Tag Archives: Caterpillar

Fortescue hits new automation milestone in the Pilbara

Automation, IoT, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , ,

Fortescue Metals Group’s autonomous haulage (AHS) fleet has marked a significant milestone, moving two billion tonnes of material, doubling the amount hauled since reaching the one billion tonne milestone in September 2019.

In 2012, Fortescue was the first in the world to deploy Caterpillar’s AHS technology on a commercial scale at its Solomon Hub operations in the Pilbara of Western Australia and the multi-class fleet has since expanded across the company’s operations with a total of 193 autonomous trucks now in operation.

Fortescue Chief Executive Officer, Elizabeth Gaines, said: “Fortescue is a leader in the implementation of autonomous haulage across our iron ore operations. Our fleet represents one of the largest in the world, with 79 trucks currently in operation at Solomon, 74 at Christmas Creek and 40 at Cloudbreak. Moving over two billion tonnes of material without a driver at the wheel is a significant milestone and a reflection of Fortescue’s ongoing commitment to increasing operational efficiency through technology and innovation.

“Most importantly, the introduction of AHS technology has led to significant safety improvements for our team members, with our fleet safely travelling over 70 million kilometres to date – the equivalent of 91 return trips to the moon.”

The continued expansion of autonomous capability across the business has demonstrated that autonomy doesn’t need to be at the expense of jobs, with the transition to autonomous haulage providing significant new opportunities for Fortescue’s workforce through the provision of training and redeployment to new roles, Fortescue said.

Gaines added: “Significantly, the adoption of autonomous haulage has allowed us to relocate many traditional site-based roles to our integrated operations centre in Perth, providing opportunities for parents and women in particular to remain engaged in our workforce. Today, almost 50% of our workforce in the Fortescue Hive are women.”

New Cat D11 dozer arrives at Stanwell’s Meandu coal mine

Coal technology, Mine operation news, Mining equipment, Mining services, , , , , , ,

Stanwell’s Meandu coal mine in Queensland, Australia, has taken delivery of a new Cat D11 dozer from local distributor Hastings Deering.

Ensuring safe and efficient operation, the dozer provides operators with full command, as well as delivering higher productivity at lower cost, Stanwell said.

The mine, owned by Stanwell, has a 7 Mt/y thermal coal capability and is in Queensland’s South Burnett Region.

Engineered to be rebuilt multiple times, the new D11 has a redesigned main frame delivering lower total cost of ownership over the life of the machine, Cat says. Time-saving service updates reduce daily maintenance and boost machine uptime.

The unit comes with new load-sensing hydraulics, high-horsepower reverse and the latest technology to provide higher material movement at a lower cost per tonne.

The first new generation D11 dozer in the world started work at BHP Mitsubishi Alliance’s (BMA) Blackwater coal mine in Queensland, in 2019. National Group secured the first of these dozers earlier from Cat dealer Hastings Deering as part of an order that would see six of these machines hauled by its National Heavy Haulage subsidiary.

Cat to use NMG’s Matawinie graphite mine as ‘zero-emission machine’ testbed

Energy minerals, Environmental, Mineral project development, Mining equipment, Mining project news, Power supply for mines, , , , , , , , ,

Nouveau Monde Graphite and Caterpillar have signed an agreement pursuant to which Caterpillar will develop, test and produce Cat® “zero-emission machines” for the Matawinie graphite mine, in Quebec, Canada, with a view to becoming the exclusive supplier of an all-electric mining fleet for deployment at the mine by 2028.

Looking to accelerate and tailor the equipment development, Caterpillar will engage with Nouveau Monde’s team to incorporate “voice of customer” throughout the development, and for testing of the zero-emission fleet and infrastructure prior to commercial production, the companies said.

To this point, Caterpillar has only disclosed the development of a battery-electric 15 t LHD, the R1700 XE, however it came to light just over a year ago that the OEM was working on a separate project called ‘Project Verde’.

Brian Weller, Chief Engineer, Surface Mining & Technology, Caterpillar Inc, previously stated on Project Verde: “Caterpillar has responded to customers by launching a project that is focused on energy and emissions reduction, and helping customers decrease their carbon footprints through machinery and power solutions that contribute to lower greenhouse gas.”

Speaking about the latest agreement between NMG and Cat, Arne H Frandsen, Chairman of Nouveau Monde, commented: “I recall our first meeting with Caterpillar some two years ago, outlining our vision of a zero-emission mine in Québec. Our commitment to this vision has taken us to this very important moment, not only for Nouveau Monde, but for the global mining industry as a whole. Today, alongside Caterpillar, which in my opinion is the most trusted and reputable supplier of heavy-mining equipment worldwide, we can bring the zero-emission machines vision into reality.

“I think it is remarkable that Nouveau Monde, as a representative for the new style green resources industry, is part of spearheading the electrification of the industry, by collaborating with Caterpillar.”

Eric Desaulniers, Founder, President and CEO of Nouveau Monde, added: “We are proud to be a driving force for our peers as we strive to electrify our operations to meet our carbon neutrality commitments while maintaining the productivity and efficiency standards of our mining operations. Even more gratifying and important to our corporate mission is that our project can serve as a springboard for the future of the mining industry by collaborating with Caterpillar on these cutting-edge technologies.”

Denise Johnson, Caterpillar Group President, said: “The collaboration between Caterpillar and Nouveau Monde marks an important milestone in the mining industry. Through integrated technology, machines and services, the entire Caterpillar team is proud to support Nouveau Monde as they work towards constructing and establishing their first zero-emission mine.”

In November last year, NMG issued an “international call for pre-qualification” related to the fleet and charging infrastructure at Matawinie following work by the company’s International Task Force Committee. This work had allowed Nouveau Monde to explore “technologies, best practices and operational parameters to bring its vision to life in a cost-effective and technologically advanced way”.

As part of this pre-qualification program, companies were able to submit detailed proposals and performance specifications from their production equipment solutions between November 30 and January 30, 2021.

In the 2018 definitive feasibility study on Matawinie, Medatech Engineering Services Ltd and ABB Inc – both companies in Nouveau Monde’s taskforce committee – came up with the fleet outline at Matawinie.

“The mine will be using an all-electric, zero-emission mine fleet, consisting of electric battery-driven 36.3-t mining trucks, battery-driven front-end loaders, cable reel excavators and bulldozers, and battery-driven service vehicles,” the report read.

The mine, scheduled to produce 100,000 t/y of graphite concentrate, was also expected to use an electric in-pit mobile crusher and overland conveyor system to feed crushed material to the plant.

Immersive to supply simulators, solutions for Rio’s Gudai-Darri automation

Mining equipment, Mining services, Mining software, Steel and iron ore, , , , , , , , , , , , ,

Rio Tinto has enlisted the help of Immersive Technologies and its equipment simulators to further its autonomous haulage footprint at the new Gudai-Darri iron ore mine in Western Australia.

The mine, which will operate Caterpillar autonomous trucks equipped with Cat MineStar™ Command for Hauling system, will use simulation-based training solutions from Immersive Technologies to address the workforce development challenges within autonomous haulage operations with a focus on improving the safety and efficiency of their operator workforce, Immersive said.

Rio has used such systems from Immersive for over 17 years, understanding the value of investing in simulators for operator capability development, including equipment productivity and reliability initiatives, Immersive said.

Rio Tinto Vice President, Human Resources, Scott Browne, said: “This is an important component of our comprehensive training program for AHS, which includes supporting new team members as well as upskilling existing employees. Gudai-Darri will be one of the world’s most technologically advanced mines. Preparations are well under way to ensure its workforce is ready to take on the high-tech jobs on offer.”

Focused on capability development in the usage of the autonomous system, Rio Tinto partnered with Immersive Technologies to provide a solution to support the mine-readiness schedule and objectives, Immersive said. Specific training products include a platform which simulates a Cat 6060 excavator, Cat D10T dozer and Cat 18M grader. All simulator modules are equipped with an autonomous system panel and provide a safe and effective environment for training by allowing learners to operate their equipment while interacting with the autonomous trucks and managing their work areas as required, the company added.

The simulator solution is complimented by machine pre-start inspection software, which provides a detailed visualisation of equipment components, including autonomous components fitted to machines. Additionally, a ‘Virtual Classroom’ product hosts complex autonomous procedures that immerses learners in a safe and repeatable virtual environment which enables the development of deep knowledge and muscle memory of operational procedures, Immersive said.

Greg Karadjian, Regional Vice President Australia of Immersive, said: “Immersive Technologies is at the forefront of workforce development for autonomous haulage mining operations with deployments of simulation-based training solutions in more than 17 autonomous sites globally, by utilising blended learning systems, simulation and human performance analytics our solutions are preparing the workforces of the future.”

Back in 2019, Rio, Caterpillar and WesTrac signed an agreement to supply and support mining machines, automation and enterprise technology systems at Gudai-Darri, with Rio confirming the supply of a fleet of 20 autonomous 793F trucks as well as four autonomous blast drills.

Gudai-Darri will deliver a new production hub for Rio Tinto’s iron ore business in the Pilbara. Once complete, the mine will have an annual capacity of 43 Mt, underpinning production of the Pilbara Blend, Rio’s flagship iron ore product.

Cat’s new D9 dozer set for mining market splash

Equipment maintenance, Mining equipment, Mining safety, Mining services, , , , , , , , , ,

Caterpillar is in the process of building the first new D9 large track-type tractors for the international market as you read this, with the popular mining dozer set to benefit from significant upgrades.

Nearly half of all Cat large dozers sold are D9s, with many of these workhorses regularly on show at mine operations across the globe. They compete in the same 400 horsepower (298 kWh)/50-ton (45-t) size class as the Komatsu D275 and Liebherr PR766/PR764.

Reviewing machine updates during a press event in late March, Todd Cole, Cat’s D9 Dozer Cat Application Specialist, listed off several reasons why miners might want to consider buying a machine for their earthmoving needs:

A 5% reduction in fuel consumption, as much as a 4% cut in maintenance and repair costs, a newly integrated Caterpillar AutoLube system, a quick opening hinged door for radiator access, safer underside maintenance inspections…the list goes on.

Many of these benefits, when combined, account for an up to 3% lower overall cost per unit in terms of bank cubic metres.

A 10-in cab display interface with HD multi-colour touchscreen enables users to navigate through various machine diagnostics, plus monitor the action of the ripper behind. There is also an optional four-camera system offering 360-degree view around the machine to further enhance operating safety.

Numerous grease point eliminations on the D9, compared with the D9T predecessor, further improve operational longevity and operating costs.

The fuel consumption benefits are felt thanks to a stator clutch torque converter that, according to Cole, frees up when torque multiplication is not needed (when tramming, for instance). This improved drivetrain efficiency and leads to less fuel consumption, which, when combined with a fuel tank that has 6% extra capacity over its predecessor, means the dozer runs for longer.

In terms of the undercarriage, customers can select from not one, but three factory-fitted link assembly options.

The Cat Heavy Duty Extended Life (HDXL) Undercarriage System with DuraLink™ is field proven to deliver 20-40% longer wear life in moderate- to high-impact applications such as hard rock, landfill and forestry, according to Cat. The Heavy Duty (HD) and General Duty links provide further options for less abrasive conditions.

The new dozer features the Cat C18 engine, which has a range of exhaust after-treatment solutions available that brings it in-line with US EPA Tier 4 Final/EU Stage V regulations, and configurations equivalent to US EPA Tier 2 and Tier 3.

With remote control operation also in the works for the new dozer, according to Cole, expect to see even more D9s running around mine sites in the next few years.

Thiess hits new heights with SATS dozer technology at Lake Vermont

Automation, Coal technology, Mine operation news, Mining equipment, Mining services, , , , , , , , , ,

Thiess says it has safely expanded its Cat MineStar™ Command for Dozing program at the Lake Vermont coal operation in Queensland, Australia, owned by Jellinbah Group.

A total of six Caterpillar D11 dozers fitted with Semi-autonomous Tractor System (SATS) technology have been mobilised at the project, currently making it the largest deployment of the technology globally, the contractor claims.

The SATS solution enables one operator to remotely control up to four dozers from an office environment. Lake Vermont is currently running six SATS dozers from two side-by-side remote operator stations.

Beginning the pilot in early 2020, the team has moved more than 1.9 million bank cubic metres and recorded zero autonomy-related injuries.

Thiess Autonomous Services Manager, Trent Smith, has seen significant productivity improvements with the technology enabling his team to deliver more consistent dozing.

“We’ve seen our utilisations go up about 25%,” he said. “We’re simply running 22 to 23 hours per day in autonomous mode.

“Another advantage is its ability to remove wastage within a dozer process – the machine simply won’t stop. It follows exactly the design that you’ve given it and it never waivers from that plan.”

The technology has also proven safety benefits for dozer operators by removing them from a high-risk working environment.

“Our operators control the machines from our office on-site, reducing the risk of injury from mounting and dismounting equipment and from ergonomic challenges presented during ripping applications,” Smith said.

Working collaboratively with Thiess’ in-house technical support teams has enabled the project team to solve use and skill challenges rapidly, the company said.

“The crew that started initially really struggled with the system because it was such a big change from their role and operating out in the field,” Smith said. “We spent a lot of time investing in our people with the OEM (original equipment manufacturer) to try and lift their skill and knowledge of the system and we’ve seen them grow into highly capable operators.

“They started out initially running two dozers and now they are quite comfortable operating four at a time.”

Thiess partnered with Caterpillar and Hastings Deering to implement and optimise the technology at the project, with Hastings Deering Product Manager, Simon Zillman, recognising Thiess’ focus on the integration of people and process when applying advanced technology.

To take advantage of the autonomation benefits, Thiess altered a portion of its production schedule so SATS dozers could continue working in the overburden, taking advantage of the consistent and optimised operation.

“Thiess has been excellent to work with,” Zillman said. “The team is very dynamic and right across the board everyone is proactive to make it work.

“Our relationship with Thiess is collaborative at all levels, from the mechanics who are fixing the machines in the field right through to the senior management.”

The Lake Vermont operation is also using Command for Dozing to reduce unit costs through increasing dozer utilisation, increased process consistency and increased execution of best practice mining operations, Thiess said.

Thiess, Caterpillar and Hastings Deering have also collaborated on the use of autonomous drilling at Lake Vermont, with the second robotised drill mobilised to site last year.

Immersive to deliver training simulator to Newmont Ahafo gold mine

Equipment maintenance, IoT, Mining equipment, Mining services, Precious metals, , , , , , , , , ,

Immersive Technologies is to deliver its 100th Conversion Kit® for Caterpillar® equipment owners within the continent of Africa, with the milestone high-fidelity operator training simulator set for the Newmont-majority owned Ahafo gold mine, in Ghana.

The order includes simulation for training operators of the 777G and 785C haul trucks, D11T dozers, and 6030 shovels and excavators. These units mark the 98th, 99th, 100th and 101st conversion kits that Immersive Technologies has delivered to further workforce development initiatives in the Africa region for mines who require high-fidelity simulation solutions for their Caterpillar equipment, it said.

Johan Stemmet, Regional Vice President Africa, said: “We are excited to provide a high level of value and service to Newmont for this important mining project by supporting community skills development and increasing operator safety and productivity levels. We continue to put the customer first and deliver industry-endorsed solutions for all OEM makes as evidenced by our leading market share across the largest global miners.”

Hastings Deering rebuild program pays off for Rio Tinto’s Gove operation

Equipment maintenance, Industrial minerals, Mine operation news, Mineral project development, Mining equipment, Mining maintenance, Mining services, , , , , , , , , , ,

Hastings Deering has been sustain output at Rio Tinto’s Gove bauxite open-pit operation in the Northern Territory of Australia by boosting engine power during the rebuild of dozers.

The Cat D11T dozer is purpose built to move more material and ensure maximum availability through its planned life cycle, the Caterpillar dealer says. For Rio Tinto, Dozer 79, had built up over 37,000 hours ripping and pushing bauxite at its open-pit operation.

Rio Tinto knew it wanted to undergo a Cat Certified Rebuild for its dozer but had to come up with an innovate way to do this while minimising equipment down time, Hastings Deering said.

Brendan Coleing, Superintendent, Mining Maintenance, said the Gove operation has focused heavily on building safe and reliable machinery to meet the targeted life of its assets and maintenance schedules.

“With a 24/7 operation, we need to plan and strategically think about our assets, their maintenance and lifecycle,” he said. “By planning large maintenance projects in advance, at Rio Tinto, we’ve been able to compensate for machinery downtime and achieve some great energy efficiencies.”

One of the key projects that helped to allow for the nine-week Cat Certified Rebuild (CCR) was the D11R repower project.

In early 2020, the Hastings Deering team worked with Rio Tinto on an alternative solution for engine replacement in its D11R fleet that reduced costs, fuel use and emissions while extending lifespans. This incorporated replacing the 3508 engines the machines originally came with, with the newer C32 engines.

“Recent success with repowering our D11 fleet with C32 engines has helped our mining operations move more bauxite due to increased power in the machine,” Coleing states. “This in turn allowed us to remove Dozer 79 out of production, and into the workshop to complete a Cat Certified Rebuild.”

Alongside the increase in machine availability, this project presented a budgeted fuel burn reduction of up to 25%.

“Our like-for-like material movements are now done with significantly less fuel which is a great environmental outcome,” Coleing said. “They’re also quieter, making them a little more comfortable for the operator.”

With Cat equipment built to perform over multiple lifetimes, the CCR was the most efficient way to help get the most economic value out of the original asset investment.

A CCR is a full machine rebuild that provides a like-new machine, inclusive of all Cat updates, to help achieve a full machine life supported by the Caterpillar warranty, Hastings Deering says.

Brad Read, Service Manager at Hastings Deering, said the CCR program is an efficient way for customers to improve the planned lifecycle of their machines.

“Given Dozer 79’s upcoming power train, hydraulic and major component change outs, a CCR was a cost-effective way for us to maintain the asset through to the end of its target life,” he said. “Customers opt for a CCR as it provides the ability to rebuild their machine, including all technological advancements, over purchasing a new machine. This helps to reduce capital expenditure.”

Read said that the CCR offered an extended scope or work over a standard rebuild and took careful planning between the Rio Tinto and Hastings Deering teams.

“The CCR takes up to nine weeks to complete and covers an extended scope of work including power train replacement, hydraulics and electrical components, cab overhaul, work implement overhaul and ET testing and painting,” he said.

“Effective planning is critical to the success of a large-scale project like a CCR. The team needs to ensure all stages of the rebuild have been planned, scheduled and are on time to guarantee machine delivery back to the customer.”

“It is essential to support our customers in their operation.”

By successfully planning the CCR after the success of the C32 repower project, Rio Tinto and Hastings Deering were able to improve the performance of its equipment and compensate for the removal of Dozer 79, Hastings Deering said.

Coleing said: “By undertaking work in this manner, we’ve removed a massive amount of forward log of work that not only gave us immediate availability but provided us with an improved asset through to the end of the machine life.”

Cat boosts productivity and efficiency with new 992 Wheel Loader

Equipment maintenance, Mining equipment, Mining safety, Mining services, , , , , , ,

Building on a more than half-century legacy that includes the best-selling large mining loader model of all time, the new Cat® 992 Wheel Loader sets a new standard by offering up to 32% greater productivity, Caterpillar says.

This new large mining loader reduces maintenance costs by as much as 10% and offers up to 48% greater payload-per-fuel efficiency than the earlier model 992K, the company claims.

Powered by the new Cat C32B engine with US EPA Tier 4 Final/EU Stage V and Tier 2 equivalent emission engine options, the new 992 meets the global industry’s demand for high-production equipment with greater payloads, Cat says. Powertrain design enhancements to the transmission, axles and final drive, along with the new engine, deliver a 20% longer interval for planned component replacement.

Offering both standard- and high-lift configurations, the 992 delivers the lowest cost-per-tonne when paired with fleets of Cat 775, 777 and 785 trucks, according to the company. Standard-lift payload capacities reach 23.1 t for quarry face applications and 27.2 t for loose material handling, while high-lift capacities reach 20.4 t and 24.5 t in respective applications.

Productive and efficient

A new Z-bar linkage optimised for performance, and improvements to rimpull and breakout force, deliver greater machine capacity and efficiency. The new 992 has demonstrated in field testing up to 48% greater payload-per-fuel efficiency in applications where a four-pass match to 90.7 t trucks was achieved, versus five passes with the 992K. The powerful and efficient 992 provides up to 9.5% more rimpull during digging and up to 20% more breakout force, increasing productivity, the company claims.

The new Cat 992 wheel loader features an on-demand throttle mode to optimise payload-per-fuel efficiency without slowing production. New standard automatic retarding controls disable the impeller clutch, enable the lockup clutch, and use the implement and fan pumps retarding to slow the machine on grade. The available advanced automatic retarding controls with engine brake feature offers full control of the loader’s speed on grade to maintain a desired hold speed, according to Cat.

Automating critical digging cycle elements, optional new Autodig components further improve productivity and efficiency while reducing tyre wear. To stop slippage before it happens, a tyre slip prevention feature reduces rimpull before the tyres are set and increases rimpull when downward force is applied to the tyre. The tyre set function detects pile contact and automatically lifts against the pile to set the tyres and increase available traction. The lift stall prevention feature automatically manages rimpull in-dig to prevent hydraulic stall while lifting through the face, so the 992 spends less time in the pile.

An optional new Payload Overload Prevention tool allows for productivity and efficiency improvements by providing a large enough bucket to be used to achieve target pass match across a range of material densities without the risk of overload. With the overload value fully adjustable based on the target payload, this feature can be configured to automatically stop or slow the lift function when the overload value is exceeded, Cat says.

Improvements to the setback and strike plane angles, a longer bucket floor and a stronger and larger bottom section increase the bucket fill factor by 10%. The taller side plate with level top surface helps to improve visibility beyond the bucket edge to the material pile.

Available Operator Coaching empowers operators to exceed productivity targets by measuring and providing feedback to teach optimal operating techniques. Among other operating techniques, this feature shows how to properly shorten travel, avoid unracking in-dig, enter the pile with a level bucket, reduce the dump height and use the kickout.

Comfort and safety

The newly redesigned Cat 992 wheel loader cab increases visibility, offers intuitive control and incorporates next-generation technology to boost efficiency by providing easily accessible information. Its taller windshield increases the glass surface area by 25%, resulting in 10% greater visibility. Cat says operators will appreciate the cab’s 50% increase in legroom and more width by the knees.

Providing shift-long operating comfort, the new 992 controls feature electrohydraulic speed-sensing steering with force feedback. Two 254-mm colour LED monitors display machine control and operating functions. A separate 203-mm screen provides a dedicated viewing feed of the standard rear-view camera, upgradable with an optional 270° vision and object detection.

Total cost of ownership

Extended major component life on the new 992 and improved service access deliver up to 10% lower maintenance costs. Automatic lubrication to Z-bar linkage pins with robust guarding, meanwhile, helps to deliver more reliable operation. A front walkaround platform simplifies cleaning of cab windows. Two large openings per machine side offer quick and convenient access to the improved cooling package, reducing cleaning time, Cat says.

Improved hydraulic systems filtration and pump prognostics for the implement pump reduce machine downtime. The new loader displays the remaining useful life for the engine air filter, allowing technicians to plan for machine servicing.

Offering convenient and improved access to maintenance items, the service centre has been relocated to the left-hand side of the machine, along with the fuel tanks. S∙O∙SSM fluid sampling ports are safely accessed from ground level and filters are organised by type and change interval to increase maintenance efficiency.

First of two Cat 6040 shovels head to Centamin’s Sukari gold mine

Mine operation news, Mining equipment, Mining services, Precious metals, , , , , ,

Mantrac Egypt says it has completed the assembly, commissioning and handover of a Caterpillar 6040 BH hydraulic shovel to Centamin’s Sukari gold mine in the country.

This is the first of two new excavators heading to the operation.

The Cat dealer said: “With gross power over 2,000 hp (1,491 kW) and approximately 40 t bucket payload, more volume of material will be moved and at lower cost per tonne.”

Back in December, Centamin said it would soon be adding new Cat 6040 hydraulic face shovels to its existing fleet at Sukari. This is part of a plan to position Sukari to reliably produce 450,000-500,000 oz/y of gold at all-in sustaining costs below $900/oz sold from 2024. This has also seen Centamin take on Capital Ltd as open-pit waste mining contractor.

These new shovels are included in the company’s financial year 2021-2023 capital expenditure plans. Also included is a 36 MW solar plant, an explosives contract and the addition of lightweight truck trays.