Tag Archives: Caterpillar

WesTrac Training Centre

WesTrac launches new tech experience centre as part of training, education plans

Automation, Careers in mining, Mining equipment, Mining safety, Mining services, Sustainable mining, , , , , ,

Caterpillar® dealer WesTrac has today launched a new Technology Experience Centre in Tomago, New South Wales, built to showcase the latest in equipment, technology and innovation.

The new state-of-the-art centre provides customers with a hands-on experience to demonstrate the advantages of using the latest Cat products and technology in mining and construction, the company says.

The education and training facility features a dedicated Remote Operator Station, where visitors can remotely operate a Cat 320 next generation hydraulic excavator, located in the on-site WesTrac dig pit. The operator station can also be configured for the remote operation of multiple other Cat machines from mini excavators and skid steer loaders to large mining equipment such as dozers and drills.

The Technology Experience Centre also includes the latest in 3D printing solutions as well as live demonstrations of cutting-edge technology including Cat MineStar technology. The Cat MineStar technology suite includes solutions for precision machine control and guidance, automation, remote operation, fleet health optimisation and fatigue monitoring.

Cat MineStar Command enables remote-control operations right through to full automation of machines, providing customers with a number of operational benefits. WesTrac and Caterpillar successfully deployed Command for drilling in partnership with Thiess, which saw a world first for Caterpillar with the successful remote operation of three drill rigs by a single operator. The team have also deployed Command line of sight and non-line of sight dozer solutions across multiple mine sites in New South Wales.

The centre demonstrates how WesTrac and Caterpillar’s technology can be incorporated into a variety of operations, increasing site safety, productivity, efficiency and sustainability, it says. it also adds a new element to the suite of information already available on owning and operating Cat equipment.

The new facility is supported by the WesTrac Training Institute that offers accredited and post trade training to both customers and team members, including operator training for the effective operation of Cat equipment using the latest technology systems.

WesTrac Chief Executive NSW/ACT, Adrian Howard, says the Technology Experience Centre reinforces WesTrac’s commitment to helping mining and heavy construction customers implement better technology into their fleets.

“The centre will greatly benefit our customers by delivering a practical and educational experience with the cutting-edge technology used by WesTrac and our Cat products,” he says. “We want our customers to walk away from the Technology Experience Centre feeling confident about using technology to deliver improved safety and productivity outcomes to their operations.

“Importantly, we want them to understand that these technologies are readily available, they can realise the benefits of them immediately and we’re there to assist them with deployment and continued support. The opening of the Technology Experience Centre in Tomago is an important occasion for the future of technology at WesTrac and I want to congratulate the WesTrac team for turning this vision into a reality.”

General Manager Resource Industries NSW/ACT, Jody Scott, says the Technology Experience Centre was designed to provide a facility for both new buyers and existing customers at WesTrac.

“We wanted a space where we could provide our customers with greater insight into both the competitive advantage of Cat products and the ongoing development of future technology at WesTrac,” he says. “When designing the centre, it was vital for customer experience to remain at the forefront, which is why it can accommodate meeting spaces and events as well as training with the Cat products our customers have invested in.

“We have a skilled and experienced team based at the Technology Experience Centre, ready to deliver comprehensive and tailored technology training experiences that are unrivalled in thhee industry.”

DavidRea-Tucson-ElectricMine2023

Cat R1700 XE battery-electric LHD completes the test at Glencore Nickel Rim South

Automation, Base metals, Environmental, Mining equipment, Mining events, Power supply for mines, Sustainable mining, , , , , , , , , , , , , , , , ,

The first field follow trial of Caterpillar’s R1700 XE battery-electric loader has been deemed a success by one Glencore trial participant, with the machine anticipated to surpass the productivity performance of the equivalent diesel LHD running at Glencore’s Nickel Rim South mine, in Sudbury, Canada.

Speaking in a video, Paul Kant, Glencore’s Maintenance General Foreman at the mine, said the battery-electric loader was likely to outperform the diesel-powered Cat® R1700G it was being benchmarked against at the operation over the trial period.

The mine has been using the machine, a 15-t payload loader, as part of ongoing plans to incorporate new technology at its Sudbury Integrated Nickel Operations. This includes the development of an all-electric equipment fleet at the Onaping Depth project.

The Sudbury Integrated Nickel Operations have played a significant role in the development of the R1700 XE, hosting a proof-of-concept trial of a battery-electric R1300 LHD at one of the mines where the machine ran in trials alongside its diesel equivalent. Caterpillar used the insight gained from this testing to develop the commercial R1700 XE.

The R1700 XE is rated with a 24,190 kg lift and tilt breakout, and, according to Caterpillar, features a battery-electric design that delivers superior productivity in underground applications with the benefits of minimal heat and no engine exhaust emissions. It offers an 18 km/h top speed.

It is designed to work with the Cat MEC500 Mobile Equipment Charger, a 1,656 kg (2,037 kg with optional skid) portable charger that, Caterpillar says, eliminates the need for regular battery handling and swapping, allowing for more efficient charging and production. The MEC500 offers a 500 kW capability at a range of 300-1,000 V and up to 700 Amps. The adjustable output can be used to trickle charge or quickly charge the R1700 XE – with a single unit delivering a full charge to the R1700 XE in less than 30 minutes or two units in parallel achieving this in less than 20 minutes.

The R1700 XE in Sudbury, working alongside either one or two MEC500s, has clocked more than 11,000 machine hours. During initial test operations, the customer indicated a circa-320,000 kg reduction of CO2 emissions and displayed a more than 10% improvement in speed on grade.

According to Glencore, the R1700 XEs Caterpillar has put out in the field to date have also exhibited lower energy consumption compared with the diesel equivalent – more than 10%, in fact

Speaking at The Electric Mine 2023 conference in Tucson, Arizona, in May, David Rea, VP and General Manager, Caterpillar Inc (pictured at the top), said of the machine: “We’re delivering for our customers improvements in safety, cost, productivity and sustainability.”

Machine availability in these field-follow trials has been helped by an up to 150-minute run time between charges and an average 18.5-minute charge rate with the dual chargers.

According to Glencore, the machines Caterpillar has put out in the field to date have also exhibited lower energy consumption compared with the diesel equivalent – more than 10%, in fact. And, while trials to date have all been in manual mode, Rea said the R1700 XE units in the field could be equipped for teleremote operation and were also “factory ready” for Caterpillar’s fully autonomous loading system.

Operations are being facilitated thanks to some “800 channels of machine data” flowing off the machines to those supporting the loaders, Rea said. This has allowed personnel from Caterpillar and Cat dealers to diagnose problems in the field and optimise the machine’s charging and operating strategies.

While Caterpillar continues to clock up the operating machine hours for its R1700 XE, it is also in the process of developing its first battery-electric truck.

“We’re not just stopping at the loader; we also need a truck to go alongside that loader,” Rea said in Tucson, adding that this would be a three-pass match for the R1700 XE – therefore, a truck boasting at least a 45-t payload.

Rea confirmed the new truck would be charged by the MEC500, but the company was working on both a fast charge and battery swap option for the vehicle.

“Our alliance with Newmont is leading the development of this truck,” Rea said, referencing a strategic alliance Caterpillar and Newmont announced in 2021 to deliver “26 first-of-a-kind battery-electric autonomous vehicles in both an underground and open pit operation by 2027”.

This agreement involves the introduction of these vehicles to Cripple Creek and Victor (open pit) and Tanami (underground) in USA and Australia, respectively.

“The first deployment of this [battery-electric] truck will be at Newmont Tanami,” Rea confirmed at the event.

Perkins premieres new off-highway engine, reveals future fuel-agnostic plans

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Perkins says it is addressing evolving industry demands for improved fuel efficiency and performance with a “next-generation” 13-litre diesel engine suitable for off-road applications.

Available in 2026, the Perkins® 2600 Series engine platform is designed for demanding requirements, as well as the realities of moving towards a lower-carbon future.

Perkins says the new 2600 Series achieves best-in-class power density, torque and fuel efficiency for heavy duty off-highway applications, with applications in mining, including excavators, dozers, drills, trucks, feeders, screens and pumps, among others.

It comes with eight power ratings from 340 kW to 515 kW, offering up to 3,200 Nm of peak torque. Industrial open power units configured with engine-mounted aftertreatment and cooling packs will also be available from the factory to reduce installation and validation costs for OEMs, the company said.

Perkins will offer 2600 Series engines configured to meet the emissions standards of higher regulated countries, such as EU Stage V, U.S. EPA Tier 4 Final, China Non-road IV, Korea Stage V, and Japan 2014, as well as versions for lesser regulated countries. The engines are compatible with renewable liquid fuels such as 100% hydrotreated vegetable oils (HVO), B100 distilled Biodiesel and up to B100 fatty acid methyl ester standard biodiesel.

Additionally, the platform’s core architecture supports the future development of spark-ignited natural-gas and hydrogen fuel capabilities, according to the company.

To date, engineers have completed more than 20,000 hours of design validation on the 13-litre engine platform, with early OEM pilots available in 2025 and commercial production scheduled to begin in 2026.

Speaking at a press event held in London yesterday, Product Marketing Manager, Allen Chen, said prototypes were already out in the field in construction, agriculture and material handling applications, some of which were testing the highest power category.

He also said the new design piggybacked off the development of the smaller 904 Series engine, and was engineered for “tomorrow” with options for a drop-in exhaust gas recirculation system should future regulations require further emission reductions.

Hybrid power options – diesel-electric, among them – were also front of mind when designing this engine, Chen added.

Perkins says it is continuously developing and optimising a large, fast-growing portfolio of advanced power product and service solutions designed to help customers manage the energy transition to a more sustainable, lower-carbon future, including:

  • 48-, 300- and 600-volt lithium-ion battery solutions with modular designs and factory-installed telematics that Perkins is developing to optimise performance and packaging in numerous next-generation off-highway applications;
  • EU Stage V and U.S. EPA Tier 4 Final industrial diesel engines and industrial open power units that are already available to help OEMs reduce greenhouse gas emissions from their machines;
  • A full range of engines that today, without modification, can use a wide range of lower-carbon intensity drop-in fuels such as HVO and biodiesel;
  • Highly configurable integrated, end-to-end diesel-electric hybrid powertrains, suitable for a wide range of off-highway applications;
  • Connectivity solutions with hardware reading important engine data, displayed to the customer as timely insights; and
  • Aftermarket capabilities promoting sustainability through improved fuel efficiency and prolonged machine life cycles, such as Perkins Hypercare packages and overhaul kits to full replacement engine solutions.
Perkins says it has highly configurable integrated, end-to-end diesel-electric hybrid powertrains, suitable for a wide range of off-highway applications

At that same press event, Paul Moore, Head of Powertrain System Integration Engineering – Industrial Power Systems division, revealed details of “Project Coeus”, which has been established to come up with a “compact drop-in solution for flexible low carbon intensity power”. Such a solution would leverage hardware and software that allows the use of alternative fuels – ethanol, methanol, bio-methane and hydrogen – to be used within the Perkins engine portfolio.

Moore said a solution could be demonstrated in a machine in three years’ time that allowed such agnostic fuel supply options.

Jaz Gill, Vice President of Global Sales, Marketing, Service and Parts, said of the 2600 Series: “As the off-highway industry advances toward a lower-carbon future, equipment manufacturers still face expectations for long-term productivity and reliability in the world’s most demanding work environments. The new Perkins 2600 Series engine platform demonstrates how we’re leveraging our experience, intelligence and commitment to help OEMs navigate the energy transition with power solutions that deliver exceptional performance on the work site.”

The Perkins 2600 Series showcases the company’s commitment to innovations that support the success of customers by challenging traditional assumptions – which was evidenced by the 82 patents granted to date across the entire engine platform, the company said.

The engines are designed to perform at altitudes of up to 12,000 ft (3,658 m), and in extreme ambient temperatures as high as 60°C and as low as minus 40°C with aids.

The engine supports quality, reliability and easier maintenance through numerous design enhancements, including the integration of components as well as a reduction in the number of leak joints by more than 45%, the company says. Together, the upgrades result in lower fluids consumption and extended oil and fuel filter service intervals as long as 1,000 hours, reducing operating costs and downtime.

Perkins said: “2600 Series engines will offer telematics solutions enabling OEMs to collect, analyse and integrate key engine performance data within a connected intelligent platform. By modularising and eliminating components, its architecture is space-protected to accommodate configuration adjustments anticipated for future tiers of emission standards in the US and EU without relocating customer connection points. All eight power ratings for higher regulated markets will be available on a common core engine, enabling OEMs to reduce their inventory and integration costs.”

It added: “The combination of the all-new rear gear train, stiffer core architecture, and common rail fuel system reduces noise by up to 3 dB when compared with Perkins current 13-, 15- and single-turbo 18-litre engines.”

The launch came at the same time Perkins unveiled a new global strategy to advance sustainable power with a brand refresh – a move, it said, better reflects its commitment to helping customers confidently challenge conventional wisdom and explore new ways to achieve their power and climate-related goals.

A subsidiary of Caterpillar Inc. for over 25 years, Perkins says it pioneered diesel engine power in the 1930s and has continuously evolved to help customers navigate technological change and solve complex challenges. Since its founding, the brand has manufactured over 22 million engines – with more than 4.5 million in use in over 5,000 different applications today.

The new Perkins brand strategy communicates a clear promise – “delivering smarter solutions to advance sustainable power” – and a renewed sense of purpose rooted in helping customers build and power a better, more sustainable world, it said.

Mining and space sectors collaborate to solve the biggest challenges

Automation, Communications in mining, Environmental, IoT, Mineral exploration, Mineral processing, Mining industry recognition, Mining safety, Mining services, Mining software, Power supply for mines, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,

A quiet revolution is underway in the mining sector as innovations and knowledge gleaned from space exploration help improve productivity, reduce emissions and create better outcomes for workers and communities, AROSE* Program Director, Michelle Keegan, explains.

The extreme demands of Space exploration and the drive for efficiency in the mining industry is creating new forms of cross-sector collaboration not seen before. The transfer of expertise and technology between these two sectors is also delivering solutions to some of humanity’s greatest challenges.

There are many commonalities between modern resource businesses and space exploration. Both require a focus on a smaller footprint, the delivery of zero-carbon emission operations and a reliance on substantial amounts of data to support decision making. They both operate in sensitive and challenging geographic environments and need to work in a way that reduces risks to their employees and the environments in which they operate.

The space industry provides a rich learning platform for the resources sector, for new approaches to increasingly difficult challenges. But the benefits of collaboration are not all one way. The space sector too is benefitting from the technological innovations and experience of miners here on Earth.

Technology developments in exploration precision, resource planning, advanced mineral detection sensors, in-situ extraction methodologies and advanced safety systems, present opportunities for insights and application in space.

Deep thinking around regulatory frameworks for responsible and sustainable space exploration and development will be enhanced through the experiences, both positive and negative, in terrestrial resource development.

Diversity of thinking

The opportunity to transfer technology and drive diversity of thinking from the space sector into mining will accelerate in the years ahead. Global demand for the critical minerals required to meet the world’s ambitious decarbonisation goals illustrates the need to leapfrog current approaches across the mining project lifecycle, from exploration through to production.

Rio Tinto CEO, Jakob Stausholm, recently described the global mining giant as a “technology company”.¹ In saying this he recognises Rio’s success in tackling the big challenges will rely on the miner’s ability to integrate new technologies and novel approaches to problem solving.

In a world where mining is becoming more complex, more difficult and more expensive, the ability to reduce costs (and emissions) and win the support of governments and local communities will rely on the ability to deploy technology to mine and process ore more efficiently and more safely, both for people and the environment.

Many post-carbon technologies, such as solar energy and battery storage systems, have been advanced through space exploration. Also, it is the systems engineering approach to project design, pioneered for space exploration, that increasingly is being adopted by terrestrial resources, technology and services companies.

Australia’s leading mining and oil and gas operators, as well as their major service companies, are aligning themselves with space-focussed businesses, researchers and industry organisations because they recognise the value of cross-sector collaboration. This new collaboration model is leading to greater technology and expertise transfer between space and resources. Miners also recognise the benefits of their best people being exposed to new knowledge and new ways of problem solving.

Trailblazer Lunar Rover project

The AROSE consortium was created for exactly this type of collaboration – to drive the growth of Australia’s space industry and bring together companies from resources and other industries, to leverage their collective capabilities and go after the toughest challenges in new ways. The Trailblazer Lunar Rover project is a first significant focal point for our space capable businesses and like-minded resources companies to pursue shared technology opportunities.

The AROSE Resources Advisory Board, established in 2022, creates an ongoing opportunity for the most innovative mining company leaders to provide input into the rover project, while taking learnings back to their businesses at the same time.

NASA understands well the benefits of this type of collaboration. Earlier this year AROSE participated in the first of a series of workshops with NASA and the United States Geological Service to look specifically at the areas of intersect between the resources and space sectors.

The mining industry is at a turning point in its decarbonisation journey. It has a once-in-a-generation opportunity to build new capabilities that will lay the foundations for long-term, sustainably driven growth. With an aggressive timeline to zero emissions, a great opportunity for the mining industry to solve this tough challenge is the successful building of relationships with uncommon partners like those in the space sector.

However, a broader partnership opportunity exists between mining and space. The domains we see as offering the best collaboration opportunities between space and mining include:

  • Automation and robotics;
  • Remote operations and control;
  • Geoscience;
  • Satellite communications and imagery;
  • Artificial intelligence;
  • Systems engineering;
  • Waste minimisation;
  • Digital design, including user experience and user interface; and
  • Data analytics.

It is evident space and mining projects are approached very differently. The design of a resources project is most typically achieved by bringing together the experiences of past projects, with a focus on budget and schedule. Operating concept or operating philosophy often takes second priority and does not drive the project design. As a result, an integrated systems design is never achieved. And while available technology enables some level of electrification, automation and digital decision making, the value that could be derived is never fully realised.

Andrew Dempster, Director at Australian Centre for Space Engineering Research at the University of NSW, says, “the high-level difference between the approaches of the two industries is that the mining (and oil and gas) decision points are all and always commercial, whereas the agency-driven space projects have more technical ‘system engineering’ decision criteria.”²

Dempster states “a fundamental observation about the difference between mining engineering and the space engineering disciplines (electrical, electronic, software, mechanical) is that the latter designs a product…while the former designs a business. It appears this is the fundamental disconnect”.

For many years the mining industry value chain has been unchallenged. Valuable resources are mined, processed then moved to a distribution point via rail or road and then shipped to a customer. However, there are several collaboration opportunities that could lead to mining companies rethinking value chain design, and these opportunities have the potential to alter the mining flowchart.

Perhaps the ideal approach we can use in mining is an integration of both approaches, and in this way adopt systems engineering thinking at the outset.

AI and data analytics

With an increasing need to build in automation, sensing and electrification, underpinned by digital platforms, the concept of operations needs an integrated approach more than ever. The growth in the application of AI and data analytics techniques to quickly interpret geological and physical properties of rock in mining has been exponential. As data streams become more complex and decision pressures more acute the demand for more sophisticated approaches to AI will only increase.

The space industry has had an even greater need to manage and interpret a plethora of complex data in real time to support mission critical decisions and there are obvious crossover opportunities to be explored in this arena.

With the hunt underway to locate resources on the moon or other planets to extend human life into outer space, the opportunity exists for mining technology companies to assist with rock knowledge acquisition and mineralogical interpretation of data required for successful space exploration.

Robotics and automation

The application of robotics and automation is expanding in the resources sector with the drive to remove people from harm and increase efficiency and precision in the mining process. Mining technology company IMDEX was motivated to partner with AROSE as a way of bringing space insights to the development of its BLAST DOG technology (pictured below), an automated logging system that collects detailed geoscience data from blast holes.

Major challenges IMDEX faced during the BLAST DOG development phase included: autonomous navigation over rough terrain; locating and positioning accurately over a blast hole; lowering and retrieving a sensitive, high-tech probe down the hole; and managing the transfer of high volumes of data through remote communication systems. IMDEX is refining its approach based on insights gleaned from companies involved in addressing these same challenges in space.

The recent affiliate agreement between AROSE and the Robotics Australia Group will increase this application across the industry.

Autonomous vehicles

In mining, the scale of operation has been linear until recently. If you wanted to increase mining output, you purchased more large equipment. Then came the introduction of fleet automation technologies, developed first by Caterpillar in 1996 and refined in partnership with Rio Tinto and other early adopters in the early 2000s.

Of the 1.5 million vehicles in use across heavy industry globally, only 1,200 vehicles are autonomous.³ Australia has the largest fleet of autonomous haul trucks in the world, with more than 700 in operation across 25 mines.4 Clearly the market potential is enormous.

These remotely operated technologies are challenging the need for ever larger truck sizes. The largest autonomous truck today might be the last of its kind as mining organisations consider what the ‘right size’ truck is for the future.

Smaller size trucks would allow miners to fully electrify their operations much sooner. In addition to the environmental benefits, there are operational and cost benefits that support this approach. The large autonomous trucks currently in use need enormous bi-directional roads. Reducing the size of mining vehicles can have a direct impact on strip ratios, and with a mine that can be up to 1 km deep, the roads that service the mine contribute significantly to the overall footprint.

While every mine design is different, there is a growing body of evidence that smaller autonomous vehicles can lower mine development costs (narrower benches, steeper pits, etc), speed operations and boost overall fleet utilisation.

The space industry has similar challenges with its autonomous vehicles. Where the mining industry is an expert at moving billions of tonnes of material by operating hundreds of autonomous vehicles all year round, the space industry today has only operated 11 semi-autonomous vehicles on a planetary body. This observation isn’t to diminish the significant achievement, as space exploration is extremely difficult, but to highlight the convergence of terrestrial and space objectives. For the space industry to perform in-situ resource utilisation activities anywhere off-earth, there is an opportunity to adopt learnings from the mining industry.

Likewise, the mining industry is moving towards smaller more specific/targeted mining practices and can learn from space industry experience in developing small-scale highly efficient and robust robotic solutions.

The space industry also provides a rich learning platform for the resources sector for new approaches to minimise and utilise the waste stream, with the ultimate goal of zero waste mining operations.

The companies which provide technology and services to the mining majors also realise they need to diversify their offering to include space. This ‘full stack’ approach may be a matter of business survival in a competitive future.

Remote operations specialist Fugro is a leader in this area. Fugro’s new SpAARC (Space Automation, Artificial Intelligence and Robotics Control) remote operations centre in Perth, Western Australia, has been specifically designed to share facilities between its established oil and gas and mining business and its fledgling space offering.

Fugro’s new SpAARC remote operations centre in Perth, Western Australia, has been specifically designed to share facilities between its established oil and gas and mining business and its fledgling space offering

Fugro and Nova Systems are leading the AROSE consortium’s Trailblazer Lunar Rover design team. Woodside Energy and Rio Tinto are also supporting the AROSE Trailblazer effort by providing knowledge transfer of their terrestrial robotic and automation capabilities.

Woodside has also formed a collaboration with NASA on robotics and remote operations. NASA sees Woodside as a great test bed of robotics in harsh environments, as Woodside is doing similar tasks at its operations which NASA envisages doing on the Moon and Mars.5

The largest challenges facing the mining industry are the need to get to zero emissions, the need to get to zero harm and zero waste. There’s urgency in the call to solve all of these. It is now well-recognised that we need more collaboration not just within our sector, but across sectors. With the Moon to Mars program now underway, and the Trailblazer Lunar Rover program in place, this really is a tangible point in time where things are moving forward, a tangible point where people realise that this isn’t a dream, this is a reality.

* AROSE (Australian Remote Operations for Space and Earth) is an industry-led not-for-profit organisation dedicated to ensuring Australia is the trusted leader in Remote Operations science, technology and services on Earth and in Space.

Sources:
1. ‘Solving our largest on earth challenges through the benefit of technology transfer between space and mining,’ Michelle Keegan, Gavin Gillett, Clytie Dangar, World Mining Congress 2023.

References
1. ‘We’re a tech company’: Rio boss draws on lessons of history, Australian Financial Review, 2 August 2023. https://www.afr.com/chanticleer/we-re-a-tech-company-rio-boss-draws-on-lessons-of-history-20230801-p5dt2p
2. Integrating the approaches to space and mining project life cycles, Andrew Dempster, 5th International Future Mining Conference 2021. https://www.ausimm.com/publications/conference-proceedings/fifth-international-future-mining-conference-2021/integrating-the-approaches-to-space-and-mining-project-life-cycles/
3. No swarming yet in trillion-dollar market, Investmets, 4 August 2023. https://www.investmets.com/no-swarming-yet-in-trillion-dollar-market/
4. Global autonomous mining truck population tops thousand mark, to reach 1,800 by 2025, Mining.com, 18 May 2022. https://www.mining.com/global-autonomous-mining-truck-population-tops-thousand-mark-to-reach-1800-by-2025-report/
5. https://cciwa.com/business-toolbox/growth/why-woodsides-partnership-with-nasa-is-a-win-win/

WesTrac and Hushpak’s expertise delivering sound results on board Cat 793Fs for Bloomfield

Environmental, Mine operation news, Mining equipment, Mining safety, Mining services, , , , , , , , , , , , , ,

WesTrac and its subsidiary Hushpak have delivered what they say is as an innovative sound suppression solution to The Bloomfield Group that has reduced the noise output of 19 Cat 793F mining trucks.

Managing the sound output from heavy machinery can be a challenging task on mine sites, but this is starting to become easier for many businesses, according to WesTrac.

“That’s thanks to a range of innovative sound suppression offerings from leading Caterpillar dealer WesTrac, which in the last two years has delivered 19 Cat 793F large mining trucks to Hunter Valley-based mining customer The Bloomfield Group showcasing these capabilities,” it said.

Using a combination of Caterpillar factory options and inhouse, customised solutions, WesTrac was tasked with reducing the noise of the Cat 793F trucks to levels that aligned to Bloomfields’ requirements at its Bloomfield and Rix’s Creek mines – in close proximity to Maitland and Singleton, respectively.

According to WesTrac NSW Strategic Growth Manager, Alan Corcoran, the solution achieved that goal on time, within budget and included several requested customisations.

“Working with our subsidiary Hushpak, we devised a solution that passed the sound output tests in the first instance,” Corcoran says.

Hushpak is a standalone engineering business specialising in sound suppression and attenuation on both mobile and fixed plant. WesTrac acquired the company in March 2022.

“Sound comes from various outputs, particularly on mobile plant,” he explains. “The engine, transmission, fan, hydraulic pumps and various other components compound to make these large machines quite noisy.

“Caterpillar offer ready-to-order sound suppression kits for mining machines, but, in some cases, there are gaps in the product offering. Many of our customers have unique needs, especially in areas like the Hunter Valley, where mine sites are in closer proximity to towns and residential areas.

“These customers have additional requirements that need further sound suppression. Meeting these unique needs, on all types of mining equipment, such as this customer’s 793F trucks, led to this project to bridge the gap.”

“These 793Fs are a 20-year investment for our business and are setting the foundation for our haulage fleet moving forward,” David Worboys says

Such is the case for Bloomfield, which produces around 2.5 Mt/y of saleable coal from its mines in New South Wales, where all haulage and ancillary machinery fleet are Cat products.

Following extensive market research carried out in 2020, Bloomfield Plant and Equipment Manager, David Worboys, and his broader team settled on the 220-t-class Caterpillar 793F truck and have since taken delivery of 19 units from WesTrac’s Tomago branch, now working at Rix’s Creek and Bloomfield mine.

Worboys says all trucks fitted out with the Hushpak-engineered sound attenuation package were contributing to ongoing site noise compliance and minimising impact to nearby communities.

“We pride ourselves on being good neighbours, and therefore we make every effort to minimise the noise impacts on them,” he says. “We use engineering best practice where we can, to achieve as high sound output reduction as we can.

“These 793Fs are a 20-year investment for our business and are setting the foundation for our haulage fleet moving forward.”

With that in mind, WesTrac’s equipment specialists and engineers worked with Hushpak and Bloomfield to develop a customised solution for the 793F that took airflow, weld locations, centre of gravity, visibility and access for maintenance into consideration.

On completion of the first 793F fit out, WesTrac engaged an independent tester to assess the noise output. Testing was carried out at WesTrac’s NSW headquarters in Tomago.

Following delivery of the first two trucks to site, WesTrac and Hushpak continued to work with Bloomfield to administer minor adjustments that have been carried through to other trucks delivered.

“Through collaboration, using expertise from us on site and working with WesTrac and Hushpak to come up with solutions introduced into the sound attenuation package has ultimately delivered a great product,” Worboys says.

Corcoran said WesTrac’s ability to tailor solutions to meet customer requirements as well as broader requirements such as emission reduction targets fuels the company’s continuous improvement program.

Autonomous equipment commissioning ramps up at Côté gold project

Automation, Mineral project development, Mining equipment, Mining project news, Mining safety, Mining services, Precious metals, , , , , , , , , , , , , , ,

IAMGOLD has released its latest quarterly results, highlighting the significant progress it has made on its majority-owned Côté gold project in northeastern Ontario, Canada.

The company is the majority owner and operator of Côté, with the next biggest stake owned by Sumitomo Metal Mining. Côté has a mine life of 18 years, and will produce an average of 365,000 oz/y over this term. Some 236 Mt of ore will be mined, along with 568 Mt of waste, with an average processed grade of 0.96 g/t Au.

In the latest results, IAMGOLD said the project was estimated to be 85.7% complete as of the end of June. Since commencement of construction, $2.23 billion ($1.56 billion at the 70% held by IAMGOLD) of the planned $2.965 billion ($2.08 billion at 70%) of project expenditure has been incurred.

Autonomous operations have been incorporated into the Côté mine design with a focus on early operations readiness. The Autonomous Control Room equipped for Caterpillar Command for hauling was completed in mid-September and the project achieved a major milestone in January with the initial deployment of the autonomous 231 t Cat 793F CMD haul trucks working with Toromont Cat. On January 22, the mine saw the safe operation of a full load, haul, and dump cycle using autonomous dump trucks.

During the June quarter 2023, up to seven Cat 793F haul trucks have begun operating in autonomous mode and a total of 14 haul trucks have been commissioned. Autonomous drilling with two Epiroc Pit Vipers began in this quarter, with a third nearing commissioning completion. In total, the company is expected to operate six autonomous Epiroc Pit Viper 231 blasthole drill rigs, complemented by two Epiroc D65 SmartROC crawler rigs, which will be remote operation ready.

In addition it will deploy electric Caterpillar hydraulic shovels – namely two 6060FS units, AC-powered via tethered cable.

The company said owner mining has progressed well with nearly 1.1 Mt mined in the June quarter. The stockpile has approximately 2 Mt of material on track to the target build-up of 5 Mt by the end of the year. The IAMGOLD mine operations team started operating 24/7 effectively in July.

The project timeline remains in place, with production expected to commence in early 2024.

Bingham Canyon to become first Rio Tinto site equipped with Cat MineStar Fleet

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The Bingham Canyon copper mine in Utah, USA, has selected the Cat® MineStar™ Fleet management system as part of its plans to optimise open pit operations at the mine, owned by Rio Tinto, Caterpillar says.

Caterpillar Inc and Wheeler Machinery recently completed installation of a Cat MineStar Fleet management system at the mine, which, rather than upgrading the mine’s previous fleet management system, chose to deploy MineStar Fleet. This switch has, Caterpillar says, optimised the mine site’s equipment tracking, production recording, material management and truck assignment, and it has further expanded the technology relationship between Caterpillar and Rio Tinto.

Ryan Howell, Mining Technology Commercial Product Manager at Caterpillar, said: “For 15 years, Rio Tinto has used MineStar Terrain and has expanded its MineStar capabilities in recent years at locations like Gudai Darri and Marandoo, autonomous mine sites in Western Australia. Bingham Canyon Mine is the first MineStar Fleet site in Rio Tinto history, and this extends the company’s application of MineStar capabilities. Our team is proud of this MineStar Fleet system installation. We are honoured to be there to support the mine site’s fleet management needs.”

Joshua Wood, Principal Advisor, Surface Mining Centre of Excellence at Rio Tinto, added: “The close collaboration between the Rio Tinto Group team, Caterpillar, dealer and Kennecott ensured a successful deployment at Kennecott and their desire to be the flagship for future MineStar sites.”

Even though it wasn’t the easiest route for the mine, the cost-benefit analysis showed significant benefits long term using MineStar Fleet, including seamless integration with MineStar Terrain currently used by the mine, Caterpillar said.

Mike Gray, General Manager for Wheeler Machinery, said: “A true partnership with the supplier, dealer and customer allows for large-scale technology projects like this to be completed successfully with minimal impact to production.”

An incremental approach was devised to minimise the system installation loss-time impact on mining operations for bringing nearly 100 trucks, plus more than 40 supporting dozers, shovels and drills, online with MineStar Fleet. Caterpillar and Wheeler worked together to provide a quick turn-around time with best-in-class implementation, Caterpillar said.

Bryce Olson, Mine Monitoring and Control Superintendent at the Kennecott Bingham Canyon Mine, said: “We have been impressed with the partnership, and we share the same vision and have the correct team to get us there. We flipped the switch, and we haven’t gone backwards. We immediately started using MineStar Fleet’s open assignment, load-haul-dump and auto fuel advanced features.”

Cat MineStar Fleet automatically records and tracks data up and down a mine’s value chain, providing insights that help miners identify what is working and fix what is not to meet production targets, Caterpillar says. Fleet allows miners to view the entire operation at a glance on a computer and gain insights into key cost drivers – such as fuel, tyres, service parts and idle time – and improve haul fleet production and shovel utilisation.

Caterpillar boosts payload, performance with new 995 wheel loader

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Building on the success of the 994K, the new Cat® 995 Wheel Loader features up to 19% increased productivity than the previous model with its higher rated payload and 6% increase in hydraulic force with equal hydraulic cycle time, Caterpillar says.

This new loader delivers up to 13% lower hourly fuel consumption and offers up to an additional 8% efficiency gain when operating in Enhanced Eco Mode compared with throttle lock mode, according to the company. It is also up to 19% more efficient than the 994K in equal comparisons of throttle lock operation.

Enhancements to the front linkage include an improved casting design, increased weld size, larger bearings and pins, and profile changes for increased service life. New, larger capacity buckets available for the 995 incorporate an extended floor for fast loading, high fill factors reaching 115%, and excellent material retention. Buckets are interchangeable between the 995 and 994K.  

Built to the same size as the 994K but offering a higher rated payload, the new 995 enables a one-pass reduction when loading Cat 785, 789 and 793 mining trucks. This equates to up to a 33% increase in production and efficiency when loading the 785, up to a 25% increase with the 789 and up to a 20% increase with the 793.

The new 995 meets the global industry’s demand for high production and greater payloads with its powerful Cat 3516E engine offering configurations based on regional needs, meeting EU Stage V/US EPA Tier 4 Final or US EPA Tier 1 equivalent emissions, the company says. Its 39% torque rise ensures high lugging forces during digging and acceleration in high rim pull conditions.

Comfort and visibility

The redesigned next generation operator environment for the new 995 has 50% more legroom and boasts features that improve operator confidence while reducing fatigue. Its pressurised cab reduces vibration feedback, lowers sound levels and includes automatic temperature control. Providing shift-long comfort, its new electro hydraulic speed-sensing steering with force feedback automatically stiffens when traveling at higher speeds and softens as speed decreases to boost operator confidence.

Designed for visibility, the cab’s taller windshield provides a 25% increase in glass surface area and a 64% increase in wiper sweep area to better see the bucket. Two 254-mm colour LED monitors display machine control, operating functions and the electronic operator’s manual. A third 203-mm screen offers a dedicated view of the standard rearview camera and is upgradable to a multi-view camera system that offers 270° vision with rear object detection.

Access and egress to the cab along with all service areas being accessed from either ground level or a platform improves safety on the job. Wide stairs with full handrails on each side are positioned at a 45° angle for easy access. An optional powered access system – raised and lowered from either the cab or ground level – enhances ingress and egress to and from the rear platform even further.

Confidence-boosting technology

Integrated with electronics, the new Cat 995 wheel loader offers flexible levels of information and technologies for a smart machine and more informed operator, maximising the productivity of both. Standard tip up prevention technology avoids unnecessary stress on the drivetrain and structural components by delivering full breakout forces while preventing the back tyres from significantly lifting off the ground.

New optional Autodig components automate three of the dig cycle’s most difficult parts in both rehandling and tough digging applications to improve productivity and reduce tyre wear.

Reducing tyre wear, Tire Slip Prevention reduces rimpull before the tyres are set and increases rimpull when downward force is applied. Auto Set Tires detects pile contact and automatically lifts against the pile to set the tyres and increase available traction, discouraging premature racking. Lift Stall Prevention manages rimpull in-dig to prevent hydraulic stall when lifting through the face, so the 995 spends less time in the pile.

An onboard interactive training tool, optional Operator Coaching measures and reports on individual operator behaviours that have an impact on efficiency, production and component life. Instructional videos provide training on measured behaviours, showing both the incorrect and recommended behaviours. Among 21 total monitored operating technique aspects, the system shows how to properly reduce tire rotation, avoid unracking in-dig, enter the pile with a level bucket, avoid excessive usages of the impeller clutch, reduce dump height and use the kick out.

Available Payload Overload Prevention improves productivity and efficiency by allowing a larger bucket to be used to achieve pass-match targets across a range of material densities without risk of overload. It is configurable to either stop or slow lift arms when the maximum allowed payload, including bucket weight, is exceeded.

Standard Vital Information Management System (VIMS) on the new 995 allows customers to connect directly to the machine to access a wide range of sensor information and enhanced machine data. Taking the guesswork out of asset management, standard Cat Product Link™ provides remote access to machine operating data via the easy-to-use VisionLink® interface. The 995 supports a variety of Cat MineStar™ solutions including Health, Guide and Terrain.

Reduced maintenance

Offering a 500-hour engine oil change interval and improved air filter life, the 995 spends more time working. The number of steering hoses has been reduced from 15 to 10 and tubes cut from 11 to one to improve steering system reliability. An enhanced service station provides access to functions like coolant and oil as well as level indicators, and it features a Cat battery charging connector and indicator lights for fuel tanks.

The loader’s redesigned pump bay improves access to transmission components, offers discharge ports on the side of the pumps and has simplified lines routed directly to the high-pressure screens. The bay includes a brake pump filter, implement pilot filter and implement discharge screens, and diagnostic ports are accessible from the front walk deck and pump bay. Ground line service now includes a steering pilot filter, transmission filters and steering pump discharge screen.

Caterpillar boosts payload and speed with lower-emission R2900 XE LHD

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The first diesel electric underground load-haul-dump (LHD) loader from Caterpillar, the new Cat® R2900 XE LHD, has officially been launched with a goal of meeting the underground mining industry’s needs for bigger payloads, faster loading and reduced emissions.

Built on the platform of Caterpillar’s most popular underground loader, this new LHD – which was previewed at MINExpo 2021 in Las Vegas – features optimised lift arm and component geometry plus load-sensing hydraulics to improve breakout force by 35% over the Cat R2900G, the company claims.

The world’s first R2900 XE has already been delivered to Western Australia-based gold miner Westgold Resources.

The R2900 XE works faster in tough conditions, delivering 52% quicker acceleration and improved machine response over the R2900G. It accelerates from 0-24 km/h in 6.4 seconds and achieves a 7% higher speed on grade, according to Caterpillar. Variable piston pumps deliver higher flow rates for faster hydraulic cylinder cycle times and powerful lift forces. Boasting a higher, 18.5-t payload for faster load times, the new LHD model offers a 3- to 4-pass match to the Cat AD63 truck for greater efficiency. Combined, these features deliver a 20% increase in productivity for the R2900 XE, Caterpillar says.

The loader’s redesigned buckets are available in four sizes with capacities ranging from 7.4 to 9.8 cu.m to match material density needs for a variety of loading, hauling and dumping conditions. Offering an optimised balance between productivity and bucket life, the full range of Cat ground engaging tools (GET) includes Modular Weld-on, Bolt-on Half Arrow and Durilock™ mechanically attached shrouds. To further protect the bucket, a range of heel shrouds, wear plates and bars are available in weld-on or mechanically attached designs.

The Cat C15 engine on board offers a variety of emission reduction and aftertreatment options, including an EU Stage V/US EPA Tier 4 Final configuration and diesel particulate filter. It delivers the power needed – up to 335 kW – with greater than 31% increased fuel efficiency compared with the R2900G. Its lower engine revolutions per minute results in reduced fuel burn, heat, noise, vibration and exhaust emissions, while offering an increase in power and productivity, according to Caterpillar.

High-efficiency electric drive

Drawing from decades of experience, the new R2900 XE LHD features a switch reluctance electric drive system. It is Caterpillar designed, integrated, validated and supported, and its continuously variable speed control delivers improved power and cycle times, Caterpillar says. With no driveline or powertrain shock loads, it offers smoother directional changing and implemented virtual gears for machine controllability. Automatic retarding controls maintain speed on grade. The drive system prevents coasting in neutral and combines with the anti-rollback feature to further increase operating safety.

Its new axle design offers increased component size and, together with the four-gear planetary final drive groups, provides greater strength and longer life. Larger wheel bearings and increased brake sizing further increase final drive life. Flange-mounted rims allow for safer tyre and rim changes. The differentials and final drives are built to withstand the forces of high torque and impact loads, providing high torque multiplication to reduce drivetrain stress. The traction control system, meanwhile, reduces tyre spin in difficult underfoot conditions to improve productivity, increase tyre life and reduce consumable costs.

The operator environment is built on Caterpillar’s R1700 platform, incorporating the latest improvements in productivity, safety and comfort. The cab’s enclosed design provides fresh, pressurised, temperature-controlled air circulation with air conditioning to enhance operator comfort and decrease fatigue. Resiliently mounted to the frame, the ROPS/FOPS structures isolate the operator from vibration for a more comfortable ride. The cab design incorporates two emergency exits, while available rearview and forward- and rear-facing side-view cameras help to improve visibility around the machine to enhance safety for operators and other workers.

Combining selection of direction, virtual gears and steering into a single lever, the standard STIC™ steering and transmission integrated control delivers maximum responsiveness and machine control, Caterpillar says. Low-effort, electric-over-hydraulic joystick controls feature simultaneous lift and tilt functions to optimise operating efficiency, while a two-pedal design with improved spacing and position facilitates more efficient foot control.

Caterpillar adds that the optional ride control improves cycle times and load retention when operating in rough terrain. By engaging/disengaging the ride control system at preset speeds, the system automatically dampens bucket forces and stabilises the machine, reducing fore and aft pitching motion. It incorporates a nitrogen/oil accumulator system in the lift circuit to act as a shock absorber.

Scalable technology solutions

The new R2900 XE ships from the factory equipped ready for Cat MineStar™ solutions, a comprehensive suite of technology offerings. From machine health monitoring to fully automated haul and dump cycles, scalable levels of technologies can be tailored to meet each mine site’s unique needs, Caterpillar says. Standard Product Link™ Elite boosts machine connectivity by enabling the loader to collect and transmit health and condition monitoring information into locally or cloud-hosted applications.

Mine sites can choose between a range of available MineStar technologies, including:

  • Command for underground – enables remote operation of LHD machines, from line-of-sight to full autonomy, allowing operators to be relocated to a safe, comfortable location to improve productivity, efficiency and safety;
  • Detect for underground – uses peer-to-peer proximity detection to reduce the risk of unintended interactions between people and machines by “seeing” in the dark;
  • Fleet for underground – gives real-time access to accurate information such as cycle time, payload, machine position, and other key operational parameters and automatically tracks and records data up and down the value chain; and
  • Health – collects and transmits equipment data necessary for proactive maintenance services and predictive equipment analysis.

New Autodig technology optimises loading by automating crucial parts of the digging cycle, Caterpillar says.

“When combined with Command for underground, Autodig offers a true automated machine, providing high-speed auto tramming and full cycle autonomy,” the company explains. “Featuring an onboard payload weight scale, Cat Payload Management provides material management, cycle count and timing recording, and wireless production detail reporting capabilities. Optional tyre pressure monitoring is fully integrated into the R2900 XE, allowing operators to determine on-the-fly if the tyres are properly inflated.”

With more robust structures, increased powertrain durability, longer lasting components, improved maintenance and extended service intervals, the new R2900 XE can be maintained in less time, helping to lower cost-per-tonne operation, Caterpillar says. The machine’s electric drive reduces the number of moving parts compared with traditional mechanical drive systems. Extended oil change intervals, together with the electric drivetrain, reduces the amount of oils used. Sight gauges visible from ground level simplify fluid level checks, and all filters are positioned vertically to provide spill-free servicing, Caterpillar claims. Electrical connectors are sealed to lock out dust and moisture, while harnesses are covered for protection.

Machine design eliminates castings and reduces weight to increase the life and strength of the frame without sacrificing performance. The frame, powertrain, engine and components are built to be rebuilt using new, remanufactured, or rebuilt parts and components, allowing mines to take advantage of multiple lives of like-new performance to lower operating costs.

Agnico Eagle’s Detour Lake mine adds Cat 798 haul trucks to fleet

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With the aim of ramping up production at the Detour Lake gold mine in Ontario, Canada, Agnico Eagle Mines has commissioned four Cat® 798 AC haul trucks at the open-pit operation.

These trucks, which come with a 372-t payload and are electric drive, were introduced to the market in 2019, joining the mechanical-drive Cat 797F in the 400-short-ton size class.

Agnico said these new vehicles were introduced to the fleet in the March quarter, with an additional two units planned to be commissioned in the June quarter.

In the March quarter of 2023, the Detour Lake mill set a record for first quarter throughput and activities continued to focus on mill process optimisation and improving availability with the goal of achieving and potentially exceeding throughput of 28 Mt/y. This helped the company produce 161,857 oz of gold in the three-month period.

While the company’s near-term focus is on open-pit operations at the mine, it is also looking to integrate additional drill data into a revised mineral resource model that will be used to evaluate potential underground mining scenarios.

The population of Cat 798 AC trucks has been growing in the last few years, with the Antamina, Toquepala and Cuajone copper mines in Peru. Last year, Finning announced it would deliver 13 Caterpillar 798s to Codelco’s Ministro Hales open-pit copper mine, while BHP, Caterpillar and Finning International announced, in August, that a haul truck fleet replacement process at the Escondida mine, the world’s largest copper producer, would also the OEM and dealer provide Cat 798s to the operation.