Tag Archives: Komatsu

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

Automation, Equipment maintenance, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

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.

Komatsu, Becker-Warkop team up for Warrior Met Coal longwall PRS solution

Coal technology, Mining equipment, , , , , ,

Komatsu says it has partnered with Poland-based Becker-Warkop Sp. z o.o. to produce a set of Joy custom-designed longwall powered roof supports (PRS), manufactured by Becker-Warkop, for Warrior Met Coal’s operations in the US.

These supports will also include Joy’s Faceboss RS20s roof support controls, which can help provide full face automation, Komatsu said.

Last year, Komatsu announced plans to provide Joy-engineered PRS solutions through partnerships with PRS manufacturers to, it said, best meet customer needs to reduce costs and maximise performance.

Warrior Met Coal, meanwhile, recently announced plans to relaunch the development of its Blue Creek reserves into a new, world-class longwall mine located in Alabama, USA, near its existing mines.

Mark Brocklehurst, Global Product Director – PRS Engineering at Komatsu, said he was delighted that Warrior Met Coal had selected Komatsu and Becker-Warkop for its next set of longwall PRS.

“Our Joy-engineered PRS solutions are designed to help our customers to mine efficiently and safely with the added flexibility of enabling access to lower cost manufacturing sources to reduce up-front investment, and we are pleased that we can offer a solution which meets their needs.”

Komatsu to acquire underground mining visualisation and tracking company MST Global

Automation, Communications in mining, IoT, Mining equipment, Mining mergers and acquisitions, Mining services, Mining software, , , , ,

Komatsu Ltd, through its wholly owned subsidiary in Australia, has agreed to acquire Mine Site Technologies Pty Ltd, a provider of operational optimisation platforms for underground mining that leverage communication devices and position tracking systems.

The deal, set to close on July 1 on the condition all necessary procedures for closing are completed, will see the two companies help customers build digital ecosystems with real-time insights and alerts, voice and communication technologies, software solutions, robust network infrastructure and wireless and geospatial technologies.

Together, the companies will work to increase availability of high-speed, low latency digital communication, which is necessary to: provide mission-critical communication, integrate IoT sensors, increase the volume of information communicated and enable real-time tracking, monitoring and automation of mine operations.

For 30 years, Sydney-based MST Global has delivered innovative solutions to address the needs of customers today and for the future. The company specialises in developing and delivering ruggedised, fit-for-purpose solutions and services partnering with mining and tunnelling customers on their digital strategy to unearth safety and productivity improvements.

Komatsu said: “MST Global solutions enable communication between operators and mining equipment, as well as position tracking for operators and equipment, leveraging optical fibre broadband communication systems, which create a real-time geospatial digital twin of underground operations: an important and fundamental building block for digitalisation.”

The company’s solutions offer a platform to visualise and monitor the underground mining environment and enable control from a remote operations centre, thus optimising mine operations to increase safety and productivity while safeguarding the environment, the company added. The solutions contribute to the digitisation and automation of underground mining operations.

One of the more recent additions to MST’s portfolio is HELIX, a next-generation software platform that brings underground miners’ “software, hardware and third-party integrations into one platform”, MST says. This builds on MST’s 2D Visualisation and Tracking software, ICA and Minedash, while having all the luxuries of a modern interface and platform and building “your digital ecosystem”, it says.

By adding MST Global’s experience and expertise in the introduction of communication devices and optimisation platforms, Komatsu says it aims to enhance the speed at which it offers advanced technology solutions, including the automation and teleoperation of mining equipment underground.

Komatsu, in line with its ongoing mid-term management plan “DANTOTSU Value – Together, to ‘The Next’ for sustainable growth”, is working to expand offerings for underground hard-rock mining, creating new value for customers with the development of new equipment, processes and technologies that will help operations step forward to the next stage for the workplace of the future and provide a more sustainable environment for the next generation, it says.

Komatsu launches Joy MATS6 shearer for Chinese longwall mining market

Automation, Coal technology, Mining equipment, Mining safety, Mining services, Mining software, Steel and iron ore, , , , , , , ,

To help Chinese longwall mines realise higher production and less downtime, Komatsu has introduced the Joy MATS6 shearer.

The Joy MATS6 Tier II comes with the reliability attributes of Joy machines, with all components manufactured under rigorous Joy quality processes. Because the machines are assembled in China with many Chinese-made components, a MATS6 shearer can be built and delivered relatively quickly, according to Komatsu.

Advanced control systems protect the machine from mechanical and thermal overload, while advanced diagnostics enable faster troubleshooting.

In addition, by incorporating the tie-rod chassis connection, the MATS6 can be assembled faster, both in the workshop and underground, and its modular design allows more material to pass under the machine body. Comprised of three high-tensile fabrications with a slim main section, the MATS6 has no under-frame. This design allows quicker adaptation to different mining scenarios, more efficient rebuilds and easier maintenance, Komatsu says.

Coming with longer lasting components, the MATS6 is able to mine larger panels reliably between rebuilds or even mining multiple panels without a rebuild. Additionally, the machine’s longer machine chassis life can provide a higher return on initial investment.

The machine weighs 115 t, has a cutting height of 2.5-6 m, a maximum total power of 2,495 kW, cutting power of 2 x 900 kW and 1,200 kN of haulage pull.

Any discussion of increasing longwall productivity and moving toward zero harm must include automation. Joy’s latest shearer pitch steering technology offers access to fully automated cutting sequences, including gate end turnarounds and optimal drum positioning for highly efficient cycle times and consistency. This is available as an option for the MATS6.

Advanced automation tools, including Radio Motion Monitoring, Landmark, and REST Api, meanwhile, enable remote operation to help keep workers out of harm’s way.

Komatsu boosts longwall performance with Joy Compak Next Gen hydraulic control system

Coal technology, Equipment maintenance, Mining equipment, Mining services, , , ,

Komatsu is looking to reinforce its longwall system powered roof supports (PRS) with the multifunctional Joy Compak Next Gen hydraulic control system, helping, it says, improve the performance of customers’ PRS and facilitate the shearer cutting rate with exceptional cycle time performance.

Engineered to be durable and reliable in rugged environments, the Joy Compak system features corrosion-resistant materials on valve block assemblies, components and the main body. With a reduced number of components to lessen wear and tear, the spool valve in the system is engineered to handle higher flow rates, to help reduce the risk of part failure and promote extended life, Komatsu said. Providing flexibility to suit the individual needs of your operation, the Joy Compak Next Gen hydraulic system can be conveniently upgraded or retrofit to any PRS system (regardless of manufacturer).

The high-performance valve technology of the Compak hydraulic control system helps improve cycle times by up to 12%, compared with the previous model. Designed with operators in mind, this hydraulic system’s overall size is reduced by up to 27% and weight by up to 30%, the company says, making it easier to position, while improving accessibility. Hosing position has also been conveniently located for better access, it added.

The reliable hydraulic valve system helps control modern automated longwall powered roof supports from the Faceboss electronic control system using solenoid control or through manual control with the solenoid push button override function. Ergonomically positioned for ease of access, operators can control the main override function easily and effectively through an integrated push button within the solenoid, Komatsu says.

Seals play a crucial role in the functionality of the hydraulic spools that operate roof support functions, and Komatsu’s seal technology helps prevent leakage in your hydraulic spools, it says. A simplified, standardised hydraulic circuit design helps provide a reduction in the number of spool valves without impacting performance of the Compak hydraulic system. This design minimises fitting and connecting hoses, to help reduce potential leak points.

Komatsu says the system can easily expand (over 16 functions) to increase functional requirements to suit the operation’s needs. For example, a standard 10-spool valve can be expanded through separate two- and four-spool expansion modules.

To help reduce lead times for replacement parts and streamline maintenance, the hydraulic control system features a modular design incorporating a series of standard components. Easy to change cartridge-style construction makes replacement straightforward and manageable, with manifolds, valve assemblies, cartridge valves and fittings all standard as part of the system’s modular design. The modular approach also makes upgrades easy, the company added.

Komatsu releases updated Joy 02ESV battery-power scoop for soft-rock mines

Coal technology, Equipment maintenance, Mining equipment, , , , , , , , ,

Komatsu has redesigned its Joy 02ESV soft-rock scoops with 240 V of battery power and OptiDrive technology to improve operator comfort and offer a longer operating time between charges.

Coming in three different models – 02ESV36, 02ESV56 and 02ESV60 – the scoops offer bucket capacities of 3-5 cu.m and maximum payloads of 18.2-28.7 t. The smallest scoop, the 02ESV36, is suited to seam heights of 91-160 cm, while the largest scoop, the 02ESV60, has a recommended seam height of 142-211 cm.

The OptiDrive technology can improve reliability, boost operator productivity, improve motor performance and help reduce maintenance costs, according to Komatsu. It is also easier to maintain and troubleshoot because it has fewer cable runs.

Designed to help minimise downtime, these scoops have new electronics that eliminate switches, and the colour display provides real-time operational and fault information to keep operators informed. Additional drive input modules allow the OptiDrive control system to interface with third-party proximity detection systems.

With less heat and noise compared with diesel power, the 240 V battery power contributes to improved working conditions. These Joy scoops also have improved motor efficiency for increased motor life and enhanced tramming, while improved ergonomics help keep operators more comfortable, Komatsu said.

To provide increased power and reduced downtime in the most demanding applications, the scoops are equipped with Dana drive axles configured specifically for the application. For durability and longevity, the centre section has been redesigned and includes heavy-duty pivot bearings and pins. The frame is rigorously engineered for reliability and transporting heavy payloads, according to the company.

Komatsu brings hybrid drive, narrow vein LHDs to Australian hard-rock market

Environmental, Equipment maintenance, Mining equipment, Power supply for mines, Sustainable mining, , , , , , , , ,

Komatsu Australia says it has, for the first time, entered the hard-rock underground mining market with a concerted solution made up of two larger hybrid LHDs and two diesel-powered narrow-vein loaders.

Two high-tech hybrid drive underground loaders, equipped with durable independent electric motors in each wheel, headline this substantial investment by Komatsu to provide a complete service solution to miners and contractors, it said.

“Providing hard-rock miners with reliable underground loaders is part of a broader understanding of the need to assist their overall productivity in the face of global competition,” Joshua Foale, Product Manager Mining, Komatsu Australia, said.

The hybrid Komatsu WX22H and WX18H LHDs each claim to be the lowest total operating costs in their class.

Meanwhile, Komatsu’s analysis shows the conventionally powered Komatsu WX07 7 t loader (pictured) is 14% more productive than any other machine in its category. The WX04 4 t LHD offers 20% more breakout force in its class, based on published information.

Komatsu hybrid loaders

Komatsu’s WX22H and smaller WX18H achieve up to 20% increase in tonnes moved, compared with conventionally powered loaders, the OEM said. They also have an up to 20% decrease in fuel costs, based on operating trials.

An independent life cycle analysis identified a 30% reduction in operating costs, compared with their conventionally powered counterparts.

Improved work cycle performance is achieved by use of high efficiency electric traction motors in each wheel, making conventional mechanical power drive redundant, resulting in substantial reductions in operating costs, Komatsu said.

The Komatsu WX18H produces 280 kW

The Kinetic Energy Storage System (KESS) is at the heart of the switched reluctance hybrid drive, which captures and reuses braking energy from each of the four wheels. Heat-energy generated when the machine stops abruptly at the dig face is captured by the bi-directional KESS loop instead of being lost to the atmosphere.

KESS stores and releases 3 MJ of energy, supplementing power from the conventional diesel engine for greater acceleration to maximise cycle performance, according to the company.

A smart traction system provides smoother acceleration and results in less tyre wear and component degradation. It generates less inertia at each stop, significantly reducing potential damage to the drive train.

Fewer underground emissions, lower heat rejection and greater operator comfort are all intended benefits of the hybrid system.

Komatsu’s 22 tonne WX22H produces 320 kW, with the smaller WX18H producing 280 kW.

Both engines are rated to the strictest EU Stage V requirements for emission control, and both use the same KESS, capable of delivering 410 kW, effectively doubling power delivery on demand.

A Joy 22HD hybrid LHD (now the WX22H) using SR drive and KESS has previously been tested at OZ Minerals’ Prominent Hill copper-gold mine in South Australia, in addition to a WX18H having been trialled at Codelco’s El Teniente underground mine in Chile.

Narrow-vein focus

Komatsu has designed the WX04 and WX07 for maximum productivity, with the WX07 a forerunner of a new breed of LHDs using improved chassis, power train and operator cabin environment.

Large capacity fuel tanks – 243 litres in the case of the WX07 – allows longer operational cycles between refuelling, while the cabin access, visibility and ergonomics have been optimised. Critical service points have been placed at ground level to minimise the need for technicians to climb or use ladders to reach key areas, the company said.

A new more efficient bucket design enables greater penetration into a load pile for fast bucket filling.

The Komatsu WX04 delivers 97 kW and the WX07 delivers 160 kW.

Komatsu says it range of hard-rock mining machines establishes new standards of strength and durability.

“In developing our machines, we have been specific in providing protection for critical structural components, linkages and joints,” Foale said. “Reliability has been a paramount consideration in the design of long-life moving parts.

“In the case of our hybrid drive machines, there are no commutators, brushes or rotor windings to replace, and our wiring systems are double insulated.”

Master Builders Solutions reinforces decline work at Hillgrove’s Kanmantoo

Base metals, Explosives and blasting, Mineral project development, Mining equipment, Mining services, Mining techniques, , , , , , , ,

Master Builders Solutions has helped the team at the Kanmantoo copper mine in South Australia speed up the excavation of its new decline portal by supplying fast-reacting, instantly thickening anchoring resin.

Kanmantoo, owned by Hillgrove Resources, is currently going through the initial stages of developing an underground operation at the former operating open-pit mine. It has employed a Komatsu MC51 to excavate a circa-500 m decline, with the continuous cutting trial focused on demonstrating the commercial viability of the machine and trial new materials handling and ground support processes.

One of these new processes includes the use of Master Building Solutions’ MasterRoc RBA 380 anchoring resin, which, according to the company, reacts in just three minutes.

This resin has been injected into 10, 9 m self-drilling anchors (SDAs) at the decline portal of Kanmantoo since mechanised cutting operations recently started up.

Master Builders Solutions explained: “Traditionally, cementitious grouts are used to encapsulate the SDAs, which can pose hazards such as dust inhalation and burns to contractors. In waiting for these grouts to cure, mining teams also lose critical heading for approximately 12 hours.”

In choosing the MasterRoc RBA 380, Hillgrove Resources was able to continue the safe excavation with the Komatsu MC51 after just five minutes, according to Master Builders Solutions.

Also involved in this project are Strata Consolidation and PYBAR Mining Services (now part of Metarock Group Limited).

Master Builders Solutions recently announced a planned transaction with Sika that would see the Switzerland-based shotcrete major acquire the company, formerly referred to as BASF Construction Chemicals.

Altaley Mining engages MGA Contratista Minera SA as Tahuehueto mine contractor

Comminution of minerals, Mine operation news, Mineral project development, Mining equipment, Mining services, Precious metals, , , , , , , , , ,

Altaley Mining Corp has engaged MGA Contratista Minera SA de CV as the underground mining contractor for the soon-to-be-operating Tahuehueto gold mine, in north-western Durango state, Mexico.

MGA is, Altaley says, a prominent mining contractor located in Durango city with over 20 years of underground mining  and civil engineering experience. Its clients have included Newmont (Goldcorp), Pan American Silver, Endeavour Silver, Grupo Mexico, Fresnillo, First Majestic Silver, Omega and others.

MGA is now mobilising its mining equipment (including a Caterpillar R1300G LHD and a Komatsu Joy DR-1SB hydrualic jumbo drill) to Tahuehueto to continue underground drift and stope development to advance the mine into production. Previous underground development during 2018 and 2019 completed between 70-80% of required development for the initial one to two years of mine production.

MGA will complete the development work required to initiate mine production and continue as the project’s primary underground mining contractor in the initial years of Tahuehueto’s production.

First production through the mill, which is at an advanced stage of construction, is anticipated near the end of 2021 when the first ball mill is to be commissioned. In the March quarter of 2022, the second ball mill will be installed and brought online to, thereafter, ramp up production to the mine’s anticipated 1,000 t/d capacity.

Altaley said construction at the Tahuehueto mine site is on time and budget, and management is not expecting any cost overruns at this point in time.

Ralph Shearing, CEO and President, stated: “MGA is a highly qualified professional underground mining contractor which ensures that mill feed tonnages will be available to sustain continuous milling operations on an ongoing basis. Altaley is pleased to have secured MGA as Tahuehueto’s underground mining contractor and is counting down the weeks remaining to reach production near the end of this year.”

Komatsu MC51 gets cutting at Hillgrove’s Kanmantoo copper project

Base metals, Explosives and blasting, Mine operation news, Mineral project development, Mining equipment, Mining services, Sustainable mining, , , , , , ,

The world’s first portal cut using “transformational continuous mining technology” is now underway with the help of Hillgrove Resources’ team at the Kanmantoo copper mine in South Australia and Komatsu’s MC51 machine, powered by DynaCut tech.

The underground decline at Kanmantoo commenced last Friday, just over a month after Hillgrove announced that the South Australian Government had awarded it a A$2 million ($1.5 million) grant to trial the new underground mining technology.

The continuous mining technology, which is also being tested at Vale’s Garson mine in Ontario, Canada, and has previously been trialled at Newcrest’s Cadia mine, removes the need for blasting, providing the potential to transform the traditional underground development process and result in improved safety and operational performance, Hillgrove said.

On top of this, the Komatsu MC51 technology is 100% electrically powered, providing a mine development option for companies pursuing zero-emission mining.

The Komatsu MC51 will be used to develop a portal and a circa-500 m underground decline at Kanmantoo, a former-operating open-pit mine that is transitioning to underground operations. This transition is permitted and benefits from having all existing infrastructure in place, including an operational 3.6 Mt/y processing facility and tailings storage facility, Hillgrove said.

The continuous cutting trial will focus on demonstrating the commercial viability of the machine and trial new materials handling and ground support processes. Ground support assistance is to be provided by PYBAR Mining Services.

“The underground decline has multiple benefits to Hillgrove, including the development of underground drilling platforms which reduce drilling cost as Hillgrove continues to expand and infill drill the existing Kanmantoo Underground resource,” the company has previously said.

It could also help bring forward potential first copper production and reduce future development costs, Hillgrove added.

Hillgrove CEO and Managing Director, Lachlan Wallace, said the development of the underground decline and establishment of underground drilling platforms was a key milestone in the Kanmantoo Underground development program.

“We are also excited to advance the mine development in a way that leads the industry towards zero-emission mining, which is without question the way of the future,” he said.

On top of the A$2 million grant from the South Australian Government, Hillgrove says it has secured favourable payment terms from Komatsu, which sees no payments until funding for the mine development is secured. The deferred and contingent nature of the agreement and grant funding results in minimal cash outflow to Hillgrove while the company focuses on the drilling program.