up their cycle times, according to the company. The optional Tier 4 engine has shown a reduction in fuel usage by as much as 9%, while advanced electronic transmission controls deliver faster cycle times, faster acceleration, less spillage and reduced haul road maintenance, on top of improved engine and powertrain life. Longer-life components, extended service intervals and easier maintenance contribute to higher mechanical availability.

“The individual features, components, software and systems that make up the Next Generation 785 have one very important thing in common: they are all manufactured by Caterpillar and supported by the Cat dealer network.

“This integration ensures that the entire truck, from tyres to transmissions, engines to electronics, can be fully optimised to deliver the lowest cost per tonne in any manned or autonomous site applications in the world.”

Cat revamps 6060 hydraulic mining shovel

Equipment maintenance, IoT, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, , , , , , , , ,

Caterpillar has launched its next generation 6060 hydraulic mining shovel, which, it says, features multiple design enhancements and new components that advance machine performance, durability, serviceability, and operator comfort.

The new 6060, which replaces the 6060B in the hydraulic mining shovel lineup, features updated engines, optimised hydraulics, heavy-duty structures and undercarriage, Cat electronics and a state-of-the-art cab, according to the company. It is also fully integrated into Caterpillar product support systems for efficient Cat dealer services.

One of these new-generation shovels is set to operate at Anglo American’s in-development Quellaveco mine, in Peru, as part of a fleet that includes autonomous 794 AC trucks.

The 600-t class mining shovel has a bucket payload of about 61 t/pass in both face shovel and backhoe configurations. This makes it an efficient four-pass match with the 231-t payload Cat 793 mining truck and five-pass match with the 291-t payload Cat 794 AC mining truck.

Twin Cat 3512E engines are optimised for high performance, fuel efficient operation and increased durability, according to the company.

For North America, the engines are equipped with a maintenance-free diesel oxidation catalyst emissions control system, do not use diesel exhaust fluid and comply with US EPA Tier 4 Final regulations, Cat says. The updated engine design boosts reliability and extends time between overhauls by 10%.

The combination of this updated engine and optimised hydraulics enables 10-15% percent better fuel efficiency compared with the previous face shovel model, with 3-5% greater efficiency for the backhoe configuration, Cat says. For reduced maintenance, engine oil and filter change intervals are doubled to 1,000 hours.

Structural, undercarriage and slew ring upgrades help maximise uptime and productivity and lower cost per tonne, according to Cat. To boost longevity, the Cat undercarriage features heavy-duty rollers, idlers and tracks, along with a revised track tensioning system. The superstructure frame, face shovel and backhoe attachment structures, meanwhile, have been redesigned to reduce structural repair and extend service life via increased plate thicknesses and geometrical improvements. The slew ring design extends component life with a triple-race roller bearing and sealed internal gearing.

“The 6060 features a new, state-of-the-art cab and operator station with industry-leading visibility provided by the large floor window and expansive windshield and side windows,” Cat said. “Unrestricted lines of sight to the crawler tracks and pit floor aid the operator when repositioning the shovel and when loading trucks.”

A pneumatically cushioned operator seat can be heated and ventilated. It also has integrated joysticks and is multi-adjustable to offer optimal ergonomics.

This cab also includes two additional seats: a full-size seat and laptop desk for a trainer and a fold-up seat for an observer. The three-seat cab design is the first in this size class of shovels, Cat says.

Improved sound suppression on the power module keeps spectator sound levels low, while the sound suppressed cab provides a quiet working environment for the operator, according to the company.

The first of several features within the available Operator Assist suite, Enhanced Motion Control is standard on the shovel. This improves machine controllability and loading efficiency while reducing linkage and cylinder mechanical contact, according to Cat.

The machine’s five-circuit hydraulics design allows simultaneous control over two cylinder motions, two travel motions and swing to boost digging and loading efficiency, the company added.

The next-generation design helps improve service and maintenance efficiency by offering more room inside the service compartment and easy ground-level accessibility to the service station, Cat says.

Integration of Cat hoses in the design allows for local hose sourcing, while improved hose and component organisation further reduces machine downtime.

Sensors located throughout the 6060 monitor operating data, record faults and give audible and visual notifications of issues to the operator. Product Link™ Elite, which is standard for the first time on the 6060, enables data communication for remote machine health monitoring.

The 6060 comes ready to accept Cat MineStar™ Solutions, a suite of mining technologies geared to enhance mine safety, improve efficiency and reduce operating costs.

In addition to the next generation diesel-powered 6060, Caterpillar continues to offer the electrically powered 6060 AC FS (face shovel) for mines optimised for such machines.