Tag Archives: Caterpillar

Cat energy storage, microgrid and Dynamic Gas Blending solutions on show at MINExpo

Environmental, Mining events, Power supply for mines, Sustainable mining, , , , ,

At MINExpo 2021 next week, Caterpillar Inc is highlighting the company’s wide range of industry expertise combined with power solutions that, it says, deliver the reliability, efficiency and sustainability for boosting the performance of mining operations.

MINExpo 2021 is set to run from September 13-15 in Las Vegas, USA.

These power solutions range from Cat® Energy Storage, Cat Hybrid Microgrid Systems and fuel-flexible Dynamic Gas Blending (DGB) solutions, which are all included in the company’s portfolio of renewable power solutions. The wide variety of these solutions supports customers’ sustainability goals and can be configured to minimise their greenhouse gas footprints while also reducing total cost of ownership, according to Cat.

Jason Kaiser, Vice President, Caterpillar Electric Power Division, said: “Power needs vary widely from mine site to mine site, and they are becoming increasingly complex as mining companies address the sustainability requirements of their environmental, social and corporate governance initiatives. With our decades of experience in the mining industry and full portfolio of technologies – including numerous solutions that readily incorporate renewable energy sources – Caterpillar can supply integrated power solutions designed, installed, and supported from a single source to ensure superior performance over the long haul.”

Caterpillar says it offers a complete technology suite of hybrid energy solutions designed to reduce fuel expenses, lower utility bills, decrease emissions and reduce the total cost of ownership while increasing energy resiliency in even the most challenging environments. Key components include Cat Photovoltaic Solar Modules, the Cat Master Microgrid Controller, Cat Connect Remote Asset Monitoring, Cat Bi-Directional Power inverters, Cat Energy Storage System modules and Cat generator sets.

Enerpac EVO solution gives WesTrac and Cat 994K wheel loader a needed lift

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

Enerpac’s EVO synchronous lifting system has come to the rescue of WesTrac in Western Australia, with the Caterpillar dealer in need of an efficient, portable and safe solution to lift its Cat® 994K wheel loader.

The system needed to be operated independently without manual intervention and provide a locking function during the lift, according to Enerpac.

The 200 t Cat wheel loader had to be lifted to a height of 400-450 mm with an accuracy of +/- 2 mm across four lift points: a process carried out on uneven ground, which caused the lifting points to be at different heights. The lifting equipment needed to work independently to the pump and required forklift pockets so it could be manoeuvred into place easily, according to Enerpac.

Enerpac recommended its EVO synchronous lifting system, which, the company says, allows one device to control the entire lifting operation while providing status updates at every point of the process without the need for manual monitoring. By digitally monitoring and controlling lifting operations, users enhance safety and eliminate costly downtime, it says.

“Utilising proven synchronised lifting technology, combined with an expertise in high tonnage cylinder manufacturing, a customised Enerpac solution was developed to provide a high-precision lifting system to lift the Cat wheel loader on challenging ground conditions,” Enerpac explained.

Sanjesh Balgovind, Heavy Lifting Technology Special Projects Manager, Enerpac, said: “With an intuitive user interface, the custom EVO synchronous lifting system is easy to set up and control. It combines high pressure hydraulics and computer controls to monitor and control precise lifting and movement of heavy loads, such as WesTrac’s 200 t Cat wheel loader.”

Assembling and transporting over-dimension vehicles like the Cat wheel loader requires several steps, according to Balgovind.

“It often involves locating and positioning the lifting equipment at the appropriate lift points, removing the wheels, attaching wheel stands, and lowering the vehicle to the ground followed by removing the lifting equipment,” Balgovind says.

“Thereafter, a multi-wheel trailer would be placed under the vehicle and the wheel stands removed before it is ready for transportation. Using short stroke cylinders without synchronous lifting would be time-consuming, cumbersome and could introduce additional risk if the load is lifted at different heights.”

Through an integrated human machine interface, all movements are operated from a central control system displaying live operation and real time status updates of each lifting position. The Enerpac EVO system can deliver an accuracy of up to 1 mm across all lift points and provides stroke feedback and indicative load at each point, according to the company. In addition, there are built-in warning and stop alarms to ensure optimum safety.

The custom HCRL-Series 100-ton (91 t) 18 in stroke cylinders have servo motor-driven lock nuts that provide mechanical load holding across all lift points for a safe work environment, according to the company, while its hardened and robust surface is designed to resist side-loading and cyclic wear. The locknut drive controller is mounted on the cylinder and keeps the locking collar 3-6 mm from the cylinder body. The cylinders are then affixed in custom steel frames with lifting pockets.

The lifting frames are then placed at the respective lift points with forklifts and connected to a custom EVO-Series synchronous lifting system, ready for lifting. As the rear of the truck requires a higher lift point, the frames are further attached to stands for additional height. The cylinders are then placed at the respective lift points with forklifts and connected to the EVO system, ready for lifting. A flow of 3 litres per minute is used to ensure that the locking collar adjustment can keep up with cylinder extension and retraction.

“At a rate of 1 mm/s, the wheel loader is lifted with significant safety and productivity gains,” Balgovind says. “The auto-locking cylinders provide an improved safety application as the load is always mechanically locked during both lifting and lowering operations.

“It is a safe and effective solution for applications with potential safety risks of working with hydraulic-suspended loads. In addition, given the portability of the system, it was brought to site easily and could function in a convenient manner.”

Caterpillar to add hydrogen to generator, power generation solution mix

Environmental, Mining industry recognition, Mining services, Power supply for mines, , , , ,

Caterpillar Inc says it will begin offering Cat® generator sets capable of operating on 100% hydrogen, including fully renewable green hydrogen, on a designed-to-order basis in late 2021.

More immediately, the company will launch commercially available power generation solutions that can be configured to operate on natural gas blended with up to 25% hydrogen, it said.

“These market-focused innovations build upon Caterpillar’s hydrogen solutions portfolio, including Solar® Turbines’ gas turbine generator sets, which have run on high hydrogen blends for decades and are capable of operating on 100% hydrogen today,” the company said. “The ability to work with hydrogen fuel helps address customers’ carbon-reduction goals with high-performing, cost-effective technologies.”

Joe Creed, Caterpillar Group President of Energy & Transportation, said: “At Caterpillar, we are working alongside our customers to understand their needs, and they are looking for reliable power sources that support their climate-related goals. Our continued investment in new products, technologies and services is one way we’re supporting them with the quality solutions they’ve come to count on from Caterpillar.”

With the reciprocating engine capabilities of up to 100% hydrogen, Caterpillar says it is expanding on its legacy in gas engines and Solar gas turbines with more than 35 years of experience with high-hydrogen fuel.

It added: “Caterpillar continues to make investments aimed at improving the capability of hydrogen-powered solutions and replicating them across engine platforms as this fuel will likely play a role in customers’ plans for a reduced-carbon future.”

Australia’s IMARC mining event rescheduled to January 2022

Mining events, , , , , , , , , , , , , , , , ,

Due to ongoing travel and gathering restrictions, and the rise of COVID-19 infections around Australia, Beacon Events, the organisers of the International Mining and Resources Conference (IMARC), has today announced its decision to reschedule the 2021 edition.

IMARC 2021 will move to the new dates of January 31-February 2, 2022, with the hybrid event taking place in-person at the Melbourne Showgrounds, and online for those that cannot attend in-person.

IMARC Managing Director, Anita Richards, said that while it is disappointing that the event has had to be postponed from 2021, it is the responsible action to take under the circumstances as the health and safety of IMARC’s participants is our number one priority.

“The rescheduling comes after much deliberation with our founding partners, and in consultation with our sponsors, exhibitors, supporters and various Victorian Government agencies who have been very supportive of the decision,” she said.

Victorian Government’s Head of Resources, Department of Jobs, Precincts and Regions, John Krbaleski, added: “IMARC is a home-grown industry event that has become a major international resources conference. There is significant interest in IMARC and it’s clear that industry is keen to see it go ahead in January 2022.”

Austmine CEO, Christine Gibbs Stewart, said: “Considering the health and safety of our members, delegates, and staff members, we support postponing IMARC 2021 until January 2022. We know how important this event is to our members who are exhibiting and attending, as well as the METS sector overall, and we encourage everyone to consider this as an opportunity to refocus your efforts and support the event in 2022.”

AusIMM CEO, Stephen Durkin, added: “We’re looking forward to reconnecting with our mining community at IMARC in January 2022. The rescheduled event will provide an opportunity for delegates to network with leaders and experts from across the sector and take part in thought-provoking conversations about the future of our industry.”

BHP, MMG, Newcrest, Mitsui, OceanaGold and Kirkland Lake Gold have all confirmed their continued support for IMARC in January 2022, with their executive leadership teams confirmed to speak within the conference program, Beacon Events said.

In addition to the Federal Minister for Resources, the Hon Keith Pitt, and major sponsors METS Ignited, Caterpillar, ABB and World Gold Council who have also confirmed their support and participation.

IMARC 2021’s new dates are aligned with the expected easing of restrictions from all states across Australia, allowing for strong domestic representation, according to Beacon Events.

Richards said: “Holding IMARC at the start of 2022 helps create a unique opportunity for the industry to kick off the year with new conversations, develop existing relationships and create business opportunities for the coming year. With better weather comes opportunities for outdoor events and networking, alongside some major events at that time of year here in Melbourne.”

There is an expectation that when IMARC returns in 2022, from October 17-19, there will be greater international travel freedoms, allowing for the conference to attract a large domestic and international audience in-person once again, Beacon Events said.

International Mining is a media sponsor of IMARC

New Cat 6040 hydraulic shovel receives added engine configuration, new undercarriage

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

Caterpillar has revamped its 6040 hydraulic mining shovel with an added engine configuration to meet US EPA Tier 4 Final and EU Stage V emission standards, new heavy-duty undercarriage, as well as enhanced integration to improve servicing efficiency and parts sourcing.

The new engine configuration includes two Cat C32 engines, offering a total gross power rating of 1,550 kW. The engine package includes maintenance-free diesel oxidation catalysts and does not require diesel exhaust fluid/AdBlue or diesel particulate filters.

The new engine option joins the twin C32 configuration with optimised fuel efficiency settings to meet China Nonroad Stage III emission standards, equivalent to US EPA Tier 2, as well as China Smoke Category III limits. An engine oil extension option, plus new Cat Type 4 filters for both engine configurations, help to further reduce maintenance costs.

Connecting to Cat MineStar™ Solutions’ suite of integrated technology, new Product Link Elite comes standard on the 6040 shovel.

Product Link Elite delivers enhanced communication through a dual data path, allowing data transfer to both the local server and cloud simultaneously. Caterpillar’s next generation of on-board hardware, Product Link Elite features an easily configurable interface and customisable data-push frequency, Cat says. Information transfer from the equipment can be configured via cellular, satellite or mine network connection to meet the mine site’s needs.

The new 6040 shovel delivers increased uptime with its heavy-duty undercarriage, Cat claims. Improved heavy-duty load rollers and idlers now feature duo cone seals, steel-back bronze bearings and fixed axle technology to increase service life and eliminate overheating during travel. Track pad, tensioning and wear updates deliver a higher level of durability and reliability to lower operating costs. Retrofit kits for the heavy-duty rollers are available for field units to improve existing fleet reliability.

Like previous series, the new 6040 shovel can be equipped with backhoe or Cat TriPower™ Face Shovel front end designs. To deliver high machine reliability in harsh mining conditions, the rugged front attachments feature high-strength steel and castings, joined and thermally stressed-relieved, to extend service life and achieve production targets. With its 39.6 t bucket payload, the 6040 shovel offers an optimal four-pass match with the Cat 785 haul truck, five-pass match with Cat 789 and six-pass match with Cat 793 mining trucks, Cat says.

For the first time, the new Cat 6040 hydraulic mining shovel fully integrates the undercarriage, engine module, superstructure main frame, carbody and crawler frames, hydraulic lines and motors, and counterweight into Caterpillar systems to improve servicing efficiency and parts sourcing.

Alkane boosts Tomingley UG mining fleet with Sandvik, Epiroc, Cat and Volvo equipment

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

Alkane Resources is rolling out a A$16 million ($11.8 million) upgrade of its underground mining equipment fleet to support the development of the Tomingley Gold Extension project in New South Wales, Australia.

Alkane’s Tomingley Gold Operations (TGO) recently received a new Sandvik DL432i production drill, a fully-mechanised, highly versatile and compact electro-hydraulic top hammer longhole drill, to replace an older model drill, it said.

TGO, which recently replaced three of its Cat 2900 loaders, will also soon be receiving four new Epiroc MT65 trucks (65 t payload), four Volvo integrated tool carriers, as well as a Cat 140M grader and a new development jumbo drill.

TGO General Manager, Jason Hughes, said: “Our original underground second hand fleet has done a great job getting the project started with a very low capital outlay for what was a planned three-year mine life. Now, with an extended underground mine life out until at least 2026, it’s time to replace it with a new modern fleet.

“By committing A$16 million to a new fleet, we will be ensuring TGO will be an efficient and productive mining operation well into the future.”

The mine produced 56,958 oz of gold in the 12 months to June 30, 2021, with plans for it to produce 55,000-60,000 oz in the 12 months to June 30, 2022.

Finning captures large Cat equipment order from Codelco’s Andina, Chuquicamata mines

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

Caterpillar’s relationship with Codelco in Chile continues to strengthen with the OEM, through its Finning dealer, set to deliver mining support equipment and underground loaders to two of the copper miners’ operations.

The orders, revealed in Finning’s June quarter 2021 results, contributed to a building equipment backlog in mining and construction registered during the three-month period in South America.

New equipment sales were up 48% year-on-year in the June quarter in South America and up 14% from the March quarter of this year, driven by improved market activity, mostly in construction, Finning noted.

Finning’s backlog in South America included the Codelco orders.

First was a recently awarded order for Caterpillar support equipment from Codelco’s Andina mine, valued at C$40 million ($32 million), for delivery in the first half of 2022. In addition, the company plans to provide 27 Caterpillar R3000H underground loaders to Codelco’s Chuquicamata mine, with 10 of these machines included in its June quarter backlog.

The 20 t class R3000H was launched in 2012 and remains Cat’s largest model. It replaced the R2900 XTRA, providing added value for hard rock mine operators with a significant increase in truck loading capacity, being able to three pass load 60 t class trucks, and having enhanced digging and breakout performance, faster speeds on grade, a strengthened front frame, and an available Ventilation Reduction Package. Since then there have been a number of deployments of the LHD but there are only a few underground mines in the world with a potential requirement for large numbers of loaders of this class at one operation. One of these is Codelco’s new Chuquicamata Underground blockcave copper mine. This is one of the largest single large LHD orders ever made and will help the mine achieve its intended production rate of 140,000 t/d which is a rate on a par with sister operation and the world’s largest existing underground copper mine, El Teniente. Chuqui Underground includes four levels of production; a 7.5 km main access tunnel, five clean air injection ramps and two air extraction shafts. It will produce 366,000 t of fine copper and more than 18,000 t of fine molybdenum per year & extending Chuqui’s minelife to 2060.

Overall, Finning registered June quarter revenue of C$1.8 billion and net revenue of C$1.7 billion, up 30% and 28%, respectively, from a year earlier when COVID-19-related reductions in market activity hit.

All regions delivered a strong quarter, demonstrating operating leverage in a recovering market, Finning noted. June quarter EBIT as a percentage of net revenue was 9.3% in Canada, 9.8% in South America and 5.3% in the UK & Ireland, representing a step-up in profitability levels for all regions, the company said.

The company’s consolidated equipment backlog at June 30, 2021, increased to C$1.4 billion, from C$1.2 billion at March 31, 2021, with order intake in Canada and South America outpacing deliveries in the quarter, Finning said.

“We are pleased with our strong execution and results in the second (June) quarter,” Scott Thomson, President and CEO of Finning International, said. “With a reduced cost base and more efficient operations and supply chain, we are confident in our improved earnings capacity, which puts us firmly on track to achieve the mid-cycle targets we set out during our Investor Day in June.”

 

WesTrac to rebuild Rio’s Pilbara dozers at Geraldton facility

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

Rio Tinto, WesTrac and the Western Australia Government have agreed on a project that will see dozers from Rio’s Pilbara operations head to WesTrac’s Geraldton facility for rebuilds, with up to 54 machines committed between 2021 and 2025.

Western Australia Regional Development Minister, Alannah MacTiernan, welcomed the news, saying it would provide a major boost for the Mid-West’s mining equipment, technology and services (METS) sector.

The project was negotiated between the State Government through the Mid West Development Commission and industry after feasibility studies identified WesTrac’s Perth and Pilbara facilities were at capacity and unable to accommodate the additional repairs and maintenance required by Rio’s mining operations.

The Geraldton facility will receive up to 12 dozer rebuilds annually, from various Pilbara operations, according to the statement.

The project will support two new, localised apprenticeship opportunities in the Mid-West as well as creating new local skilled jobs and providing pathways to employment with Rio Tinto, the government said. The project also reduces transport times and negates logistical difficulties mining companies face getting heavy machinery in and out of the metropolitan area.

“The state will look to expand the initiative into a cross-regional Smart Specialisation project with linkages to the Kimberley and Goldfields regions, using the Mid-West as a demonstration pilot,” it added.

MacTiernan said: “This is a fantastic initiative that will see more work carried out in our regional centres, rather than shifting to Perth. It confirms that geography is not a barrier to global success for our regionally-based METS facilities, but in fact an advantage.”

Rio Tinto Port, Rail and Core Services Managing Director, Richard Cohen, said: “Rio Tinto is committed to growing regional Western Australia by supporting jobs and training opportunities for local people. Regional investment initiatives like the METS project will deliver ongoing benefits to the local economy.

“By unlocking the capabilities of the Geraldton WesTrac branch, we are significantly reducing transport time by removing the roughly 900-km round trip to Perth. This will lower costs, improve productivity and reduce the risk of driving related incidents that can occur on congested metropolitan roads.”

WesTrac CEO, Jarvas Croome, said the company was committed to developing capacity and capability throughout the state.

“Like many providers in the METS sector, WesTrac is seeing strong demand across all areas of our business due to the level of mining and construction activity,” he said. “That applies to new and used equipment sales, training, maintenance services and equipment rebuilds, and if there are opportunities to expand our offerings in regional centres and provide efficient outcomes for our customers, we’ll happily consider them.”

As well as multiple metropolitan operations, WesTrac currently has branches in eight regional centres including the major Western Australia mining regions. The company also operates as the authorised dealer of Caterpillar equipment in New South Wales and the Australian Capital Territory.

Berco bolsters Excavator Line with Cat 6020B undercarriage replacement range

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

Berco, a leader in the manufacturing and supply of undercarriages and components to OEMs and the aftermarket, has reached another milestone with the launch of its complete undercarriage replacement range for the Cat 6020B hydraulic mining shovel.

Developed specifically for the high-quality demand mining segment of the aftermarket, this is the first “non-captive” range available to purchase, according to the company. This means that aside from Cat, Berco is the only company currently capable of providing a full and significantly more affordable variety of undercarriage replacement components for this particular machine, Berco said.

Launched in 2014, the Cat 6020B is a 230 ton (224 t) excavator at the high end of the mining range. Depending on the abrasiveness of the soil, undercarriage components need to be replaced every four-to-five years, according to Berco, meaning there are significant numbers of this particular model currently due undercarriage maintenance. This number, moreover, is forecast to grow in the coming years.

To meet this demand, Berco is supplying a full range of undercarriage components including the chain, the bottom rollers, the top rollers, the drive sprocket and idlers with supports. Everything is set to be available from September onwards.

“These machines must be capable of working in harsh environments for 20-24 hours a day without stopping, because when the main excavator on a site is out of service, it has a direct knock-on effect on all of the secondary machines,” Diego Buffoni, Head of Aftermarket Berco, said. “We are particularly proud of this new range launch, which will offer a great business opportunity for our partner distributors worldwide. On top of Berco’s acclaimed high quality, which it provides, it also signifies the path we are on, which is to supply comprehensive and affordable solutions to all aftermarket customers.”

For the Cat 6020B hydraulic mining shovel range, Berco used a “reverse engineering” process to deconstruct the original equipment components. Three-dimensional material scanning was carried out to gain a complete understanding of the initial design criteria, while laboratory analysis determined the materials used as well as the heat treatments and microstructures.

“Having gained a full understanding of all of the components in question, company engineers then proceeded to develop their very own Berco-quality aftermarket undercarriage system, which is further boosted by the addition of another Berco innovation: BPR2™ (Berco Positive Pin Retention2™ system),” the company said. “This improves the working lifetime of the components by mechanically locking the link to the pin which results in the avoidance of ‘end-play generation’ and ‘pin walking’ in an undercarriage.”

For the track chain, a newly designed track link with a 350 mm pitch was produced using the “drop forged” process made from a mild carbon steel grade with boron. Unlike the original equipment product, however, the chemical composition of the Berco version is enriched with chromium to increase tensile resistance. In addition, the track bushing has a high resistance to wear. With 60 HRC hardness, it can contain pitch elongation, according to the company. The case depth has also been increased by 20-25% when compared with the original. The track pin, moreover, has deeper case depth and higher core hardiness, resulting in an improved bending load resistance, Berco said.

The track roller can, because of its lubrication and seal features, adopt an “all-weather” configuration, ranging from -40°C to 50°C. Additionally, three top rollers without a central flange support the heavy weight of the chain, and the oil filling hole has been moved to the outer collar to ensure full access to it.

With Berco’s Dozer Line already complete, the launch of its range for the Cat 6020B hydraulic mining shovel brings the company closer to finishing its Excavator Line too.

Accounting for a large portion of all aftermarket sales, Berco says the mining market segment is of particular importance to it. The company is now looking to further strengthen its position by extending its mining ranges and becoming the only high-quality alternative to OEM components.

Newmont to add to Ghana gold production with Ahafo North development

Mineral project development, Mining equipment, Mining finance, Precious metals, , , , , , , ,

Newmont Corp’s Board of Directors has approved advancing the Ahafo North project, in Ghana, into the execution phase, setting the company up to develop four open-pit mines and a standalone 3.7 Mt/y plant.

The project exceeds the company’s required internal rate of return, adding profitable production from the best unmined gold deposit in West Africa, it said.

Newmont President and CEO, Tom Palmer, said: “I am pleased to announce the approval of full funding for the Ahafo North project, expanding our existing footprint in Ghana and adding more than 3 Moz of gold production over an initial 13-year mine life. The development of this prolific orebody will leverage our proven operating model and will be supported by our existing world-class Ahafo South operation.

“The project will be developed and operated in a sustainable and responsible manner to create value for all our stakeholders.”

Located some 30 km north of Newmont’s existing Ahafo South operations (pictured) – which are expected to produce 515,000 oz of gold this year – Ahafo North’s production is expected to average approximately 275,000-325,000 oz/y with all-in sustaining costs of $600-$700/oz for the first five years. Projected capital costs are estimated to be between $750-$850 million with construction expected to be complete in the second half of 2023. At current gold prices, the project is expected to deliver more than a 30% internal rate of return, Newmont said.

The project will create approximately 1,800 jobs at the peak of construction with more than 550 permanent roles created once the mine is operational.

“Newmont will work to create lasting value for host communities through local sourcing and hiring,” the company said, adding that a key aspect of the Ahafo North project’s workforce planning will be a target to achieve gender parity in the workforce when operations begin.

The full scope of funding will be deployed to high-impact activities, including but not limited to finalising engineering and EPCM services, relocating the national highway and support of additional resettlement activities, mining development for four open pits, constructing and commissioning a 3.7 Mt/y plant, constructing a tailings and wastewater management storage facility, long-lead sourcing including the acquisition of 14 Caterpillar 770 haul trucks.