Cat® has released a new double clip back bucket for draglines that, it says, features an innovative design that increases fill speedand reduces bucket weight for faster cycle times and greater payload.
The patented design alsoeliminates the high–maintenancespreader bar from the rigging system, it said.
The wide mouth, aggressive lip angle, and low front height reduce drag power required to fill the bucket, according to the company, while the design minimises the required fill distance for improved productivity and reduced bucket wear.
Cat said: “The unique shape of the rear wall enables the bucket to fill without upper rear corner voids, and it increases material density in the bucket for optimum payloads on every pass. It also clearly shows the operator when the bucket is full and should exit the cut.”
Eliminating thehoist rigging spreader bar has additional benefits, such as reduced wear and tear on the top rails and trunnions, Cat said. Meanwhile, fewer system components result in less inventory management and reduced maintenance cost. Therigging system design also gives the operator better control of the bucket and reduces the opportunity for an inexperienced operator to damage it, the company said.
“The unique trunnion design and location on the clipped portion of the bucket protects the lower hoist link from wear and provides quick dumping of the payload,” Cat said, adding that the design includes a cast-in deflector to protect and increase the life of the trunnion.
“The new Cat bucket is available for awide range of dragline sizes and applications, no matter what the brand of machine,” Cat said. “Using data-driven analysis, Caterpillar designs each bucket for thespecific dragline andapplication.”
The design process uses all significant parameters, including ground density, wear package, rigging package and bucket weight to optimise performancewithin the dragline’s rated suspended load, Cat explained.Reduced dead weight of the double clip back bucket, as compared with conventional designs, ranges from 2-10% depending on the application, it added.
Cat dragline buckets also include wear packages based on the mine’s material abrasiveness and digging conditions. The Cat dragline bucket lip nose casting supports the Cat CapSure™adapter and tooth system. The system delivers long wear life and hammerless installationof teethfor enhancedsafety and faster removal and replacement.
Newmont’s Boddington operation, in Australia, is to become the world’s first open-pit gold mine with an autonomous haul truck fleet after the miner’s Board of Directors unanimously approved investment in an Autonomous Haulage System (AHS) from Caterpillar.
The move, which will enhance safety and productivity and is expected to be fully operational in 2021, will also see the Boddington mine life extended, according to Newmont.
Tom Palmer, President and Chief Executive Officer, said: “Not only does Boddington continue to deliver strong performance, our investment in autonomous haul trucks will generate an internal rate of return greater than 35% with a more controlled and efficient haulage operation.
“We are also uniquely positioned in the gold sector to support effective implementation and operation of the fleet thanks to the technical capabilities and previous experience of leaders in our business. Simply put, Boddington will be a safer, more productive world-class gold mine in a top-tier jurisdiction.”
Total net investment in Boddington’s AHS will be $150 million, with efficiencies expected to extend the mine’s life by at least two years, Newmont said. The project will involve adding some new AHS-enabled Caterpillar 793Fs to the haulage fleet and retrofitting some existing 793Fs with AHS capabilities, a Newmont spokesperson confirmed. The company said it also saw additional upside potential from the replication of the AHS at other Newmont operations.
The company said: “Boddington’s autonomous Caterpillar haul trucks will feature rigorous safety controls that reduce employee exposure to potential vehicle interactions. No injuries have been recorded from AHS operations since their introduction into the mining industry.”
Newmont said it is also executing a “robust people strategy” at Boddington, providing opportunities for reskilling and redeployment of haul truck drivers to other roles supporting the AHS.
Boddington is Western Australia’s largest gold producer, delivering 709,000 oz of gold and 77 MIb (34,927 t) of copper in 2018. The mine directly employs around 2,000 people and is located 135 km southeast of Perth in Western Australia.
Barloworld says its Mongolia subsidiary has entered into an agreement to acquire 100% of Wagner Asia Equipment and 49% of SGMS LLC to help establish a new Eurasia-focused equipment unit.
The Caterpillar dealer has agreed to pay $216.8 million as part of the transaction, which will see the remainder of SGMS continue to be held by Battur Battulga, a Mongolian citizen actively involved in managing SGMS, which, Barloworld says, supplies equipment, parts and services to a key customer.
Through Wagner International LLC and its subsidiaries, the Wagner family have been doing business in Mongolia for over 22 years and are a long-standing Caterpillar dealer in selected states in the US.
Wagner Asia Equipment is engaged in the business of selling and distributing construction equipment, mining equipment, power systems, and related goods and services in Mongolia, primarily under the Caterpillar brand, according to Barloworld. It recently presented four 55 t CAT773 E dump trucks to Ulz Group, a Mongolia-based company focused on mining, exploration and construction (ceremony pictured).
Barloworld, in a SENS release, said it had consistently stated its desire to allocate capital to opportunities that complement its competencies as part of its medium-term strategy.
“The group balance sheet is strong and this opportunity, adjacent to the current Russian operation, presents an attractive growth prospect within the Equipment division,” it said. “The Wagner Asia Equipment business will be combined with the current Barloworld Russian business unit into a newly formed Equipment Eurasia unit.”
The proposed transaction is subject to the following outstanding conditions:
The conclusion of various agreements with Caterpillar Inc (or an associated entity) in respect of the Caterpillar dealership in Mongolia;
The carve-out, exclusion or transfer of non-core assets, liabilities, agreements, customers and debtors held by Wagner Asia Equipment prior to completion of the proposed transaction;
Obtaining the consent and associated waiver of Battur Battulga to the proposed transaction and the entry into of a new shareholders’ agreement;
Obtaining the consent(s) and/or waiver(s) from certain third parties in respect of certain rights arising from the change of control contemplated by the proposed transaction; and
Gaining the necessary board approvals of the seller, the purchaser and Barloworld.
The proposed transaction is expected to complete on or about April 1, 2020, with a long stop date of October 1, 2020, Barloworld says.
Caterpillar and its southern Africa dealer, Barloworld Equipment, are set to present a broad range of machines, technology and support services at next week’s Mining Indaba, in Cape Town, South Africa.
The Caterpillar exhibit at Indaba, running from February 3-6, will feature digital displays of electric power generation systems, surface and underground mining equipment, and Cat MineStar™ technology capabilities – ranging from vehicle safety systems, such as operator fatigue monitoring, to production systems using teleremote, semi-autonomous and autonomous machine operation.
Using MineStar Command for underground, the new R1700 (pictured) can be operated from a remote location to keep miners away from potential hazards, Cat says. “The system also boosts utilisation by allowing immediate entry after blasting and by reducing shift change time to nearly zero.”
In addition to the R1700, Caterpillar has introduced several LHDs and underground trucks equipped with EU Stage V engines and emission controls. “Reducing emissions helps miners improve the underground working environment,” it said. On top of this, and with the goal of zero underground emissions in mind, Caterpillar is continuing to develop the battery-powered R1700 XE.
Erik Elsmark, Region Manager for the Caterpillar Underground Mining Division, said: “Caterpillar and Cat dealers are supporting the whole African continent and all types of underground mining applications – big and small mines and all minerals.
“In the past several months we have delivered machines covering our full product range, demonstrating that we are well positioned to meet our customers’ needs.
“Starting with our AD22 underground articulated truck to our R2900 LHD, our equipment delivers exactly the size class and power needed for the application. With distribution centres in Southern Africa and Middle East and our dealer network in all countries of the African continent, we are able to achieve world-class service.”
The extensive line of Cat surface mining machines and technologies will also be a talking point at the event.
Cat MineStar Command now includes systems for autonomous operation of mining trucks, semi-autonomous operation of dozers, and semi-autonomous as well as autonomous rotary drills. These systems enhance safety, boost production and lower cost per tonne, Cat says.
Mine power experts will also be on call at the show, with the representatives keen to talk about the ability for Cat generators to deliver reliable, continuous power, temporary power, or a combined heat and power solution. “The Cat team customises and installs systems for every phase of mining,” it said.
Caterpillar says it offers the industry’s widest range of diesel, gas and dual fuel generator sets; automatic transfer switches, and switchgear for seamless integration. Additionally, it offers microgrids, fully-integrated power systems that utilise solar panels, energy storage and monitoring and control systems in conjunction with any configuration of Cat gen sets.
Caterpillar dealer WesTrac has announced it will build a technology training facility in Collie, Western Australia, focused on providing courses in autonomous operations.
The centre will be the only Caterpillar Autonomous Training Facility in the world apart from Cat’s own testing and training ground in Arizona, USA. The facility will be developed on land owned by Bluewaters Farm Holdings in Collie’s Coolangatta Industrial Estate.
The project is supported by a grant through the Collie Futures Fund, awarded to WesTrac by the State Government’s Department of Jobs, Tourism, Science and Innovation.
The announcement was made at a ground-turning event in Collie attended by Western Australia Premier, Mark McGowan; Minister for Regional Development, Alannah MacTiernan; Collie-Preston MLA, Mick Murray; and WesTrac CEO, Jarvas Croome.
Croome said the investment includes a new fully autonomous Cat 789D off-highway truck, construction of an autonomous operations zone and training room facilities. The construction is scheduled to commence this month at the greenfield site near Collie’s Bluewaters Power Station.
Local contractor Piacentini & Son will carry out the earthworks and installation of key infrastructure, with training scheduled to commence in May.
“The initial focus will be to provide training in fit-out and maintenance requirements for the conversion and operation of existing Caterpillar haulage vehicles,” Croome said.
“Over time, we anticipate expanding the range of courses on offer to ensure the facility caters for the recognised skills of the future that will be in demand as the resource sector evolves.
“It’s an opportunity to position Collie and Western Australia as a world leader in advanced technology and skills development in automation and autonomous operations.”
McGowan said: “People will come from all over the world to utilise this facility – the first of its kind in the southern hemisphere and the second worldwide for Caterpillar.”
While WesTrac had evaluated several potential locations, Collie was the ideal centre for the training facility, according to Croome.
“The town has a long mining history and an experienced workforce with the potential to help run and develop the training facility over time,” he said.
“There’s also a vibrant community and plenty of supporting business infrastructure, plus a unique range of natural attractions and easy access to the wider South West region, which adds appeal for Australian and international training participants.”
Croome said WesTrac and Caterpillar clients across the Asia Pacific region had shown significant interest in having access to such training and strong demand was expected when the facility commenced operations.
Caterpillar has announced that Jean Savage, currently Vice President of the Surface Mining & Technology Division, has elected to retire from the company.
Trinity Industries, a provider of railcar products and services in North America, had earlier announced that Savage, a member of the Board of Directors, would be appointed CEO and President, effective February 17. She is to retire from Cat, effective February 14.
Savage joined Caterpillar in 2002 and held numerous leadership roles in Caterpillar’s Progress Rail division, before being named VP of the Advanced Components and Systems division in 2014. Savage went on to lead the Innovation and Technology division before being named VP of the Surface Mining and Technology division in 2017.
Prior to joining Cat, Savage worked for 14 years at Parker Hannifin, a leader in motion and control technologies and systems, where she held a variety of manufacturing and engineering positions. In addition, Savage served nine years in the Army Reserves as a military intelligence officer.
Denise Johnson, Resource Industries Group President, said: “We thank Jean for her 17 years of service to Caterpillar. Jean has been instrumental in delivering Caterpillar mining products and services that are focused on accelerating customer benefits in safety and productivity. We appreciate all of her contributions and wish her well in her new role at Trinity Industries.”
Cat said a replacement for Savage will be named at a later date.
RCT says it has installed its ControlMaster® Line-of-Sight solution on equipment at an open-pit diamond mine in South Africa.
In 2019, RCT installed and commissioned the solution on a CAT 994 wheel loader, which has been utilised to clear pit benches of debris falling from the crest of the bench above at the mine, owned by a major mining company, RCT said.
RCT’s locally-based Field Service Technician carried out commissioning works and empowered site equipment operators with the training necessary to efficiently manage the wheel loader, it said.
RCT’s Johannesburg-based Business Development Manager for Africa, Mike Thomas, said: “South Africa’s Department of Mining Regulations prohibited any mining personnel to be in close proximity with the bench’s toe.
“The Line-of-Sight technology meant equipment operators could stand at a safe distance in accordance with regulations and carry out their work as if they were sitting in the machine’s cab.”
He concluded: “Our ControlMaster automation technology integrated seamlessly into the wheel loader’s operating system and carries out the same range of functions as specified by the original equipment manufacturer.”
When the International Council on Mining and Metals (ICMM) launched its Innovation for Cleaner, Safer Vehicles (ICSV) program just over a year ago, some industry participants may not have realised how much progress could be made so quickly by taking a collaborative approach.
The ICMM has proven influential across the mining industry since its foundation in 2002 in areas such as corporate and social governance, environmental responsibility, and stakeholder relations, yet it has rarely, until this point, engaged directly as an industry group with original equipment manufacturers (OEMs) and service providers.
Close to 12 months after being established, it’s clear to see the program and the council itself has been successful in bridging a divide.
It has been able to corral a significant portion of the mining and mining OEM market players into a major industry discussion on core focus areas set to dominate the sector for the next two decades.
Now 27 of the world’s leading mining companies and 16 of the best-known truck and mining equipment suppliers are collaborating in a non-competitive space “to accelerate the development of a new generation of mining vehicles that will make vehicles cleaner and safer,” the ICMM says.
The ICSV program was created to address three of the most critical safety, health and environment performance issues in the ICMM’s mission towards zero harm and decarbonisation. Achieving this goal would involve the industry introducing and adopting the next generation of equipment to respond to the challenges.
More specifically, the program aims to:
Introduce greenhouse gas emission-free surface mining vehicles by 2040;
Minimise the operational impact of diesel exhaust by 2025; and
Make collision avoidance technology (capable of eliminating vehicle related collisions) available to mining companies by 2025.
In all three, it seeks to address the industry’s innovation challenge of ‘who motivates who’ or the chicken and egg analogy, according to Sarah Bell, Director, Health, Safety and Product Stewardship for the ICMM.
“You can imagine a mining company saying, ‘we can’t adopt technology that doesn’t yet exist’ or an OEM saying, ‘we can’t invest in development because we’re getting mixed market signals’. This is, of course, why this program has been set up in the way it has,” she told IM. “Bringing both the mining company and OEMs together, they have been able to work through these normal innovation challenges and align on defining the direction of travel and critical complexity to be solved for each of the ambitions set.”
The list of companies the ICMM has been able to involve in this program is impressive.
It is being guided by a CEO advisory group of six; three from the mining community – Andrew Mackenzie (CEO, BHP), Mark Cutifani (CEO, Anglo American) and Nick Holland (CEO, Gold Fields) – and three from the mining equipment supply side – Denise Johnson (Group President of Resource Industries at Caterpillar), Max Moriyama (President of the Mining Business Division at Komatsu) and Henrik Ager (President of Sandvik Mining and Rock Technology).
On the mining company front, ICMM membership makes up around 30% of the total metal market share, with some 46% in copper, 27% in gold and 42% in iron ore. Participating OEMs and third-party technology providers, meanwhile, include the three majors above, plus Cummins, Epiroc, Wabtec Corporation (formerly GE), Hexagon Mining, Hitachi Construction Machinery, Liebherr, MacLean Engineering, MTU, Modular Mining Systems, PBE Group, Nerospec, Future Digital Communication and Miller Technology.
Bell says the high-level participation builds the “widespread confidence” needed to accelerate investment in these three key areas”, while the ICMM’s focus on the leadership side of the technology integration equation and change management has proven “absolutely key”.
She clarified: “This collaboration operates under anti-competition and anti-trust rules. Our role is to convene the parties, motivate action and promote solutions.”
The program offers a “safe space for the OEMs and members to work openly in a non-competitive environment”, she added, explaining that the aim is not to come up with “preferred technologies”, but define the “functional and operational pathways required to meet the ambitions set”.
Vehicle interaction (VI)
Some of the ambitions look easier to achieve than others.
For instance, collision avoidance and proximity detection technology has made huge strides in the last decade, with the ICMM arguing its 2025 target is like a “sprint”, compared with the “10,000 m race” that is minimising DPM underground by 2025 and the longer-term aim to introduce GHG-free surface mining vehicles by 2040.
“There are regulations that require implementation of collision avoidance and proximity detection technology by the end of 2020 in South Africa,” Bell said. This will undoubtedly provide a catalyst for further developments to speed up.
The ICSV program is also leveraging the work of the Earth Moving Equipment Safety Round Table (EMESRT) in its development of fundamental functional/performance requirements for operators and technology providers.
These requirements were updated and released by EMESRT in September and are known as ‘PR5A’.
Bell delved into some detail about these requirements:
“The EMERST requirements are designed around a nine-level system that seeks to eliminate material unwanted scenarios such as – equipment to person, equipment to equipment, equipment to environment and loss of control,” she said.
“The fundamental change with this newly released set of functional requirements by EMESRT is that the mining industry users have defined the functional needs for levels 7-9 (operator awareness, advisory controls, and intervention controls). That stronger level of collaboration hasn’t necessarily been there.”
EMESRT and its guidelines have been given an expanded global platform through the ICMM’s ICSV, with the program, this year, providing the convening environment for users and technology providers to help finalise these updated requirements, according to Bell.
With all of this already in place, one could be forgiven for thinking the majority of the hard work involved with achieving the 2025 goal is done, but the working group focused on VI knows that while OEMs continue to retrofit third-party vehicle collision and avoidance systems to their machines the job is not complete.
“Let’s think about the seatbelt analogy: you don’t give buyers of vehicles a choice as to whether they want a seatbelt in their car; it just comes with the car,” Bell said.
“At the moment, by design, vehicles don’t always have this collision and avoidance systems built in, therefore there is a big opportunity for collaboration between OEMs and third-party technology providers.”
Underground DPM goals
“The DPM working group have recognised that, in the case of the DPM ambition, ‘the future is already here, it’s just unevenly distributed’,” Bell said.
“Bringing together the OEMs and the mining companies this year through the ICSV program has enabled the group to explore the variety of existing solutions out there today,” she added.
These existing solutions include higher-tier engines, battery-electric equipment, tethered electric machinery, fuel cell-equipped machines for narrow vein mining and solutions to remove DPMs and other emissions from the environment like Johnson Matthey’s CRT system.
And, there are numerous examples from North America – Newmont Goldcorp at Borden, and Glencore and Vale in Sudbury – South America – Codelco at El Teniente Underground – and Europe – Agnico Eagle Mines at Kittilä (Finland, pictured) – to draw from.
Bell also mentioned some examples from Australia where regulatory changes have seen miners apply existing technology and carry out changes in their work plans and maintenance practices to minimise DPM emissions.
Haulage and loading flexibility, battery charging and mine design have all come under the spotlight since these new generation of ‘green’ machines have emerged, so achieving the 2025 goal the ICSV stated is by no means a foregone conclusion.
“There remains more work to do in achieving diesel-free vehicles underground,” Bell said.
The interested parties are aware of this and the program’s DPM maturity framework is helping miners and OEMs plot a course to reaching the target, she explained.
“The DPM maturity framework promotes existing solutions available today that would enable a mining operation to reduce their DPM emissions to a level that would meet the ambition level (shown as Level 4 – transition to zero),” she said.
These frameworks are useful for starting a “change conversation”, Bell said, explaining that mining companies can assess within their organisations where they currently sit on the five-level chart and discuss internally how to move up the levels to meet their goals.
These same frameworks look beyond minimising “the operational impact” of DPM emissions underground, with Bell explaining that Level 5 of the maturity framework involves “non-DPM emitting vehicles”.
GHG-free surface mining vehicles
Even further in the distance is the longer-term target of introducing greenhouse gas emission-free surface mining vehicles by 2040.
This ambition, more than any other, is less clearly defined in terms of technological solutions across the industry.
While battery-electric solutions look like having the goods to reach DPM-free status underground with expected developments in battery technology and charging, the jury is still out on if they can create a GHG-free large-scale open-pit mining environment.
The ability for industry to pilot and validate technology options like this “within the boundaries of anti-competition” is crucial for its later adoption in the industry, Bell said.
She said a key enabler of industry decarbonisation is access to cost competitive clean electricity, which would indicate that regions like South America and the Nordic countries could be of interest in the short and medium term for deploying pilot projects.
It is this goal where the industry R&D spend could potentially ramp up; something the ICMM and the ICSV is aware of.
“For the OEMs and mining companies to effectively minimise capital expenditure, optimise R&D expenditure and reduce the change management required by the industry, there needs to be a careful balance of encouraging innovation of solutions, whilst managing the number of plausible outcomes,” Bell said.
In terms of encouraging the development of these outcomes, carbon pricing mechanisms could provide some positive industry momentum. Vale recently acknowledged that it would apply an internal carbon tax/price of $50/t when analysing its future projects, so one would expect other companies to be factoring in such charges to their future mine developments.
Industry-wide GHG emission caps could also provide a catalyst. In countries such as Chile – where up to 80% of emissions can come from haul trucks, according to ICMM Senior Programme Officer, Verónica Martinez – carbon emission reduction legislation could really have an impact on technology developments.
While 2019 was a year when the three working groups – made up of close to 50 representatives in each work stream – outlined known barriers or opportunities that might either slow down or accelerate technology developments, 2020 will be the year that regional workshops convened to “encourage first adopters and fast followers” to move these three ambitions forward take place, Bell said.
A knowledge hub containing the previously spoken of maturity frameworks (delivered for all three groups) will allow the wider industry outside of the ICMM membership to gain a better understanding of how the miner-OEM-service provider collaboration is working.
Bell said the ICMM already has a number of members testing these group frameworks on an informal self-assessment basis to understand “how they are being received at an asset level and feedback insights to the group in an effort to understand how we may portray an industry representative picture of where we are today”.
Such strategies bode well for achieving these goals into the future and, potentially, changing the dynamic that has existed between end users and suppliers in the mining sector for decades.
Bell said: “The feedback that we got from OEMs is that mining companies had completely different objectives, but they have now greater confidence that we are aligned on the direction of travel towards the ambitions set.”
The first Caterpillar new generation D11 dozer in the world has started work at BHP Mitsubishi Alliance’s (BMA) Blackwater coal mine in Queensland, Australia, according to mining, resources, transport and logistics group National Group.
National Group secured the first of these dozers earlier this month from Cat dealer Hastings Deering as part of an order that would see six of these machines hauled by its National Heavy Haulage subsidiary, the company said.
BMA’s Blackwater coal mine, in Queensland’s Bowen Basin, produced close to 2.1 Mt of coal in the most recent September quarter, according to BHP.
In a Hastings Deering release in mid-December, National Group’s Managing Director, Mark Ackroyd, said: “The D11 is the industry’s best large dozer so it was a logical choice for us to bring in six new dozers to add to our expansive fleet.”
Along with load sensing hydraulics reducing fuel burn, the new D11 will extend out component life from fuel burn to overhaul, according to the company. Caterpillar has developed this machine to ensure faster cycle times to produce more dirt at a lower cost per tonne, National Group added.
Ackroyd said the contribution the dozers will add to production and efficiency will boost overall performance on site. “We expect to lower maintenance and repair costs by up to 5% thanks to a new case and frame design, improved bearings, redesigned pin joints, and a 30% larger oil pan.”
Jason Garea, Mining Account Manager at Hastings Deering, said: “There is a single frame now used between both the D11 standard dozer and the carry dozer applications. It’s a beefed-up frame that now does both.”
National Group has lined up all six dozers to be fitted with the new Reclamation blade, or XU Blade, which takes the dozer from a 34 cu.meter blade, to a 42.2 cu.m, according to Garea. “The best thing here is that it still handles like a U-Blade and can go into the same applications. They are far, far more productive which reduces the cost per tonne.”
The second D11 dozer is expected to be commissioned onsite at Blackwater in January.