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Caterpillar, Barloworld, AMS and Sandfire collaborate at Motheo in Botswana

Automation, Base metals, Communications in mining, Equipment maintenance, Mine operation news, Mining equipment, Mining services, Precious metals, , , , , , , , , , , , , , , , , , , , , , , ,

When Sandfire Resources produces the first ore from its new Motheo copper mine in Botswana, southern Africa, later this year, the company will officially be on its way to developing a long-life copper production hub in the central portion of the Kalahari Copper Belt of Botswana and Namibia.

That first ore from Motheo is just the beginning of the company’s long-term growth plans in the region. Before the development of the mine was even completed, Sandfire had already announced plans to enlarge the operation by exploiting an additional deposit and building an expanded processing plant to handle production.

Recognizing the potential of the Kalahari Copper Belt, Sandfire and its chosen operations partner for Motheo — Perenti Group’s African Mining Services (AMS) — made a commitment to the highest standards of productivity, safety, responsibility and sustainability.

A critical contributor to meeting that commitment will be the use of mining technology. And key partners in that effort will be Caterpillar and Cat® dealer Barloworld Equipment, who are working with Perenti/AMS to provide a suite of technology solutions that will deliver innovation to the mining operation.

Crew with mining truck

“We know that Sandfire Resources, our customer Perenti, and the entire team at Motheo is committed to using technology to build the safest, most productive operation possible,” Nathan Wescombe, a Senior Account Manager at Caterpillar, said. “We’re proud that Perenti has chosen Cat technologies to help them become the operator of choice within the region and deliver innovation to their mining practices.”

To ensure the successful deployment of technology in an area of the world where mining technology is not the norm, Caterpillar conducted a three-day information-gathering and change management workshop to consult with key stakeholders to help ensure they are technology-ready.

“Change management is a key to the implementation of technology in any operation,” Leslie Fengu, a Senior Regional representative for Caterpillar’s Mining Technology Solutions division, said. “And it’s even more critical in an area where it’s being introduced for the first time. Fortunately, Caterpillar has a team that has plenty of experience in helping our customers manage this change – understanding the challenges, developing possible solutions to address them, and providing ongoing support through implementation and beyond.”

Held in August 2022, the workshop was very well attended, met with positive feedback, provided critical knowledge of the operation, and identified opportunities moving forward to ensure success for all stakeholders, according to Caterpillar.

Greg Lawson, a General Manager at Perenti/AMS, said: “Incorporating technology into our operations is an important piece of our global strategy. Having the support of Caterpillar and Barloworld as we implement these solutions in a new region is proving to be instrumental in helping us realise our goals. We appreciate the value of their expertise not only in the technology itself but also in addressing the significant change management that goes along with its implementation.”

The Motheo copper mine

Motheo Copper Mine is located in the Kalahari Copper Belt, a major zone of strata-bound copper-silver deposits extending for 1,000 km along the northern margin of the Kalahari Craton in Namibia and Botswana.

The greenfield project is being developed by owner Sandfire Resources, an Australia-based mining and exploration company with a global presence. Open-pit mining services are provided by contractor AMS, the Africa-based surface mining arm of Perenti Group, a global mining services company also based in Australia.

Motheo represents the foundation for Sandfire’s long-term growth plans in Botswana and is expected to generate approximately 1,000 jobs during construction and 600 full-time jobs when fully operational.

After a positive feasibility study in December 2020, Sandfire’s board approved the development of Motheo. The feasibility study identified a robust initial 12.5-year operation with annual production of high-quality copper concentrate estimated at 3.2 Mt. Site construction commenced in 2021, with first production scheduled for mid-2023.

The Motheo Copper Mine will be based on an open-pit operation for the original deposit, identified as T3. The drill-and-blast operation will focus on 10-m benches, using suitable blasting methods to minimise dilution. Trucks will be loaded by 250-t excavators. Direct run-of-mine ore will be delivered directly to the crusher or placed on stockpiles for future rehandling.

AMS selected a fleet of Cat trucks to handle hauling duties, supported by a variety of other Cat machines. Barloworld recently delivered 20 139 t Cat 785 trucks, four D10T dozers, two 777 water trucks and two 18 motor graders to the mine.

Beyond the quality expected from the Cat machines, a major factor in the equipment purchase was related to the Cat MineStar™ technology products that accompany them. AMS, Caterpillar says, selected three separate but integrated solutions that will impact the efficiency and production of the operation, the uptime of machines and the safety of its people:

  • MineStar Edge™, a cloud-based equipment management and production recording platform that provides access to highly accurate production data and gives visibility to the entire mining operation;
  • Health – Equipment insights, a user-friendly data visualisation and reporting tool that allows sites to easily access, view and analyse machine health information and gain insights to help reduce unplanned downtime and prevent failures; and
  • Cat Driver Safety System, an in-cab detection technology that can help sites identify operator fatigue and distraction and address it in real time.

Introducing technology in Botswana

Sandfire and Perenti are no strangers to mining technology. Sandfire’s DeGrussa copper-gold mine in Australia was an early adopter of autonomous mining, using Cat MineStar Command for underground to automate a fleet of underground loaders. The Perenti Group, too, recognises the value of technology in mining, and has added a dedicated services and products business to its portfolio to provide technology and consulting services to the mining industry.

But bringing a technology mindset to this region is not business as usual. For Caterpillar, this is just the third such implementation in southern Africa and the first in Botswana. Cross-departmental interconnectedness is paramount for Perenti and AMS to realise its return on investment as the Motheo team strives to deliver on business demands, Fengu, whose knowledge of the region and its history are extremely valuable to technology implementation in Botswana, said.

“Disruptive technologies, such as those chosen by AMS, require a site-wide approach to achieve successful implementation and sustainable operations,” he said. “Supervisors and their teams are required to effectively manage the implementation and functional changes that will be required with technology, adapting staffed conventional mining techniques to get the most value out of the new mining system.”

To ensure the success of these systems in a country where they have not operated previously, Caterpillar identified an opportunity to leverage the knowledge and capability of its Cat Solutions & Services team, as well as other Cat and Barloworld technology experts. The initiative was led by Caterpillar Technology Change Enablement Manager, Brett Haskins, working with Joel Patterson and Jenny Krasny as key consultants.

“We organised a workshop to develop a deeper understanding of how we could assist in this change, walk through opportunities to help them become more comfortable with the technology and better appreciate how it can help support their roles in the operation,” Wescombe said.

Understanding the site and its culture

This workshop included site observations, interviews, education and facilitated discussions designed to understand the current culture – with a lens toward building operational readiness to capitalise upon the benefits that MineStar Solutions can provide.

The visit occurred over three days with a high level of engagement from every area and level of the deployment. The visit was designed to maximise exposure to the day-to-day goings-on in the operation. Pit operations, departmental interactions and daily activities were observed to determine site mining practices, with a view to assess site readiness to apply MineStar and take advantage of the offerings.

“Understanding the history of change in all organisations was an important part of the workshop and visit,” Wescombe said. “We wanted to learn about change that had been managed well and identify areas for improvement. We did that by asking a lot of questions of people from every aspect of the operation. We engaged the site at all levels – from equipment operators to a representative from Perenti’s office in Perth, Australia.”

The discussions invited participants to share concerns or perceived challenges surrounding daily operations. They were encouraged to contribute ideas around how the daily operation and a change to the site’s mining system can be effectively managed from their perspective.

Workplace culture was also explored, gaining insight into how the site is managed and identifying areas of success and opportunities for improvement. Fengu said: “The goal of this effort was to help reduce incidents and unintended operational consequences, and to provide guidance to remedy any shortcomings through application of the technology.”

In addition, the workshop was designed to strengthen the collaborative relationship between the site, corporate office, Barloworld and Caterpillar. Caterpillar says it and its dealer are essential stakeholders who are pivotal to the successful deployment of MineStar Solutions.

“In a nutshell, our goal was to best understand how we could support AMS through the process of change management,” Patterson, Caterpillar Operational Readiness Consultant, said. “We started by encouraging all participants to leave preconceived ideas at the door on the way in to the workshop and asking everyone to be open-minded to change.”

Developing a path forward

All stakeholders agree that the workshop is just the beginning of ongoing engagement into getting the maximum value from technology at Motheo.

“The workshop helped us start the process,” Sam Farhand, Group Asset Manager for Perenti, said. “We learned a lot about the site and about each other. But now the hard work begins – addressing those challenges we’ve identified and ensuring that we never stop paying attention to how the technology is being used and continuing to find new ways to reap the benefits it delivers.”

An important outcome of the workshop is a 30-plus-page report that identifies the areas impacting successful implementation of MineStar technologies at Motheo and provides recommendations and possible solutions that will help address them.

The report is designed to:

  • Ensure understanding of the “why” for change management, and the benefits of using the Caterpillar team for this initiative;
  • Summarise the vision for the deployment as voiced by Perenti and AMS employees;
  • Articulate the landscape in which the project is taking place;
  • Highlight activities on which to partner or reinforce;
  • Present identified opportunities to adapt, build and embed new processes;
  • Identify the unique needs of the people who will be impacted;
  • Outline a change management plan to support the deployment; and
  • Share immediate action items to facilitate a successful deployment.

Sharing positive feedback

When asked about the success of the workshop, all stakeholders had positive things to say.

“The on-site engagement and participation in the workshop were outstanding,” Pierre Hill, Country Manager for Barloworld Botswana, said. “Attendance was terrific. It was a fantastic example of collaboration and teamwork.”

Wescombe agreed: “We were very pleased with the willingness of the key stakeholders to break traditional silos, open up lines of communication and actively engage in rich discussions between corporate, dealer, OEM, maintenance, planning and operations.”

But the most important feedback comes from Perenti. “We thought the workshop was very beneficial,” Farhand said. “It has helped us build a strong foundation on which to base our focus on innovation and technology.”

As the Caterpillar Manager for Perenti, Wescombe is quick to point out the teamwork and collaboration necessary for the success of the workshop – and the future of the technology in the years ahead.

“Without Greg Lawson and Sam Farhand from Perenti, this event would not have happened,” he said. “They helped us gain the traction we needed from internal stakeholders to get this off the ground. Plus, Sam and the on-site AMS Motheo team were instrumental in coordinating and supporting the workshop to ensure its success.”

“Our Caterpillar and dealer teams also deserve recognition. Leslie Fengu and Joel Patterson were key contributors to this effort, along with Pierre Hill and J.P. Briggs from our Cat dealer Barloworld. These folks worked closely with the Perenti team to build a preliminary understanding of the site challenges in order to optimise discussions during the site visit.”

The collaboration was a great example of the “three-legged stool” Caterpillar talks about when dealing with its customers in partnership with dealers. “When all three entities are working toward the same goal, we’re going to be so much more successful than when we go it alone,” Wescombe said. “We’re looking forward to a lot more opportunities to work together with Perenti/AMS and Barloworld in the years ahead.”

This is an edited version of a blog that first appeared here.

New High-Performance Circle boosts Cat 24 and 24M motor grader performance

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

Caterpillar’s new High-Performance Circle (HPC) for Cat® 24 and 24M motor graders improves machine performance, efficiency and uptime availability when maintaining haul roads at large mines, according to the manufacturer.

When paired with Cat exclusive extended life blade rail wear strips, the HPC reduces total cost of ownership for the drawbar circle moldboard and downtime by up to 80%, it claims.

Providing a 16,000-hour service life, the new HPC eliminates hours of monthly planned maintenance for frequent inspection, wear strip replacement and circle shoe adjustments associated with conventional circles. Industry-leading machining capabilities designed to tight tolerances help ensure the drawbar, drives and circle perfectly align and require no adjustments for the life of the grader, Caterpillar says.

Cat proprietary heavy-duty planetary gearboxes with integrated forged pinion shaft and gear replace the work drive gearbox and pinion gear system. The gearboxes, meanwhile, have sealed-for-life slip clutches that eliminate adjustments and isolate the clutches from the rest of the drive to increase reliability. Significantly reducing maintenance time, the slip clutch assemblies can be changed out in less than an hour and come adjusted from the factory, according to the company. The brass circle wear strips and shim system is replaced with a sealed roller bearing.

The new fully-sealed roller bearing delivers smooth and effortless blade rotation. Fully integrated with standard machine auto lube, the design eliminates daily greasing and can require no maintenance, adjustment or replacement for 16,000 hours, depending on the application.

A new pinion gear shape with increased shaft diameter for improved durability allows drives to be removed vertically without drive adjustments. And dowel locators precisely position motors for easier servicing, optimal tooth contact and longer pinion life, the company says. Its new design improves component reliability to reduce downtime and maintenance costs.

Caterpillar says: “Beyond lowering total cost of ownership, less required circle maintenance reduces component handling to properly maintain the machine, which improves safety for service technicians. At 16,000 hours, if the circle teeth have reached their wear limit, they can be rotated 180° to double the component’s service life. The new HPC maintains the same machine connection interface, so it is retrofittable to all Cat 24 and 24M Motor Graders.”

Increased power and more robust structures for the new Cat 24 make it an ideal pairing for Caterpillar’s longer 8.5-m moldboard option, the company says. The grader’s new Cat C27 engine, up to 37% increase in torque and new HPC are well equipped to accommodate the blade’s increased weight and width without slowing or bogging down the machine.

At 16% longer than the standard 7.3-m blade, it helps improve safety at larger mines by reducing the amount of time spent in the middle lane to clear the windrow. When used for a wider pass, it brings haul roads back to specification in fewer passes, eliminating one pass when supporting ultra-class trucks, Caterpillar claims. Longer moldboard reach places the windrow farther away from the rear tandems to increase traction. It also allows the operator to use a more aggressive blade angle to reduce machine load, increase speed on passes and help improve material handling.

The 8.5-m moldboard option is retrofittable to existing fleet Cat 24 motor graders. It can be connected to the machine with Cat extended life blade rail wear strips, available for both standard and high-performance circles, to achieve up to three times longer service life than standard rail wear strips.

Anglo Asian bolsters Azerbaijan mining fleet with Epiroc, Cat, Paus and Tunelmak equipment

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

Anglo Asian Mining says it has placed orders for the major items of equipment required for production from its new Zafar and Gilar mines in Azerbaijan, with a fleet made up of Epiroc drills, Caterpillar loaders and auxiliary machines from the likes of Paus and Tunelmak.

The company has also made progress with the upgrades to its Gedabek flotation plant, it noted.

The equipment for Zafar and Gilar includes an underground fleet from Caterpillar and drilling machinery from Epiroc. The total equipment cost is approximately $10 million, approximately 40% of which will be met from the company’s existing cash reserves with the remaining being funded through vendor financing. The equipment is a significant investment for the company, underpinning its confidence to achieve its stated ambition to transition to mid-tier copper production status, it said.

A day before this announcement, Anglo Asian said it had completed a scoping study for the Zafar underground mine, based on ore production of 700,000 t/y and a 0.5% copper equivalent cutoff grade. Development work and the construction of two portals has also started.

Included in the drilling fleet is an Epiroc Boomer S1 D, three Epiroc T1D jumbos, one Epiroc Simba S7 D and one Epiroc H1354. The Caterpillar machinery includes three 15-t payload R1700 LHDs and two UMA 980 wheel loaders.

Auxiliary units that will complement this fleet include a Paus TSL853 Central articulated steering telescopic swivel loader, two Tunelmak ADROIT 520-2 AH 4×4 hydrostatic basket platforms and one Tunelmak ADROIT 420AH 4×4 articulated hydrostatic shotcrete pump.

Anglo Asian produced 57,618 oz of gold equivalent for the year ended December 31, 2022, but, with the addition of Zafar and Gilar, it has an ambition to become a mid-tier miner producing over 100,000 oz/y of gold equivalent.

An expansion of the flotation plant at Gedabek, the company’s flagship opeation, is underway together with adding a further line to produce zinc concentrate, it said. The total cost of the expansion, which will see it add three new rougher/scavenger cells and four cleaner cells from Maelgwyn Mineral Services, is currently estimated at $3 million which will be paid from the company’s existing cash resources. Contractors have been appointed to supply materials for the new flotation line. Additional contractors will be commissioned to modify the existing building and provide electrical services and control equipment, it added.

The modifications to the flotation plant to increase its capacity have now been broadly completed. The installation of the new flotation line using hydraulic flotation cells will be completed by the end of the year.

Stephen Westhead, Vice President of Anglo Asian, said: “The new equipment will be used to expand the company’s mining and processing operations with the development of two new underground mines this year. The expansion of our flotation plant has been broadly completed, doubling capacity and creating additional processing flexibility. This represents an important step in our medium-term growth ambition to become a mid-tier production miner, and significantly increases our capabilities within copper.”

Caterpillar gears up for SME and CONEXPO-CON/AGG shows

Automation, Equipment maintenance, IoT, Mining equipment, Mining events, Mining services, Mining software, , , , , , , , , , , , , , , , , , , , , , , , , , , ,

Caterpillar has a busy few months lined up on the conference circuit, with major product releases, service options and technologies to be highlighted at the SME MINEXCHANGE 2023 event in Denver, Colorado, and CONEXPO-CON/AGG 2023 in Las Vegas, Nevada.

Focusing beyond the iron, the Caterpillar MINEXCHANGE 2023 exhibit will highlight the company’s innovation, technological advancements, and how Caterpillar is solving mining challenges today and innovating for the future. With its “Big Difference” theme, the company will showcase how it positively impacts miners and offers a range of careers within the mining industry at the event, which runs from February 26-March 1.

This includes:

  • Big Innovation – details how Caterpillar commits significant R&D investment to technology and automation that help mining customers succeed and contribute to a better, more sustainable world; and
  • Big Opportunities – covers career opportunities at Caterpillar for creating high-tech solutions.

Inside the Cat exhibit, a Cat D8 simulator will allow conference attendees to experience operating the dozer in a virtual environment. A video wall features the themed “Big” messages that include more details on Caterpillar and its mining solutions, autonomy leadership, a real-world sustainability journey and testimonials from Cat employees. Subject matter experts will be on hand to discuss Caterpillar’s latest technology, autonomy and equipment solutions for the mining industry. In addition, seven Caterpillar subject matter experts have been selected to present eight technical abstracts at MINEXCHANGE covering diversity in the workplace to technology and automation to implementing change management.

In Las Vegas at CONEXPO-CON/AGG 2023 from March 14-18, meanwhile, Caterpillar will highlight its latest products, services and technologies while paying tribute to those who build the world’s infrastructure in what is its largest exhibit to date at the event.

The company’s 6,500 sq.m outdoor demonstration arena will anchor the massive display known as Operator Stadium (visualisation pictured below)

New Caterpillar Technology, Services and Sustainability hubs provide visitors the opportunity to look for ways to increase operating efficiencies and improve machine uptime, while new and current models and battery-electric machine prototypes will be highlighted.

The extensive Cat® equipment display in the Festival Lot is set to include more than 30 machines, including model unveilings and battery-electric model prototypes with charging stations. Visitors will see two main equipment demonstrations each day; one focused on the latest Cat technology, and one that will spotlight the company’s full equipment line up. Additionally, Caterpillar will be providing daily spotlight demonstrations that will take a deep dive into key industry topics including improving fuel efficiency and job site efficiency, the evolution of technology, and convenient, scalable solutions for all customers.

The new Cat 950 medium wheel loader on display offers, Cat says, premium performance and simple-to-use technologies to help boost operator efficiency and increase productivity, while extended service intervals help lower maintenance costs. Visitors will be treated to a preview of the Next Generation Cat 926, 930 and 938 small wheel loaders – slated for production in late 2023 – which feature new technologies designed to make work easier, a reimagined operator environment and extended service intervals.

Caterpillar Industrial Power Systems Division, meanwhile, will exhibit a wide and rapidly growing portfolio of high-efficiency Cat industrial power solutions. The exhibit includes the unveiling of a new high power internal combustion engine, as well as lithium-ion battery technologies under development. Engines on display, such as the C3.6 IPU, C7.1 and C9.3B, meet EU Stage V, U.S. EPA Tier 4 Final emission standards and are compatible with biodiesel up to B20 and hydrotreated vegetable oil (HVO) to EN15940. The booth will also showcase Caterpillar’s technical services and market expertise leveraged by the global Cat dealer network to maximise the efficiency and extend the lifecycles of off-highway equipment, including Cat remanufactured and service replacement engines.

Caterpillar says it offers a range of service options that are easy, convenient, flexible and sustainable, and will be featured in the Services Hub at the event. The new Cat Central app is the latest tool for convenient access to genuine Cat parts and support. Another new service-related solution is the new Cat SIS2GO app which, Caterpillar says, takes the guesswork out of maintaining, troubleshooting and repairing Cat equipment. Both apps are available on Windows, iOS and Android platforms.

Team members from Cat Financial will also be available to discuss the latest leasing and financing programs.

The Caterpillar Technology Hub will offer attendees the ability to experience a range of new and existing Cat technologies – VisionLink, Cat Command, VisionLink Productivity, Cat Detect, Cat Grade and Cat Payload. Caterpillar SMEs will be on hand to assist each customer in finding a scalable solution designed to fit the business’s needs and budget.

Its centerpiece exhibit, the “Looking Glass” cube, displays and interactively showcases the five key capabilities of the new Cat VisionLink® application – Geofence & Location, Fuel Theft Alerts, Diagnostics, Idle Time/Fuel Burn, and Maintenance. An interactive wall will invite visitors to explore the full suite of VisionLink capabilities for both Cat and non-Cat equipment and non-machine assets.

The hub’s multiple Cat Command stations allow attendees to remotely operate Cat machines located more than 640 km away at the Tinaja Hills Demonstration and Learning Center. They are positioned to allow attendees to better experience and learn more about the Command for Dozing, Excavating and Loading technologies.

The Caterpillar Sustainability Hub will spotlight fuel efficiency and alternative power sources; technologies to fit every operation and budget; and parts and service designed to make uptime fast and easy, the company says. Plus, customers will learn about sustainability benefits they can choose today and plan for tomorrow.

Outside the Sustainability Hub, exhibit attendees can view components of Caterpillar’s total site solution for the energy transition, including four battery-electric machine prototypes – the Cat 301.9 mini excavator, 320 medium excavator, 950 GC medium wheel loader and 906 compact wheel loader – in addition to AC and DC charging solutions. The Caterpillar-designed batteries powering these battery-electric machines are built on lithium-ion Cat technology with a modular design that offers flexible configurations across multiple applications.

RCT helps automate dozer push operations at New South Wales tailings op

Automation, Mining equipment, Mining safety, Mining services, , , , , , ,

A well-known mine in New South Wales, Australia, is now operating an autonomous dozer fleet safely and efficiently thanks to the deployment of RCT’s latest solutions, the METS company says.

The technology empowers equipment operators to stand at a safe vantage point overlooking the work zone and direct the dozer fleet to maintain a tailings dam wall on site.

The project means the autonomous dozers can push the top of the tailings dam wall and work close to edges in a way deemed as impossible to achieve safely with operators in the machine’s cab.

Mine management selected RCT’s ControlMaster® solution over global OEM tenders due to the technology’s ability to be repurposed to other mining equipment based on changing fleet demands in the future, RCT, now owned by Epiroc, said.

RCT’s Customer Service team recently mobilised to the site and commissioned ControlMaster onto two Cat D8T dozers and are continuing to support the site on an ongoing basis.

RCT Account Manager, Wayne Carrington, said the project is just the latest in a successful business relationship with the mine which stretches back many years.

“We are very pleased to provide the site with fit-for-purpose technology which safeguards their personnel while enabling them to complete vital works,” he said. “The feedback from site has been very positive with the operators loving the functionality of the solution and management is reporting that they are meeting their targets.

“The ControlMaster technology is vital to the success of this tailings dam project but, in the future, the solution can easily be integrated with any other piece of mining equipment and provide additional benefits to the mine.”

RCT turns Gold Fields’ Granny Smith mine into ‘digitally connected powerhouse’

Automation, Communications in mining, IoT, Mining equipment, Mining services, Precious metals, , , , , , , , ,

RCT’s latest partnership with Gold Fields in Australia has seen, it says, the transformation of the Granny Smith mine and machine fleet into a state-of-the-art, digitally connected powerhouse.

The project, which RCT says embodies the mining company’s key value of innovation, is designed to increase productivity.

Gold Fields’ Granny Smith mine is no stranger to RCT, having been one of its technology partners for more than 20 years.

This latest project has seen the Eastern Goldfields underground gold operation become one of the most innovative, digitally-connected mines in the world, according to RCT. The project saw its Kalgoorlie-based team of innovative technicians upgrade the site’s six existing Caterpillar loaders from analogue to digital.

This required the Kalgoorlie branch team to design and build specialised mounts and overhaul the site’s existing cabins. In addition, a total of 11 Area Access Controls (AAC) were also converted from analogue to digital to facilitate the upgrade.

“We recognise that they made a significant investment into the original technology, and we wanted to find the most cost-effective and sustainable solution available,” RCT’s Kalgoorlie Branch Manager, Rick Radcliffe, said.

The team converted three of the site’s existing analogue TeleCabins and transformed them into digital ControlMaster® Automation Centres for underground use and two surface Automation Centres to digital, bringing them into the future.

The site chose to use RCT’s own full-scale digital communications solution – RCT Connect – to meet the demands of autonomous machines across the mine site. The technology will cater to Granny Smith’s current and future machines, according to RCT.

The Kalgoorlie branch finished the upgrades in December last year, and although the technology has only been in place for a few months, the site has experienced amazing results from day one, according to the company.

Granny Smith Mine Manager, Michael Place, said: “The ability for the operators to mine from the surface with a pristine picture/video thanks to the digital network has meant they have been able to increase the number of buckets per shift, while adding to the comfort of the operators.

“Implementing the new digital infrastructure RCT Connect has significantly improved both the availability and reliability of Granny Smith’s semi-autonomous remote production loaders and stoping fronts to date.”

The upgrade saw the popular analogue technology that uses the Yagi antenna replaced with RCT Connect.

Radcliffe added: “While the Yagi’s have been a tried and tested technology for many years, our digital RCT Connect Access Points has taken the Control Master underground communications system to another level. The system is now more reliable and provides a clearer picture and improved operator visibility.

“The feedback we have received from site is that the operators love the new technology and they wished they implemented it ages ago.”

As well as experiencing the significant benefits of digital technology today, Granny Smith is futureproofing its operations, allowing it to make small, incremental changes as and when they are ready, RCT said.

RCT Connect, RCT says, is a plug-and-play system, making it easy to install and maintain. The technology has produced a clearer picture, which has greatly assisted Granny Smith personnel to continue operating their machines safely in high-risk locations.

Radcliffe concluded: “Another added benefit to moving to digital is that RCT can now remotely support our clients to a higher level and are able to monitor and complete repairs in a short timeframe, as it eliminates the need for a technician to travel to site to troubleshoot in many cases.”

U.S. Gypsum and Altorfer Cat overcome logistical hurdles in AD30 delivery to Sperry

Energy minerals, Mining equipment, Mining services, , , , , , , ,

U.S. Gypsum’s (USG) Sperry mine in Iowa, USA, has added another large piece of Cat equipment to its underground loading and hauling fleet – this time a 30-t payload Cat AD30 underground truck.

Located 192 m below the surface and accessible only by a shaft measuring 1.5 m x 1.8 m, the only way to get the new equipment into the mine was to disassemble, lower and reassemble it underground.

USG has successfully commissioned three Cat® R1600 underground loaders over the last decade, relying on Altorfer Cat, the Cat dealer serving a three-state region that includes the Sperry location near Mediapolis, Iowa.

Several of the Altorfer team members responsible for the first mine transfer of the R1600s were also on hand for the AD30 transfer, including Sales Representative, Jeff Krug, and Field Technician, Chris Wolf.

“Altorfer and United States Gypsum have had a relationship for many years, starting with surface equipment,” Krug says. “When the opportunity to offer Cat mining solutions for their underground equipment materialised, the mine quickly realised there were many of the same components in the underground machines as on the surface. Parts availability and a strong service partnership made it much easier for them to switch to Cat machines.”

Since 1959, the underground Sperry operation has produced gypsum and now produces over 590,000 t/y of raw gypsum. Most of the mine’s gypsum is used in the on-site manufacturing plant, where USG makes Sheetrock® brand wallboard. Gypsum also has medicinal and agricultural uses.

The room and pillar mine has an average ceiling height of about 3 m. Gypsum is mined using the drill and blast method, then the rock is hauled to the mine’s crusher.

“The physical size of the mine has always been a limiting factor for selection of mobile equipment,” Dennis Hollingsworth, former Mine General Foreman, says. “When Cat started producing more underground equipment, it created a new choice for us – first with the R1600s, and now the AD30.”

After the successful implementation of Sperry’s R1600 fleet, Altorfer developed best practices for the mine transfer process that were shared with other dealers around the world. Taking advantage of those lessons learned, the Altorfer team spent several weeks planning and collaborating with the Sperry team before beginning the AD30 transfer.

First, the AD30 arrived at Altorfer’s Cedar Rapids, Iowa, facility, where it was adapted to the specific requirements of the mine. The bed was removed and modified so it could meet the 1.8-m height requirement for loading. In addition, tyres were replaced with a lower profile tyre to meet the maximum height requirement of the mine.

Finally, the machine arrived on the surface of the Sperry mine. Joining Wolf were two Sperry employees who also worked on the R1600 mine transfers: Mine Maintenance Supervisor, Doug Edle, and Technician, A.J. Kuisle.

“Taking the machine apart is the most important part of the process,” Wolf says. “You need to remove things in a precise order, be two to three steps ahead and have a plan for keeping track of everything.”

The team removed the rear axle and all the cooling lines and wiring harnesses from the rear frame, then separated the rear frame from the front frame. Then they tackled the front frame, removing the cab, engine transmission and front axle and lowering them into the mine. Next was the removal of the fire suppression system and wiring harnesses, as well as hoses and valves.

Once everything was removed from the front frame, the team welded on fixtures they would use to line up the frame pieces for reassembly. Then the cutting began, with oxyacetylene torches and an air arc being used to cut the frame into smaller pieces that would fit down the shaft.

Once all the pieces and parts were down the shaft, the AD30 was cleaned and the welding team put the frame back together. Then Wolf and Kuisle got busy reassembling the rest of the machine.

“It took about three weeks to get it back together and running,” Wolf said. “We were very particular to make sure that everything was assembled correctly, that there were no hoses or wires rubbing. Then we started it up and installed the bed and made sure everything was working correctly.”

Hollingsworth is proud of the teamwork involved in the machine transfer. “Getting new equipment underground has always been a challenge,” he says “Bringing a new piece of equipment underground and re-assembling it has always been a process that our mechanics take pride in being able to accomplish. Chris Wolf has a been a part of that process four times now, and I think, feels the same way. He has done a great job helping with the teardown and reassembly of all four Cat machines.”

Altorfer’s role in the life of the new AD30 didn’t stop once the machine was assembled underground. Before handing off the keys, the team took it for a test drive. When the testing was complete, Wolf provided training to the employees who would be operating the new truck.

“The training process went well,” Hollingsworth says. “Chris came in on both shifts and trained all of the operators. It’s something we’ve come to expect from Altorfer that we don’t typically get from other manufacturers.”

And finally, about four-and-a-half weeks after the mine transfer process began, the AD30 went to work.

Hollingsworth said the mine’s satisfaction with its Cat R1600s, the long life and rebuildability of Cat machines, and the quality of Altorfer’s service all contributed to the decision to purchase the AD30. “The AD30 has been a great addition to the mine fleet,” he says. “The truck is running great. The operators took to it quickly. They like the way it drives and performs.”

Just like Sperry mine’s other Cat equipment, the new machine will be supported throughout its life by Altorfer, with more new Cat machines continuing to join the mine’s fleet in the years to come.

Duratray Suspended Dump Bodies on their way to Kibali gold mine

Equipment maintenance, Mining equipment, Precious metals, Steel and iron ore, , , , , , , ,

A new fleet of Duratray Suspended Dump Bodies (SDB) for Caterpillar 777-05 mining trucks has been completed and shipped to the Democratic Republic of the Congo (DRC) for use at the Kibali gold mine in the country.

Following manufacture in Turkey, the steel frames will be transported on sea to Kenya, then 1,800 km overland through Uganda until reaching their final destination at the Kibali mine.

Kibali is owned by Kibali Goldmines SA which is a joint venture company effectively owned 45% by each of Barrick and AngloGold Ashanti, and 10% by Société Miniére de Kilo-Moto. The mine is operated by Barrick.

Duratray International Project Manager, Csaba Nagy, said the Kibali contract represented the first post-COVID collaboration with the company’s fabriactor in Turkey, which had resulted in great success, despite current challenges such as labour shortages and high demand for steel. Simultaneously, the rubber wearmat kits, fixings, special tools and spare parts were shipped from Duratray’s principal manufacturing facility in Melbourne, Victoria.

The four Caterpillar 777-05 dump bodies will be transported in preassembled parts. Steel frame assembly then rubber component installation will take place at Kibali mine by a Duratray International Field Service crew from South Africa.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Newmont hits 100 Mt automation milestone using Cat Command for hauling at Boddington

Automation, Mine operation news, Mining equipment, Mining software, Precious metals, , , , , , , , ,

Western Australia’s largest gold mine, Boddington, has surpassed the 100 Mt milestone for material safely hauled using Cat® MineStar™ Command for hauling with the gold industry’s first autonomous haulage system (AHS) fleet, the OEM says.

Boddington, a deep open-pit surface mine owned by Newmont, delivered 696,000 oz of gold and 163,000 gold-equivalent ounces in 2021.

The mine’s fleet today includes 36 Cat 793F autonomous and four 793D staffed mining trucks to haul material, and the conversion to AHS was one of the fastest in the industry, spanning approximately seven months to roll out all 36 trucks equipped with Command, according to Caterpillar.

Newmont invested $150 million in its autonomous haulage project with goals to improve mine safety and productivity, while extending the life of the mine. The first 231-t Cat 793F was converted to autonomous operation in March 2021. A total of seven trucks from Newmont’s existing fleet were retrofitted with Command for hauling, while 29 trucks were new models.

In October 2021, the last of the 36 autonomous trucks went into operation at the mine, with the mine reaching the 100 Mt of material autonomously hauled benchmark by the end of October 2022.

Kosie Bolton, Technology Site Manager for Caterpillar, said: “The time period between rollout of the mine’s first autonomous 793F truck to full conversion of the mine’s autonomous fleet to achieving 100 Mt autonomously hauled was incredibly short. This is a true testament of the great teamwork between Boddington’s talented and dedicated workforce, Cat dealer WesTrac and Caterpillar. The supporting AHS projects will help to improve data understanding and drive operational excellence through data utilisation.”

Including the autonomous trucks, equipment equipped with MineStar Terrain, and site autonomous vehicles and trucks, the mine has 200 connected assets. An entirely new AHS intelligence office, where all the autonomous trucks and connected assets can be viewed and collected data analysed, was also completed and dedicated in October 2022. The new workspace brings together all AHS team members in a single space with tiered seating and screens at the front of the room, Caterpillar says.

James Earl, AHS Control Room Superintendent for the Newmont Boddington Mine, said: “Having everyone together in the new office allows us to post issues on the screens in front of all workers to quickly address them together. We are extremely proud to deliver the gold industry’s first autonomous haul truck fleet at Boddington. This will help extend the mine’s life, reduce safety risks and lower costs. The project’s record implementation is just another example of Newmont’s trademark ability to set and achieve ambitious goals.”

On top of this milestone, Caterpillar and Newmont agreed in November 2021 to collaborate on a number of mining technology initiatives that provide industry leading outcomes for safety, productivity, sustainability and cost.