Tag Archives: Electric Rope Shovels

Komatsu P&H 4100XPC electric rope shovels reduce truck waiting times at Capstone Mantoverde

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The recent arrival of two Komatsu P&H 4100XPC electric rope shovels at Capstone Copper’s Mantoverde operation in Chile is significantly reducing waiting time for haul trucks at the open-pit mine, the company says in its latest sustainability report.

These large buckets – two of four that the company committed to purchasing in 2022 – are able to move approximately 4,000 t/h of material per hour, and require not only operators in the cab, but also personnel to move the medium-voltage (7.2 kV) cables that supply power to the shovels, to accommodate the needs of the shovel operators.

The nominal payload of the P&H 4100 XPC is 108.9 t, making it ideal for loading 218 t to 363 t haul trucks and high capacity (8,000 t/h-plus) in-pit crusher-conveyor systems, Komatsu says.

Jamie Figueroa, an experienced operator with both diesel and electric shovels, said: “The electric shovel makes our jobs much more productive. It makes much less noise than a diesel shovel and has no emissions. It is a win-win on all fronts.”

Last year, Mantoverde received 13 Komatsu 830E haul trucks as part of its Mantoverde Development Project (MVDP). These trucks come with a 230-t capacity and are powered by a Cummins QSK60 diesel engine. Mantoverde also uses a conveyor system to stack and remove ore for heap leaching, reducing its truck haulage needs.

The MVDP is expected to enable the company to process 235 Mt of copper sulphide reserves over a 20-year expected mine life, in addition to the operation’s existing oxide reserves. It involves the addition of a sulphide concentrator (12.3 Mt/y) and tailings storage facility, and the expansion of the existing desalination plant. This is expected to see production at Mantoverde increase from around 49,000 t of copper (cathodes only) in 2021 to approximately 120,000 t of copper (copper concentrate and cathodes) post project completion in 2024. The mine will also benefit from the production of approximately 31,000 oz/y of gold.

Cat focuses on increased efficiency, production and uptime with new electric rope shovel tech

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Caterpillar has announced two new optional technology solutions – Integrated Technology Package and Operator Assist Technology Package – for the Cat® 7495 and 7495 HF Electric Rope Shovels.

The new packages eliminate the need for one-off technology customisation, offer faster technology installation and provide seamless integration of future technologies into machine operation, according to the company. They provide improved health and productivity data tracking that help to reduce the number of unplanned machine outages, creating a more predictable maintenance schedule while extending component life.

The Integrated Technology Package fully integrates Cat Electronics into the machine’s design and provides the foundation to support future technology expansion, Cat says. The new package features six standard technologies – ranging from health monitoring to cycle segmentation – to support improved uptime reliability, improved operator efficiency and enhanced cyber security. This upgrade also provides seamless integration of Cat® MineStar™ Solutions’ suite of operational technologies that help track, monitor and manage the shovel.

Building on the Integrated Technology Package, the Operator Assist Technology Package provides machine self-protection and control enhancements that simplify 7495 and 7495 HF operation, Cat claims. Without sacrificing productivity, this upgrade minimises machine self-collisions and safeguards against operator practices that cause damage. It allows less experienced operators to efficiently load trucks, while reducing the effort required to avoid poor digging practices that can impact machine availability and overall productivity.

The new Operator Assist Technology Package upgrade simplifies how the shovel is operated through machine self-protection, the company says. It automatically detects and avoids collisions between the dipper, crawler, boom bumper and cable management systems.

The technology’s LiDAR vision system scans the front of the shovel and algorithms integrate with operator commands to provide the least intrusive avoidance path. If a collision is unavoidable, the system will arrest machine motion to prevent or mitigate the collision. In summary, it reduces unplanned downtime, extends component life and improves total cost of ownership, Cat says.

The package features the second generation of Enhanced Motion Control, encompassing all the improvements of the first generation. It also offers a new feature to protect the rotating undercarriage by alerting the operator when the turning angle exceeds 20°, so corrective action can be taken.

Other features within the new Operator Assist Technology Package include:

  • Anti-swing in bank – prevents damaging side-loading forces on the dipper when the operator attempts to swing the dipper through the bank;
  • Hoist stall prevention – monitors forces and optimises crowd/retract commands to avoid stalling the dipper and prevent detrimental forces on the hoist gear-case;
  • Hoist rope slack prevention – automatically adjusts crowd and hoist references to maintain rope tension when slack is detected;
  • Boom jack minimisation – automatically adjusts hoist and crowd to maintain proper rope tension and improves cycle times;
  • Rope crowd impact prevention – measures the force on the crowd rope and automatically adjusts motor output to avoid shock loading; and
  • Rope crowd overspeed prevention – eliminates unnecessary wear on the crowd brake by providing more braking power to avert overspeed situations.

By providing the foundation for support technology expansion and integration, the Integrated Technology Package helps to provide more robust and reliable reporting, Cat says. New Cycle Segmentation establishes operating key performance indicators and identifies dwell time when idle. It divides cycle time data into digging, swinging to the truck, dumping and swinging to the bank segments. This allows miners to track machine performance across different shifts and operators.

With this introduction, legacy reporting technologies change to new Machine Health, Vibration Monitoring, Payload Management and Bearing Temperature Monitor technologies.

Machine Health delivers improved reporting capabilities and provides remote real-time machine monitoring.

Using sensors to capture data from the crowd, hoist, swing motors and gearboxes, Vibration Monitoring examines vibration signals for changes, allowing for proactive maintenance to reduce unplanned outage downtime.

Payload Management provides real-time feedback on material moved to avoid truck over/underloading, while Bearing Temperature Monitor keeps track of hoist, swing and crowd bearing temperatures and alerts the operator if figures rise beyond established thresholds.

The optional Integrated Technology Package will be available in standard and premium subscription levels, Cat says. Standard subscriptions include all package technologies and push notifications for software updates. Premium subscriptions include all standard features, plus vibration data analysis, monthly report generation from a Caterpillar engineer and in-person consultation to review the report’s findings and conclusions.

New Cat 7495 and 7495 HF shovel purchases can be optionally equipped with the Integrated Technology Package and Operator Assist Technology Package starting in 2023, while availability of these technology packages as field retrofit kits is scheduled for mid-2023.

Komatsu marks official opening of new surface mining-focused Milwaukee campus

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Komatsu has marked the official opening of the company’s new Milwaukee campus with a tree planting ceremony attended by both Komatsu President and CEO, Hiroyuki Ogawa, and Wisconsin Governor, Tony Evers.

The new 58-acre (23.5 ha) campus located in Milwaukee’s Harbor District includes a 180,000-sq.ft (16,723-sq.m) office building and a 430,000-sq.ft manufacturing facility, which produces the major components of large mining machines, including electric rope shovels, hybrid shovels, draglines and blasthole drills. The location serves as the large gearing centre of excellence and the large fabrication and machining centre of excellence for Komatsu’s surface mining business, it said.

With the new campus, Komatsu aims to create a remarkable workplace for the future in Milwaukee, where the company has more than a century of history, it says. The new facility was designed and built to enhance Komatsu’s goal of “creating value together” by leveraging technology and open spaces, providing a globally connected meeting place for both company and community, and emphasising sustainability.

“Our South Harbor campus and its many sustainability features are part of our global commitment to achieving carbon neutrality by 2050 and sustainable growth as a company,” Ogawa said. “This is an important goal for Komatsu along with society, as we all work to do our part to address global warming. Through this campus, we hope to contribute to the Milwaukee community by implementing our growth strategy.”

The new facility also reaffirms Komatsu’s commitment to support the workforce of southeast Wisconsin for future generations, by preserving existing jobs, laying the groundwork for new employment opportunities and helping attract talent to the area, the company added.

Komatsu thanked project partners Hunzinger Construction, EUA and GRAEF for their work to make the new campus possible.

Komatsu laid out plans to build a new, state-of-the-art headquarters and manufacturing campus near the location of the company’s original machine shop off South First Street back in 2018.

Caterpillar reduces TCO, improves availability on electric rope shovels

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Caterpillar says it has carried out multiple design enhancements to the lower structures on its Cat® 7495 and 7495 HF Electric Rope Shovel (ERS) models that increase machine reliability and significantly lower overall total cost of ownership.

These upgrades cover the track (crawler) frames, swing rack and rollers, propel gearboxes and rotating undercarriage.

Combined, the design advancements can improve total cost of ownership by up to 6% per operating hour and improve physical availability of the ERS by up to 0.63%, Caterpillar claims. All updates are found on current-year models and can be retrofitted independently in the field to allow existing customers to realise the gains.

Starting with the track roller frame where a re-engineered bolt-on design for track link sliders eliminates the need for casting welds. This sees Cat rope shovel customers benefitting from an up to a 22% cost-per-hour reduction with extended wear life and no maintenance. At the same time, integral wear indicators provide visual reference to help service technicians plan for slider maintenance.

Track frame life is enhanced with increased frame thickness, lowering stress in the plate for improved reliability. A new super bolt arrangement features shorter middle bolts, improving joint stiffness and maintaining pre-load. Access for cleanout has been improved with a three-hole track frame bell housing, Caterpillar says.

Distributing shovel weight more evenly to the crawler side frame, the updated tapered shear ledge reduces end loading as the ERS pitches forward during digging. New lower side frame stiffeners maintain increased track clearance to the tracks, while improving rock protection.

Saving approximately 100 hours of field assembly time, the bolt-on motor base eliminates field welding and improves motor bolt access, according to the company. Set screws simplify locating the base on the crawler and simplify motor alignment.

The swing rack on the ERS absorbs the stress from every load.

The 7495 and 7495 HF models now have a single-piece swing rack casting (below) that eliminates previous vertical welds to improve ERS durability. The number of core holes have been reduced from 20 to four, positioned strategically in low-stress areas of the swing frame and located out-board to increase web strength. Improvements to the weld joint between the swing rack and car body further reduce stress, Caterpillar says.

An updated single-piece roller path increases roller life and eliminates seams to improve ride and prevent rollers from coming loose. Five symmetrical roller segments are now pre-assembled, improving alignment quality and installation efficiency, it says. The upgraded thrust rail design improves access for inspection and retightening, while adding support to the thrust rail during operation.

The redesigned propel system on the 7495 and 7495 HF models eliminates the need to remove the propel transmission when servicing the drive tumbler and propel shaft, since they are now replaced from the out-board side of the machine. This significantly improves serviceability of the drive, decreases maintenance downtime by as much as 75% and lowers operating costs by as much as 10% versus the previous design, according to Caterpillar. The component’s design updates extend rebuild life to up to 30,000 hours.

Sealed and continuously lubricated tapered roller bearings more evenly distribute thrust to improve propel durability, while fresh grease flows equally through both sets of bearings, eliminating potential contamination from bearing surfaces, the company says. Propel gearcase metallurgy has been optimised to improve toughness, while improved microgeometry enhances gear mesh to reduce contact wear, it added.

Compatible with all ERS machines equipped with 2,006-mm track pads, a new track pad design improves structural support and steel chemistry, while a proprietary heat treatment process increases hardness by 15% and toughness by 30% to improve roller path and drive lug wear, according to Caterpillar.

The track pin design features improved alloy composition and higher toughness. A new track pin removal pocket for 7495 HF models offers an easy-to-use pin removal solution that features a weld-free integrated vertical surface to keep the cylinder stabilised during pin removal.

Canada Nickel investigates Crawford processing potential at Glencore’s Kidd concentrator

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Canada Nickel Co says it has entered into a non-binding Memorandum of Understanding (MoU) with Glencore Canada that could see material mined from Canada Nickel’s Crawford nickel-cobalt sulphide project treated and processed at Glencore’s Kidd concentrator and metallurgical site in Timmins, Ontario.

Crawford, around 40 km north of Glencore’s operations, hosts a 657 Mt measured and indicated resource grading 0.26% Ni and 0.013% Co. It is currently the subject of a preliminary economic assessment (PEA).

The Kidd operations consisting of the Kidd metallurgical site and the Kidd mine. The concentrator is located on the property of the Kidd Metallurgical Site, 27 km east of Timmins, in the Townships of Hoyle and Matheson. Built in 1966 with numerous upgrades over the years, the concentrator currently processes metal ore to produce copper and zinc concentrates. The facility has a design rated capacity of 12,500 t/d and is fully permitted with water taking and discharge permits and thickened tailings storage. The site has incoming and outgoing rail service via Ontario Northland Railway.

Canada Nickel says it has completed an initial high-level assessment of the potential arrangements envisaged under the MoU and will proceed with a detailed study on the potential for upgrading excess capacity at the Kidd concentrator and/or using the existing infrastructure in place at the Kidd metallurgical site for milling and further processing the nickel-cobalt and magnetite concentrates that are expected to be produced from Crawford.

Mark Selby, Chair and CEO of Canada Nickel, said: “The opportunity to utilise the excess capacity and existing infrastructure at the Kidd Met Site provides the potential to allow a faster, simpler, smaller scale start-up of Crawford at a vastly lower capital cost while the company continues to permit and develop the much larger-scale project currently being contemplated.

“Given the potential for this significant change in the scope of the project start-up, the release of the PEA will be delayed until the end of March 2021 to allow this option, if successful, to be incorporated.”

This study is being led by Ausenco Engineering Canada Inc, which is also supporting the assessment of the Kidd Met Site facilities.

Canada Nickel’s plans include the development of a “Zero-Carbon footprint operation”. This considers the use of electric rope shovels and trolley trucks which utilise electricity, rather than diesel fuel, as a power source wherever possible, along with a natural mineral carbonation approach for the deposition of waste rock and tailings during mining to allow material to absorb CO2.

Cat improves efficiency and cost per tonne with 7495 mining shovel upgrades

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Caterpillar has updated its 7495 and 7495 HF electric rope shovels with the result being an up to 10% increase in operating efficiency.

Drawing from more than a century of rope shovel innovation, the 2021 Cat® 7495 and 7495 HF Electric Rope Shovels (ERS) combine multiple standard feature upgrades to improve machine productivity, while component enhancements, increased frame durability and improved serviceability help reduce cost per tonne of material moved by as much as 15%.

Dan Wyatt, ERS Product Value Stream Manager, said: “Consistently, our customers tell us machine availability and productivity are primary contributors to their operation’s success. From the full adaptive control system for HydraCrowd™ to more innovative technology and data security, the advances made to the 2021 electric rope shovels reflect our commitment to meeting their needs.

“Many of these improvements are compatible with shovels in the field, so customers can realise these gains through upgrades to their existing fleets as well as new machine purchases.”

A new propel gear case for the 7495 and 7495 HF models nearly doubles the life of propel gear cases in some extreme operating conditions, Cat claims. Precise adjustments to gearing geometry and advancements in tooth hardening enhance gear case durability and productivity. The result is lower total cost of ownership of as much as $8/h when the drive system is replaced at one scheduled time.

Additionally, an ecology drain simplifies oil draining and enables kidney-loop flushing, which reduces abrasion-causing contaminants and oil change frequency.

Updates to the 7495 AC electric drive system deliver greater reliability, improved maintenance access, enhanced safety, and expanded high altitude and temperature capabilities, the company says. A liquid-cooled motion regulator cabinet efficiently dissipates heat generated by electrical components and enables operation at -40°C to +50°C and altitudes as high as 5,250 m without derating.

A faster propel transfer switch cuts lag time by 75% to improve productivity, while common motors in multiple applications means fewer parts to stock, improved parts availability and simplified maintenance, Cat says.

A reconfiguration of the crawler carriage allows drive shaft and tumbler replacement from the outboard side without removing the propel transmission. This slashes maintenance time by days while enhancing safety, Cat says. With this design, thrust loads are evenly distributed on large, tapered roller bearings rather than bronze thrust plates, increasing durability to align with 25,000-hour planned rebuilds, even in harsh environments.

Stress from every load passes through the shovel’s swing rack. This is where an enhanced design includes a single-piece rail casting that eliminates vertical segment cracks to increase durability. The rail provides a uniform path for roller movement, preventing rollers from coming loose and creating irregular wear patterns. The upgraded third rail improves access for inspection and retightening, in addition to providing added support to the thrust rail during operation. New swing girder bushings and girder-to-chassis shim designs offer improved access, reducing service time.

“All major rope shovel structures are built with high-strength steel and rugged castings, joined and thermally stress relieved to deliver reliable operation in harsh mining conditions,” Cat says. “Full penetration, profiled and ground welds are made at critical junctures, and MT, UT and X-ray inspections ensure weld quality. Structures are stress-relieved to prevent cracking, and white painted interiors facilitate inspection.”

Both the 7495 and 7495 HF ERS models now offer a full Cat bill of materials, streamlining the parts ordering process and improving parts availability, the company says.

Technology increases efficiency

Both the 7495 and 7495 HF come standard with Product Link Elite™, which transmits critical machine operating data such as utilisation, location and condition via cellular or site internet connection. Added router functionality helps to protect data security. Advanced productivity tools within Product Link Elite enable a cycle segmentation algorithm, and the combined data allows for advanced analysis of productivity, Cat says.

When linked with the available Cat MineStar™ Fleet, real-time machine tracking produces a comprehensive overview of all equipment assets to assist with fleet management and productivity.

Providing real-time feedback to improve loading efficiency, available MineStar Terrain uses guidance technology and an in-cab display to deliver precise dipper position guidance. Optional MineStar Health delivers critical event-based machine condition and operating data, while its advanced diagnostic and analytic tools improve service efficiency, the company says.

The standard Operator Assist – Enhanced Motion Control simplifies machine operation to promote high production while protecting the machine. This system is designed to yield more reliable crowd rope replacement schedules, full design life for hoist ropes, reduced wear on crowd brakes and longer life for hoist gear case components, according to Cat

HydraCrowd

A new adaptive control system (ACS) – a final piece of a multiphase enhancement initiative for HydraCrowd – delivers up to 25% cost savings on the ACS valve, resulting in up to 5% total cost of ownership saving for the entire system, Cat says. Lower initial costs, rebuildable elements and improved accessibility combine to reduce the time required for replacements. The new design also increases reliability without significantly changing the HydraCrowd maintenance schedule, according to Cat.

The new circulation filter employs two smaller, easily accessed filters that do not require roof panel removal for replacement. More affordable than the previous single-filter design, the new configuration also reduces replacement time, Cat says.

A new filter placed at the pump drive transmission improves filtration of the lubrication fluid, helping to extend the life and reliability of the system by reducing contaminants and decreasing wear. The new pump drive transmission filter assists in reducing unplanned maintenance events to decrease downtime.

Cat 7495 electric rope shovel on its way to Kinross Gold’s Paracatu mine

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A Cat 7495 electric rope shovel originally built in 2012 is on its way to Kinross Gold’s Paracatu gold mine in Minas Gerais, Brazil.

Paracatu, an open-pit mine with ore processed in ball and SAG mills, is Brazil’s largest gold mine, according to Kinross. It achieved record annual production of 619,563 gold-equivalent ounces in 2019, surpassing its 2018 record.

Kinross started an asset optimisation program in 2018, which completed in late 2019 with the successful implementation of a grade control program that led to better characterisation of the orebody, an improved ability to predict and react to ore variability, and better mill efficiency with improvements in throughput and recovery, it said.

Cat said the shovel’s ballast box and revolving frame left Green Valley, Arizona, USA, last week on two heavy haul trucks – one pulling and one pushing the 120 t load. At 61 m long and 5 m wide, the load is being escorted by a team responsible for removing and replacing power lines, traffic signals and signage along the way, it said.

Late last year, Cat updated the AC electric drive system for Cat 7495 and 7495 HF electric rope shovels to, it said, deliver even greater reliability, improved maintenance access, enhanced safety and an expanded ability to perform at high altitudes and in extreme temperatures.

Back in 2018, Kinross welcomed its second Cat 7495 electric rope shovel to its Round Mountain mine, in Nevada, as part of its Phase W expansion plan.

Cat’s 7495, 7495HF shovels receive an AC drive boost

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Caterpillar has updated the AC electric drive system for Cat® 7495 and 7495 HF electric rope shovels to, it says, deliver even greater reliability, improved maintenance access, enhanced safety and expanded ability to perform at high altitudes and in extreme temperatures.

The updated system also is designed to easily integrate with advanced technologies.

“Caterpillar and our predecessor in shovel design and manufacturing, Bucyrus, have supplied more than 300 AC electric rope shovels,” said Dale Blyth, Product Manager, Electric Rope Shovels. “The most recent advances in AC drives are integrated in this update and demonstrate how we apply our experience to help customers lower cost per tonne and bolster safety.”

Updates include a liquid-cooled motion regulator cabinet for more efficient dissipation of heat generated by electrical components.

The company said: “The new system enables shovels to operate at temperatures of -40 degrees C/F to +50 degrees C (122 degrees F) and altitudes of 5,250 m (17,220 ft) without derating.

“The reliable system also eliminates airborne contaminants in the cabinet and lengthens service intervals – for reduced costs and greater uptime. Additionally, a new, faster propel transferswitch cuts lag time by 75% for improved productivity.” 

New technologies enable consolidating two cabinets in the machinery house to create space for easier maintenance access, while the updated maintenance station is designed for integration of current and future technology solutions, including Cat MineStar™.

The drive system design uses common motors in multiple applications, according to Cat. “That means fewer parts to stock, improved parts availability and simplified maintenance.” 

The new motors also have higher power densities, smaller frame sizes and optimised footprint, which aids access, it added.

The Cat rope shovel electric drive system still features elements such as fuseless insulated-gate bipolar transistor modules. And, the on-board maintenance station continues to aid technicians in identifying faults and resolving issues.

The new electric drive system will be on all new production 7495 and 7495 HF shovels beginning in late 2020.

The system is not intended for retrofit, though some elements, such as the fast propel transfer switch, are available as upgrades to machines already in service, according to Cat.

Cat cuts electric rope shovel downtime

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Caterpillar says it has developed a propel drive system upgrade for Cat® 7495 and 7495 HF electric rope shovels that improves maintenance access, decreasing downtime by days.

The upgrade, which has operated successfully for thousands of hours in field validation, reconfigures the crawler undercarriage to allow drive shaft and tumbler replacement from the outboard side, Cat says. Improved component design, meanwhile, extends durability and increases component life to further reduce costs.

“The new design slashes maintenance time and enhances safety by enabling access to drive components without removing the propel transmission,” the mining OEM said. “Additionally, Caterpillar engineered the upgrade to be a direct replacement. No machining of the crawler frame is required for installation.”

The new robust design sees thrust loads evenly distributed on large tapered roller bearings as opposed to bronze thrust plates, while the bearings are sealed and continuously purged with fresh grease to keep them free of contaminants, Cat says. The result is increased durability in harsh environments and alignment with 25,000 h planned rebuilds.