Tag Archives: Caterpillar

Macmahon, Flanders help automate Cat drills at Tropicana gold mine

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The rollout of a A$6 million ($4.3 million) autonomous drill fleet at the Tropicana gold mine in Western Australia is believed to be an industry first for hard-rock mining, according to the mine’s contractor, Macmahon Holdings.

Macmahon says the use of hammer drilling versus the more traditional rotary concept when it comes to blasthole drilling is unique in the hard-rock space.

AngloGold Ashanti Australia (AGAA), with support from Flanders, a technology innovator and leader in autonomous drilling, and Tropicana Mining Alliance partner, Macmahon Holdings, now has five autonomous CAT MD6250 drill rigs and seven manned rigs as part of its drilling fleet.

Mining at Tropicana, which is 70% owned and managed by AngloGold Ashanti Australia and 30% by IGO, is carried out by Macmahon.

The fit out of the fifth rig in August comes only four months after the first rig was commissioned on April 27 and incorporates the ARDVARC drill control system with multi pass and down-the-hole modes to provide seamless operations with the site’s recently-installed long term evolution (LTE) telecommunications network, Macmahon said.

The project was initiated by AGAA Manager: Technology, Martin Boulton, who developed the original project scope before engaging Macmahon to further develop the business case.

He has been integral in developing the roll out schedule and managing the various technical linkages such as running the solution on the Tropicana LTE platform, according to Macmahon. This work led to the project taking out the AngloGold Ashanti Zero HARM (Hazard & Risk Management) Award in 2020.

“The autonomous drill fleet roll out has had many benefits with increased operating efficiency and asset utilisation as the equipment can operate through lightning and inclement weather, explosive detonation and eliminates the need for operator fatigue breaks,” Boulton said.

It also introduces a safer, risk-reduced method in production drilling, increases asset availability and operating efficiency and decreases asset wear, according to Macmahon.

While still early days, the autonomous fleet has already recorded an 8% increase in instantaneous penetration rates compared with the manned rigs, along with a 14% reduction in delay times in June compared with May.

These improvements can be attributed to the rigs’ ability to continue to drill safely during live blasts and lightning storm, while delays have also been removed from water refills and shift changes, the company said.

Tropicana Autonomous Drilling Systems Specialist, Richard Hill, said the autonomous project was testament to the team on site and at Flanders, and had come a long way in a relatively short period of time.

One person (drill controller) can operate up to five rigs from the one console located in the administration building at Tropicana with the automated rigs supported by two ground crew on the pit floor. To date, up to three rigs have been operated from the one console.

With roster changes on a two weeks on and one week off swing, that equates to three crews (with one back-up per crew).

“The plan is to have six drill controllers when fully mobilised, one main controller and a backup per crew,” Hill said.

However, like any new concept, it was not without some early teething problems.

The first was rod feed rates, particularly when it came to transitional ground, but the solution came with development of a new bit chasing logic and the plan is to also develop an automated bit changer that would further reduce delay times, Macmahon said.

Another challenge was managing the autonomous operating zones, which are currently required to run separately from the manned rigs as they were not equipped with collision avoidance software.

“We are working on that now and within the next couple of weeks should be able to incorporate those in the collision avoidance, and that will then increase our production as we will not have to change work areas as often,” Hill said.

Manning has also been an issue in terms of availability of ground crews to support the drill controller, but the role will now be classified as an entry-level position with a clear career pathway progression for new entrants.

Macmahon General Manager Plant & Maintenance, Mark Hatfield, said the company was thrilled with the overall performance of the fleet having achieved full conversion from design to installation and commissioning of the drill and remote operation centre in just eight weeks.

“The Flanders team have worked alongside our people providing specialist support for the duration of the trial on site, and remotely, and will work to provide continuous improvements in the coming months,” he said.

“The system provides an agnostic solution with a customisable capability, with all available drill data providing valuable insights for analysis and improved planning, and importantly, improving site safety conditions for our people.”

Zeppelin and Immersive Technologies partner on Navoi Cat truck training program

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Zeppelin International, one of the largest Caterpillar dealers in Europe and the CIS region, has partnered with Immersive Technologies to provide comprehensive training for both “green” and experienced personnel operating a range of Caterpillar truck models within Navoi Mining & Metallurgical Combine’s (NMMC) gold mining sites in Uzbekistan.

This marks the 45th country globally to use Immersive Technologies’ workforce optimisation training solutions, the Komatsu-owned company said.

“Simulator-based training establishes a safe environment for experienced operators to expand their expertise, and a risk-free arena for entry level operators to start developing their skills,” Immersive Technology said.

Zeppelin International has also acquired Immersive Technologies Custom Mine Site (CMS) technology to further train those unacquainted with the new machinery in a familiar training environment. The program will aid in increasing workforce optimisation in the areas of production efficiency and operational safety, while ensuring operators are confident and highly productive when they enter actual site operations, Immersive said.

“CMS allows detailed focus to be placed on training requirements specific to each site such as landmarks, specific mine site road rules and environmental conditions,” the company said. “Curriculum tailoring to target specific learning outcomes is managed effortlessly with the support of Immersive Technologies Professional Services, delivered on site via specialist training experts.”

Stanislav Kondratenko, Technical Director of Zeppelin Central Asia Machinery LLC, said: “At Zeppelin, we have high expectations from Immersive Technologies based on previous results and experiences. They have successfully completed the installation development and will be providing professional services to increase production efficiency and overall safety for the mine site. Utilising this technology and targeted curriculum will aid in increasing output from Navoi’s current headcount.”

Oleg Lyutyy, Business Development Advisor at Immersive Technologies, said: “Immersive has been developing and delivering training solutions for Caterpillar equipment for over 27 years. Our IM360 Simulator and Conversion Kits® for CAT® truck models, will provide the ultimate simulation for Zeppelin and the Navoi mine site to optimise production output and safety. This is yet another example of the successful collaboration between Immersive Technologies and OEM dealers around the world.”

Zeppelin has also acquired the TrainerAdvantage™ certification program that includes classroom and hands-on sessions working with the simulator under the instruction of an Immersive Technologies Certified Instructor.

Immersive’s Regional Vice President of EMEA & CIS, Johan Stemmet, said: “Innovation is the future. Production optimisation is unthinkable without innovative technologies. I look forward to seeing how the introduction of this level of training increases productivity and safety for Zeppelin International and Navoi NMMC.”

Caterpillar addresses hydraulic shovel basket wear with new two-piece bucket

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Caterpillar has introduced a new two-piece bucket for hydraulic mining shovels that, it says, reduces downtime, optimises bucket capacity and increases rebuild safety.

The design reduces downtime by limiting refurbishment to the area of the bucket subjected to most of the wear – the basket.

“The replaceable basket enables faster, easier and safer rebuilds compared to traditional buckets,” the company said. “In addition, the basket design can evolve with mine site conditions to further reduce downtime and optimise capacity over the life of the bucket.”

The durable upper structure of a bucket will host several baskets during its long service life, thus the need for optimising basket replacement, Cat said. Also, the two-piece bucket is lighter than conventional buckets, yet features high wear resistance, according to the company.

“The basket is a single piece of structural steel with no liner or wear plates, and the floor and sideplate thickness are optimised for bucket size and anticipated wear rate,” Cat said. “The basket is retrofittable onto legacy buckets used in compatible digging conditions.”

The two-piece bucket enhances both safety and serviceability, according to the company.

Replacing just the basket requires less gouging, welding, and grinding than buckets protected with wear plates, while the single-piece basket design reduces potential hazards caused by stored energy.

“After the initial design is completed for the application, replaceable baskets can be ordered in advance and stocked on site,” Cat said.

RCT pushes dozer operators in a new direction at Pilbara iron ore mine site

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RCT says it has completed its latest automation and control project for a major mining company at one of its iron ore operations in Western Australia’s Pilbara region.

The autonomous solutions specialist supplied and commissioned its ControlMaster® Line of Sight solution on one Caterpillar D10T2 dozer and one Cat D11T dozer and the associated remote control devices for operators.

Site operators can now stand at a safe location overlooking the production area and direct the dozers to push the site’s coarse ore stockpiles and other required activities, RCT said.

RCT Account Manager, Phill Dean, said the technology will protect site personnel while ensuring effective production.

“This project is part of a long-standing relationship delivering leading-edge technology to the major iron ore producer to ensure smooth day-to-day and ad-hoc business activities,” he said.

“The ControlMaster technology integrated seamlessly into both dozer’s operating systems enabling the operators to access the machine’s full range of functionality available by the OEM.”

RCT will provide ongoing after sales support, scheduled servicing and onsite technical assistance as required, it said.

RCT collaborates with Russian Cat dealer on rockbreaker project

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RCT says it has completed a tele-remote project for Russian Caterpillar dealer Vostochnaya Technica (VT) on a fixed position rockbreaker in Siberia.

The pilot project involved commissioning ControlMaster® Teleremote on a fixed position BTI rockbreaker for a large Russia-based mining company at one of its operations in Siberia.

RCT also provided a Digital Vision Kit consisting of two fixed cameras and audio capability and a Fibre Optic Control Station (FOCS) located in site offices on the mine’s surface, it said.

RCT’s Moscow-based CIS Business Development Manager, Stephen Macarow, said the tele-remote rockbreaker was the latest RCT project to be completed at mines in the region.

“RCT was selected to carry out this project due to its experience in integrating automation technology in mining equipment of all makes and models,” he said.

“Operating the rockbreaker from the mine’s surface will safeguard machine operators while also giving them the chance to better utilise the machine’s capabilities.”

As well as installing its Teleremote technology on the rockbreaker, RCT’s bespoke solutions division custom tailored the tele-remote package to the mining company’s specific requirement, RCT said.

“RCT developed a unique auto-stow function at the request of VT and the mining company,” Macarow explained. This function means operators can push a button and retract the rockbreaker arm from the grizzly or steel grate over the ore pass and bring the machine to a parked position.

VT Technology Enabled Solutions Manager, Alexander Voroshilov, said the rockbreaker project was of significant benefit to the customer.

“In order to complete this turnkey project, the VT Technology team has done a big amount of work from equipment delivery from Australia to the mine site, customs clearance, manuals translation and certification, to on-site installation and commissioning under supervision of an RCT engineer,” he said.

“The key factor of the project success is the customer support and good collaboration with a partner, so we really appreciate our partnership with RCT and the customer assistance.”

RCT says it is continuing to provide ongoing technical and after-sales support to the mine site

Autonomous trucks arrive on time at BHP’s Newman East mine

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As expected, the first fleet of autonomous trucks have arrived at BHP’s Newman East mine site with full roll out to be complete by September.

Home to BHP’s Innovation Centre, the Newman East mine will be the second of the company’s Western Australian mines to transition to fully autonomous haulage with 20 autonomous trucks due on site before the end of the year, BHP said. The first was the Jimblebar iron ore mine in the state, which transitioned in 2017.

The existing fleet of Cat 793s would be retrofitted with autonomous haulage systems, BHP previously explained.

BHP’s Newman Operations General Manager, Marie Bourgoin, said the transition would advance BHP’s technology strategy while also creating 41 new, permanent roles and investing A$33 million ($23 million) in contracts with Western Australian businesses.

“We recognise how important it is for BHP to partner with local and small businesses, particularly as we move into a post-COVID economic recovery phase,” she said.

“We are pleased to have been able to offer A$33 million in contracts to WA vendors for a range of work packages including autonomous conversion kits, trailers, training content development, and a number of engineering and construction packages.

“We know our success will be strengthened when we work together with local people and businesses. We will continue to explore further local initiatives as autonomous haulage rolls out, and beyond.”

Bourgoin said there were no redundancies as part of the transition and more than 300 people in the Newman operations workforce were undergoing training and upskilling to work on an autonomous haulage site.

“We have created new control centre and roles, which many of our truck operators have transitioned into, as well as new opportunities in truck maintenance and fuelling,” she said.

“Importantly we have created 41 new permanent roles, which are being offered locally as well as FIFO and will continue to be filled over coming months.”

Since the introduction of autonomous haulage at Jimblebar, significant events involving trucks have decreased by nearly 90%, according to BHP.

WesTrac’s Collie technology training centre to welcome new trainees next month

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The WesTrac Technology Training Centre in Collie, Western Australia, is close to completion and due to accept its first trainees within weeks, the Cat dealer says.

The facility, which is the first of its kind in the Southern Hemisphere, will deliver training courses to technicians and operators of autonomous equipment such as haul trucks used in the mining industry, according to WesTrac.

Announced in January this year and partially funded through the Western Australia Government’s Collie Futures Fund, the site near Bluewaters power station includes dedicated training facilities and an extensive “calibration pad” used for trialling and fine-tuning autonomous equipment, it said.

Western Australia Premier, Mark McGowan, was onsite today (June 29, 2020) to inspect progress, along with Regional Development Minister, Alannah MacTiernan, Collie-Preston MLA, Mick Murray, and WesTrac CEO, Jarvas Croome.

McGowan said the training centre was one of a range of new initiatives designed to secure the future of the town.

“It’s great to be here in Collie to view first-hand the progress on this facility, which is going to put Collie on the map for training technicians and operators of autonomous equipment,” he said.

“The WesTrac Technology Training Centre will result in new jobs and training opportunities for local people. At the same time, it will meet demand from around Australia and overseas from resource companies that need specialised technicians and operators of autonomous equipment to support the growth in this technology.”

Croome said earthworks and construction at the site had progressed rapidly since it was announced in January and WesTrac was preparing to accept its first intake of trainees in the coming weeks.

“We are in the final testing phase at present and plan to commence the first official eight-day training course with internal WesTrac team members in early July, followed by courses for a range of mining operators later in the month,” Croome said.

“As the only such facility outside the USA that can provide dedicated training for autonomous operations of Caterpillar equipment, we anticipate strong demand for training over the next three years as resources companies transition their fleets.”

Initially, the focus will be on conversion of existing haul trucks to operate autonomously, with additional courses to be rolled out in line with industry demand, Croome said.

Trainees will be accommodated at the nearby Collie Hills Village while undertaking courses and are expected to boost opportunities for local businesses during their time in the town.

Croome said WesTrac had been working with local businesses to supply goods and services, and expected job opportunities to grow in the future.

WesTrac tackles heavy machinery and equipment risks with ELW project

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Caterpillar dealer WesTrac is looking to remove personnel from within the footprint of live equipment in up to 90% of common maintenance tasks with its new Elimination of Live Work (ELW) project.

The ELW project has involved WesTrac staff from across the business identifying technology, tools and work processes that can eliminate safety risks involved with people working near live equipment.

Initially introduced to WesTrac by a major mining client as part of ongoing safety improvement initiatives, it has since gained industry-wide focus, the company said.

WesTrac’s Newman Branch Manager, James Davey, said the aim of the project, which involves a range of mining-focused original equipment manufacturers (OEMs) and service teams, was to eliminate significant risk factors associated with working on heavy machinery and equipment.

“The purpose of this project is not to deal with little nicks and cuts, it’s about saving lives,” Davey said. “If things go wrong when people are working on live equipment with multiple moving parts, and that can weigh hundreds of tonnes, the results could be disastrous.

“It’s an area of major focus across the Australian mining and construction sectors to continually reduce risks and enhance safety performance.”

Since commencing its own ELW project in 2018, WesTrac has devised a range of specialised tools, some itself and some in collaboration with mining companies and other OEMs.

One such tool, affectionately known as R2D2, is a remote-controlled camera mounted on an anti-vibrating base that can swivel 360° to carry out a wide range of inspections on live machines. Controlled from a tablet, the camera provides the operator with a real-time view and can record the session for closer follow-up investigation.

Davey says the camera’s resolution and 30-times optical zoom allow operators to read gauges, look for leaks and even carry out pre-maintenance checks.

“Inspections are often the first part of a task and this camera allows those carrying out the work to stay out of the danger zone, particularly if a machine is running,” he said.

WesTrac has also developed an ELW Field Service Kit with a range of tooling to allow both mobile and workshop-based mechanics to carry out numerous inspection and testing requirements without the need to work in proximity of high-risk areas, it said.

Davey said the company was currently developing work instructions, expected to be complete within the next three months, and would then deploy specialists to WesTrac’s branches, stores and sites to assist in embedding ELW practices.

“By December this year, we expect all sites to be equipped with the required tools, technology and understanding to carry out 90% of live work tasks under the ELW work practices,” he said. “For the remaining 10% of tasks that still require personnel to work within the footprint, we’re enhancing procedures to ensure an even greater focus on risk elimination.”

Davey said while equipment and service providers typically worked in competition with one another, when it came to safety the attitude was completely different.

“When it comes to saving lives and reducing risk, everyone is willing to share technology, tools and knowledge to drive better outcomes,” he said.

WesTrac has already been recognised for its ELW work with a safety award from BHP and recognition of the ELW program from the Department of Mines, Industry Regulation and Safety.

“Over the next 12 months, our goal is to transition ELW from a project to the standard ‘way we work’,” Davey concluded.

Fortescue celebrates 100th autonomous haul truck conversion at Chichester Hub

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Fortescue Metals Group has celebrated an important milestone in the rollout of autonomous haulage technology at its Chichester Hub operations, in the Pilbara of Western Australia, with the conversion of its 100th autonomous truck.

The full conversion of 108 haul trucks at the Chichester Hub, which comprises the Christmas Creek and Cloudbreak mines, is expected to be completed in September 2020, it said.

Since the introduction of Autonomous Haulage System (AHS) technology at Fortescue in 2012, 168 trucks have been converted across the company’s Solomon and Chichester Hubs. This has seen Fortescue’s autonomous haul fleet move around 1,400 Mt of material and achieve a greater than 30% increase in productivity levels (compared with previous manned fleets), it said.

Fortescue Chief Executive Officer, Elizabeth Gaines, said: “Fortescue’s AHS deployment represents the largest fleet conversion to autonomous haulage in the industry.

“Our history of embracing leading-edge technology has ensured Fortescue remains at the lowest end of the global cost curve and remains fundamental to driving sustained productivity and efficiency improvements across our business to ensure we continue to deliver enhanced returns for our shareholders and key stakeholders.

“Most importantly, the introduction of AHS technology has improved safety outcomes across our operations and we’re very pleased that the Automated Mining Projects team has also achieved this important milestone in the truck conversion program with zero harm to any team members.”

Workforce skills development has been a key aspect of Fortescue’s automation project, it said, with the company’s training and redeployment program successfully transferring or upskilling team members to new roles across the business.

“Training is at the heart of everything we do at Fortescue and as we continue the integration of autonomous trucks across our sites, this ethos has guided our efforts to ensure no redundancies due to automation and to deliver significant benefits to employees from the opportunities offered by this project,” Gaines said.

Fortescue was the first company in the world to deploy Cat autonomous haulage on a commercial scale at the Solomon Hub. It was also the first in the world to retrofit Command for Hauling (part of Caterpillar’s MineStar technology) on a Cat 789D and Komatsu 930E haul truck.

The iron ore miner’s fleet of 168 autonomous trucks have now travelled in excess of 47 Mkm since AHS was first introduced – the equivalent of 65 return trips to the moon.

And, as part of the Chichester Hub automation project, 549,500 parts have been fitted to date across 100 trucks.

K92 Mining continues to add new equipment at expanding Kainantu gold mine

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K92 Mining, despite the onset of COVID-19, has made significant progress on its plans to increase production at its Kainantu gold mine in Papua New Guinea.

In March 2020, Kainantu achieved a major milestone, commencing the first long hole stope using the modified AVOCA method. This method is ideal for narrow vein/lens higher-grade stopes and can provide higher tonnages through continuous fill and blasting, as well as improved dilution control, according to the company.

The commencement of this new mining method is significant since previous mining has been exclusively from lower productivity and higher-cost development and cut and fill stoping, K92 said.

The first stope was from the K1 Vein and, to date, long hole stoping activities have performed in-line with design and have been increasing, providing a notable positive impact on operational flexibility, the company added.

Mining operations, which have been expanding in line with the 2019 decision to expand throughput to 400,000 t/y, from 200,000 t/y, have also benefited from further additions to the mining fleet.

The Papua New Guinea COVID-19 State of Emergency declared on March 20, 2020, saw limited impact to freight, with the arrival of a third Sandvik LH517i underground LHD loader with AutoMine® capabilities, a third CAT AD45B 45 t underground truck and two Terex Articulated surface haul trucks, since its declaration. The Government of Papua New Guinea ended the COVID-19 State of Emergency on June 16, resulting in a further easing of some of the restrictions, particularly around domestic movement.

“The equipment joins a significantly expanded and modernised fleet since the decision to proceed with the Stage 2 Expansion on March 13, 2019,” K92 said.

Back in January, the company said it expected a Sandvik DS421 cable bolter to arrive this quarter, alongside a modular batching plant. The company said earlier this month that this unit (pictured), as well as three new and high powered diamond drill rigs were in transit to the mine.

Twin incline activities have recently recommenced at Kainantu with the easing of restrictions from the state of emergency. Ground support for the portal is also underway, with portalling and the installation of steel sets expected to commence in the first half of the September quarter, the company said.

The process plant, meanwhile, has achieved multiple daily throughput records during the June quarter, significantly exceeding the 200,000 t/y, or circa-550 t/d nameplate capacity, with over 700 t/d achieved on multiple occasions.

“The strong performance of the process plant and underground mine to date are expected to result in gold-equivalent production exceeding March quarter output,” the company said.

The March quarter saw K92 produce 19,240 oz of gold, 339,993 lb (154 t) of copper and 6,937 oz of silver for a total of 19,934 gold-equivalent ounces, representing the second highest quarter on record. Gold-equivalent production in 2019 was 82,256 oz, with 115,000-125,000 oz of gold-equivalent scheduled in 2020.

Preparations are also being made to recommence Stage 2 process plant commissioning in the near term, to double plant throughput capacity to 400,000 t/y. All the equipment is installed, and commissioning is expected to commence in first half of the September quarter, with completion targeted at the end of that three-month period, K92 said.

John Lewins, K92 Chief Executive Officer and Director, added that a Stage 3 Expansion preliminary economic assessment is planned for July.