Tag Archives: LHDs

Komatsu brings WX11 to the 10-t-class underground loader market

Komatsu has introduced to the global market the new WX11 LHD, an 11-tonne loader that, it says, offers best-in-class breakout force and best-in-class payload helping to maximise productivity and provide a lower total cost of ownership.

The WX11 showcases Komatsu’s commitment to providing underground hard-rock miners with an exceptional load, haul and dump solution, integrating next-generation data management capabilities, operator ergonomics, intuitive controls and compliance with EU Stage V emission requirements, the company says. As a new model within the Komatsu hard-rock family of products, the WX11 is designed to be a class-leading LHD for all underground mine operators and contractors, offerering an 8-10% payload boost above other machines in its class.

“With ease of operability, superior performance and ground-level maintenance position, the WX11 has several competitive edges in the 10-t LHD class,” it said.

It comes with rated horsepower of 209 kW at 2,000 rpm, an operating weight of 35,250 kg, several available engine certifications, adjustable ride control and on-board telemetry. Additionally, it is fitted with new heavy-duty, hard-rock Komatsu axles with SAHR brakes, Komatsu cylinders and accumulators, swing-out radiator fan assemblies to support quick washdowns, optimised kinematics for superior breakout and tilt force, and all-new engineered structures to support the additional 10% payload capacity.

Ryan Karns, Director of LHD and Truck Products at Komatsu, said: “The WX11 is a game changer for hard-rock miners. Developed through a close partnership between our experienced team and our long-time customers, this product reflects a shared commitment to design excellence. The WX11 is the LHD every miner will want to have in their operation.”

Caterpillar, Borusan make historic underground equipment delivery to Anglo Asian Mining in Azerbaijan

Anglo Asian Mining says the Caterpillar mining fleet for its new Gilar mine has now been delivered to the Gedabek mine site, marking the first time Caterpillar underground equipment will be deployed in Azerbaijan.

The equipment will be substantially vendor-financed, and this is the first time Caterpillar will provide this to a customer in Azerbaijan or the wider Caucasus region.

The underground mining fleet comprises three 15-t-payload R1700 underground loaders and two 980UMA wheel loaders with 5.6 cu.m buckets.

Borusan, the authorised regional dealer of Caterpillar equipment, will maintain a stock of spare parts and consumables within Azerbaijan and major parts will be held at Borusan regional centres in Türkiye and Kazakhstan, Anglo Asian says. This will enable efficient aftersales servicing of the machines over their lifetime, which was a major factor in the machine selection process.

The company says: “The underground mining fleet are ‘state-of-the-art’, next-generation machines constructed with safety at their core. They are more powerful and contain many new features compared to their predecessors. The operator environment has been improved and is more comfortable. Many new safety features have been added, including better access points, multiple fire suppression systems and improved visibility and lighting.”

The underground equipment will be used in the company’s new Gilar mine, which is currently under construction and development. On December 11, a maiden JORC (2012) mineral resource estimate was published for the Gilar deposit. This confirmed 6.1 Mt of mineralisation with an average copper grade of 0.88% and 1.30 g/t Au. The in-situ mineral resource is 54,000 t of copper, 255,000 oz of gold and 46,000 t of zinc, according to the company.

The Gilar mine is scheduled to begin production around the middle of 2024 and will be an important source of production, bridging the gap between declining grades at Gedabek’s existing mines and production starting from its much bigger Xarxar and Garadag contract areas.

The total cost of the equipment is $4.6 million. The $3.7 million balance due for the purchase of the equipment will be paid by the end of December 2023 from the group’s existing liquidity resources. It is anticipated that $3.7 million will be refinanced by a vendor financing loan from Caterpillar. Negotiations are continuing with Caterpillar Finance to finalise execution of the loan which is expected to close in the March quarter of 2024.

A ceremony was held on the afternoon of December 11, 2023, to mark the arrival of the equipment at Gedabek. This was attended by the group’s leadership team, Azeri and Turkish representatives from Caterpillar and Borusan, along with representatives from both the central and regional Governments of Azerbaijan. A demonstration was also given of operating one of the machines by remote control.

Sandvik to launch diesel-electric range of underground trucks, LHDs

Sandvik Mining and Rock Solutions says it is expanding its technology portfolio by developing a diesel-electric range of underground loaders and trucks to complement its battery-electric vehicle offering.

For more than 40 years, Sandvik has been driving electrification of underground mining equipmentstarting with cableelectric loaders in the early 1980s and evolving to BEV equipment today, it said. Now the company is expanding its load and haul offering to include dieselelectric equipment.

We see the future of underground mining as a combination of multiple coexisting technologies, with different solutions for varying customer needs,” Jari Söderlund, Product Management Director, Division Load and Haul, Sandvik Mining and Rock Solutions, said.“An immediate switch from diesel to battery-electric is not a feasible solution for every mine and application. Diesel-electric is another technology that can help our customers achieve their productivity and sustainability goals.

Sandvik first showcased its new Toro™ diesel-electric truck demonstrator to customers at a technology workshop in Turku, Finland, in 2022, during which participants shared their expectations for diesel-electric technology, Sandvik said. The demonstrator has since undergone extensive performance testing and the Sandvik product development team is using feedback from the workshop to ensure its future offering meets customer and industry needs.

Customers can expect the diesel-electric equipment offering to boost productivity, reduce total cost of ownership, improve availability and extend component lifetimes, it said. The equipment will benefit from the experience Sandvik has gained with its BEV installed base, and will utilise many common platforms used for the Toro load and haul product series, which has thousands of units delivered around the globe.

The diesel-electric Toro loaders and trucks will be automation compatible and available with advanced Sandvik digital service solutions as well as remote monitoring services, to further improve productivity and safety while reducing total cost of ownership.

Centamin weighs up use of hybrid diesel-electric units for Sukari Underground

It has been all change underground at Sukari for Centamin, with a switch to the owner-operator model – from contractor-led operations – likely to be followed by a transition towards an electric fleet at the gold operation in Egypt.

Having successfully grown the underground reserves by 200% in 2021, extending the life of mine in the process, the company made the decision to make the owner-operator switch last year. This move, it says, delivered cost savings and increased mining flexibility. The company went on to produce just over 440,000 oz of gold from the combined open-pit and underground operation in 2022.

Ahead of this change a detailed study on the underground operation was completed. This included assessing the benefits and limitations of using battery-operated equipment within Sukari Underground, according to a company spokesperson.

Within the underground operation, Centamin currently operates 15-t-payload LHDs and 63-t-payload trucks. These, the company says, are the predominant source of heat and diesel particulate matter.

The spokesperson told IM: “At the time [of the study], proven battery-operated equipment commercially available ranged from comparable 14-15 t loaders and smaller 42 t-50 t haulage trucks. As such, we are assessing a staged approach from conventional diesel units to hybrid diesel-electric units in the interim and then to full battery-operated loading and haulage units.”

The basis for this staged approach was driven by technology (availability and advancements), location (country and existing infrastructure), and timing (lead times, technology, infrastructure, current fleet life and underground resource expansion potential), according to the spokesperson.

“Discussions with OEMs are ongoing, not just on the fleet electrification but also to understand the future pipeline of decarbonisation technology, as this continues to be at the forefront of our operating philosophy,” the spokesperson concluded.

Sandvik to establish new production unit in Malaysia on underground LHD, truck demand

Sandvik is establishing a new production unit in Malaysia for manufacturing underground loaders and trucks in an effort to answer growing demand for its battery-electric vehicles (BEVs), the company says.

Equipment production is planned to begin in the December quarter of 2023 following factory upgrades and other site improvements.

While the new production unit within Sandvik Mining and Rock Solution’s primary focus will be BEVs, it will also manufacture conventional loaders and trucks as well as battery cages. Annual manufacturing capacity is planned to increase gradually to 300 loaders and trucks and 500 battery cages by 2030.

The new facility in the 445-ha Sendayan TechValley business park, 70 kilometers south of Malaysian capital Kuala Lumpur and 15 km west of state capital Seremban. The factory is 90 km southeast of Port Klang, Malaysia’s largest seaport and one of the busiest container terminals in the world.

Mats Eriksson, President of Sandvik Mining and Rock Solution, said: “Malaysia is among the most technologically developed countries in Southeast Asia and has abundant skilled labour, strong local industrial suppliers and reliable infrastructure. Our mining customers in Asia Pacific will enjoy shorter lead times for equipment manufactured to the same Sandvik standards for quality and safety.”

The new factory will span more than 8,000 m and include 15 versatile assembly bays. It will support the manufacture of all Sandvik load and haul equipment models and is independent of existing supplier chains, the company explained. Production ramp-up will begin later this year with Toro™ LH517i loaders followed by Toro™ LH518iB, Sandvik’s newly-announced automation-ready battery-electric loader, in the June quarter of 2024.

Patricio Apablaza, President of Sandvik Mining and Rock Solutions’ Load and Haul division, added: “Demand for our loaders and trucks is exceeding our current production capacity at our existing factories. The establishment of our new production unit in Malaysia will enable flexible manufacturing of both conventional diesel and battery-electric mining equipment.”

GHH InSiTE

GHH inSiTE – TALPA and GHH leveraging data to reduce underground equipment OPEX

At the project development and deposit exploitation stage, more focus is increasingly placed on converting the data generated by mining assets into near real time actionable insights that allow a faster reaction to the changing environment of operations.

Limited communication at the underground mine can create inefficiencies in scheduling and managing machines’ availability and uptime. These can include longer-than-planned maintenance periods, with more time spent on administrative tasks than actual revenue-driving activities. As a result, there is a need to eliminate variability and unknowns from production and equipment maintenance processes to keep up fleet availability.

Underground mining operations involving a lot of mobile machines, such as LHDs, dump trucks, drilling and auxiliary equipment, often become a closed silo of information. Once underground, the machine is hardly visible – both to the OEM that delivered it and to the central services of the mining company responsible for planning its maintenance and supplying relevant spare parts.

One example of addressing this issue is the cooperation between GHH and TALPA in implementing the GHH inSiTE digital analytics solution for a major mining company, which allowed for a reduction of equipment service costs by more than 35%/y, TALPA claims.

The system, which has been implemented in stages, began with the optimisation of service scheduling based on the information about the engine hours of the machines recorded in near real time automatic mode by the system. This was later complemented by displaying full sets of error codes and signals generated by the integrated machines. The virtual advisory to the service personnel was made available at the third stage, allowing all parties to understand issues registered at each unit and plan fit-for-purpose actions in a timely manner.

Furthermore, the system provides an interface to the central procurement system and provides equal information to the OEM, allowing for a timely supply of required spare parts and major stock optimisation opportunities.

The TALPA-powered solution enabled the mine operator to track and manage all its machines in a single system, allowing employees previously occupied with time-consuming tasks such as fault finding and service scheduling to focus on critical processes such as fleet availability for production. The customer leveraged GHH InSiTE powered by TALPA’s monitoring and analytics system’s deep capabilities to reduce costs and boost its productivity. The list of benefits included:

  • Improved service scheduling by understanding the exact time to service a fleet of over 150 machines based on permanently available knowledge of engine hours left until the next service, the recent workload of particular machines and registered errors;
  • Timely reactions to critical warnings and trends in the intervals between scheduled services in order to prevent damage to the machines requiring major overhauls;
  • Precise preparations for the service events, knowing the exact technical conditions of the machines and allowing for the timely delivery of spare parts and components;
  • Reduced downtime of machines, as the system allows for early detection of potential issues and prompt maintenance; and
  • Increased equipment availability as the system allows for better planning.

And the system also offers safeguards to ensure any recommendations not acted on by machine operators are rectified by nominated personnel within the maintenance hierarchy.

TALPA explained: “Even if the driver forgets to add the oil as indicated by the in-cabin system, this will never get missed by the Maintenance Superintendent as the system will always provide an alarm on the critical issues in the GHH machine cabin and trigger actions from that end.”

TALPA’s Industrial AI Platform solves industry-specific problems and delivers fast time to value, the company says.

“Using GHH InSiTE maintenance dashboard, powered by TALPA, allows for improving key processes throughout the workflow, delivering a clear understanding of the technical state of the fleet based on OEM standards as well as real technical conditions, and allowing optimisation of aftersales services for OEMs and technical operations for the end user,” TALPA said. “Delivered to the full extent as a service, TALPA’s platform allows for cost-efficient and worry-free implementation regardless of the fleet size and location of the operations.”

Caterpillar lowers UG mining costs, downtime with release of bolt-together LHD buckets

Caterpillar has launched “bolt-together” buckets for underground loaders that, it says, offer the same strength and durability as standard buckets, but reduce time and costs associated with transportation, assembly and rework procedures for underground mining.

The new bolt-together bucket does not require skilled maintenance operators for underground welding, resulting in a reduced safety risk, according to the company. On top of that, the design allows for efficient underground assembly, where the loader is working, to cut replacement time and lead to lower machine downtime and higher productivity.

“Optimised for moving abrasive underground materials, the new bucket design includes improved material thickness for increased strength and a rigid bucket assembly to aid in easier edge installation and removal,” Caterpillar says. “High-grade, 400 BHN materials used for bucket assembly components and high-grade wear protection ground engagement tools (GET) on the removeable shroud assembly deliver a long bucket service life for better cost saving and productivity. With proper GET selection and management, the Cat bolt-together bucket is designed to last through the first machine overhaul period to reduce replacement downtime.”

The buckets are modular in design for quick installation and removal, with the Cat GET available for the new bolt-together buckets including three edge options – bolt-on half arrow, modular weld-on and Durilock – shroud segments, and rock guard to deliver reduced downtime and accelerated repair.

The new bolt-together bucket is available in a range of capacities from 5.3-7.5 cu.m, specially designed for the Cat R1600H, R1700G, R1700 and R1700 XE LHD models. They are built in the same factory and go through the same stringent quality control process as Cat equipment and are supported by the global Cat dealer network, the company says.

GHH launches new 10-loader, the LF-10 NEO

Mining and tunnelling equipment manufacturer GHH has unveiled a new load haul dumper (LHD), the LF-10 NEO, offering, it says, the highest tipping height in its class.

This 10-t-payload loader is a powerful and compact machine and an improved version of the LF-10, already a well-established product in its class, the company said. It is the latest in a line of new GHH loaders that includes the LF-14, the LF-7 and the LF-8.

The LF-10 NEO has a z-link design and a maximum tipping height of 2.5 m. This makes it an ideal partner for loading all 30-t-payload trucks on the market, according to GHH.

“The high breakout forces, efficient boom and bucket motion times, as well as the strong power to weight ratio, makes the LF-10 NEO one of the best in class,” Ingo Rath, Product Line Manager Loaders at GHH in Germany, said.

With a length of 9.6 m and width of 2.6 m, the LF-10 NEO is compact and versatile for excellent manoeuvrability in mid-seam underground mining environments, according to GHH.

The standard bucket aboard the LF-10 NEO holds 4.6 cu.m, making loading and unloading easier and more cost effective.

With an operating weight of around 28 t, the loader manages speeds of up to 32 km/h with four-speed transmission and gradients up to 25%. It is able to tip the 10-t payload in just 2.6 seconds, GHH says.

“GHH installs the water-cooled Mercedes OM936 diesel engine with 240 kW, which is the best in the 10-t loader-size class,” Rath says. “The large fuel tank also allows for full shift operation with no worry for refuelling mid shift and losing valuable production time.”

Exhaust gas emissions comply with US EPA Tier 3 or EU Stage IIIA on the standard machine, while EU Stage V is also optional. The low fuel consumption, ease of maintainability and robust design as well as durability and reliability of the product all add to the low operating costs, the company said.

The LF-10 NEO has an operator compartment that boasts excellent ergonomics, GHH says. This is evident in the way the controls have been laid out and the general arrangement within the cabin. There is also a large footbox within the cab, providing the operator with significantly more space and comfort. The cab also offers improved visibility compared with other loaders in the class.

It comes as standard with useful safety and maintainability features such as the Proximity Detection System (PDS) interface, which allows the integration of third-party equipment. There are also optional wear sensors fitted on the brakes.

“Like other GHH vehicles, the articulated LF-10 NEO is designed for underground hard-rock mining and can be ordered with many options,” GHH said.

It also seamlessly integrates with the GHH inSiTE electronic monitoring and digital analytics system, which provides insight into the machine performance and maintenance requirements, all tailored to the specific needs of customers.

GHH concluded: “The NEO joins the company’s mid-range segment of LHD offering, which is one of the most comprehensive on the market: the range of 18 diesel and electric models with payloads from one to 21 tonnes is a weighty factor in choosing the perfect loader. And, by the way, the Germans have the same great selection in dump trucks to complement.”

Zinnwald striving for battery-electric circularity with lithium project development

The development of the integrated Zinnwald lithium project in Germany could see the incorporation of a battery-electric fleet of LHDs and the return of metal production to a region of saxony with mining history dating back to the Middle Ages.

The London-listed owner of the project, Zinnwald Lithium Plc, has just released a preliminary economic study on its namesake project focused on supplying battery-grade lithium hydroxide to the European battery sector.

As with any responsible battery metal project being developed today, the project’s ‘green credentials’ are being considered even at this early stage.

Zinnwald Lithium has been keen to flag these, mentioning the project is located close to the German chemical industry, a fact that should enable it to draw on a well trained and experienced workforce with well-developed infrastructure, plus reduce the ‘carbon footprint’ of the final end-use product.

This focus will see all aspects of the project – from mining through to production of the end product – located near to the deposit itself.

Zinnwald Lithium also said the project has the potential to be a low- or ‘zero-waste’ project, as the vast majority of both its mined product and co-products have their own large-scale end-markets.

This could see it produce not only battery-grade lithium hydroxide monohydrate products, but sulphate of potash (SOP) for the fertiliser market and precipitated calcium carbonate (PCC) – the latter being a key filling material in the paper manufacturing process.

The project now includes an underground mine with a nominal output of approximately 880,000 t/y of ore at an estimated 3,004 ppm Li and 75,000 t/y of barren rock. Processing, including mechanical separation, lithium activation and lithium fabrication, will be carried out at an industrial facility near the village of Bärenstein, near the existing underground mine access and an existing site for tailings deposition with significant remaining capacity.

With a 7-km partly-existing network of underground drives and adits from the ‘Zinnerz Altenberg’ tin mine, which closed in 1991, already mapped out, the bulk of ore haulage is expected to be via either conveyor or rail

The nominal output capacity of the project is targeted at circa-12,000 t/y LiOH with circa-56,900 t/y of SOP, 16,000 t/y of PCC, circa-75,000 t/y of granite and 100,000 t/y of sand as by-products.

The company is looking to complete the ‘circularity’ dynamic in its fleet and equipment selection, according to CEO, Anton Du Plessis, who mentioned that electric LHDs could be used to load and haul ore to an ore pass in the envisaged operation.

He said the cost estimates to use such equipment – which are factored into the project’s $336.5 million initial construction capital expenditure bill – have come from Epiroc, which has a variety of battery-operated mobile equipment.

“The base case is battery-operated loaders,” he told IM. “The final selection will be based on an optimisation study where, in particular, partly trolley-fed haulage systems will be investigated.”

Forms of automation are also being studied, Du Plessis said, with the caveat that “only select technologies we consider proven” will be evaluated.

Zinnwald Lithium is also looking at electric options for long-hole drilling underground, with both battery-based units and cabled versions under consideration and requiring firming up in the optimisation study.

With a 7-km partly-existing network of underground drives and adits from the ‘Zinnerz Altenberg’ tin mine, which closed in 1991, already mapped out, the bulk of ore haulage is expected to be via either conveyor or rail. The former, of course, will be powered by electricity, but the company is also considering potential battery-electric options for the latter, according to Du Plessis.

The company is blessed with existing infrastructure at the mine, which should help it in advancing the project at the pace its potential end-use manufacturing suppliers would like. It is already evaluating options for the construction stage – with an engineering, procurement and construction management contract the most likely option – and it has plans to conclude a feasibility study by the end of next year.

Du Plessis said while most of the fixed assets have been removed or were deemed outdated a long time ago from the former operating underground mine, other infrastructure was in good shape.

“The excavations, main level, underground workshop, ventilation shafts and, particularly, 2020 refurbished access tunnel provide a very good starting point for our project,” he said. “The access tunnel was originally constructed for dewatering the old mine and, therefore, the mine and the tunnel have been maintained very well.”

The company is now shifting to the bankable feasibility study and currently selecting partners for the project.

With what it calls a “simple, five-stage processing” route confirmed by test work for the extracted material at Zinnwald, the company is looking to select OEMs with the optimal concept for the project, Du Plessis said.

“In the PEA, mineral processing equipment cost is based on Metso Outotec estimates, pyrometallurgy is based on Cemtec technology, and hydrometallurgy is based on various providers’ technology,” he clarified.

Sandvik to deliver ‘biggest BEV fleet to date’ for Foran’s McIlvenna Bay

Foran Mining has selected Sandvik Mining and Rock Solutions to supply a fleet of 20 battery-electric vehicles (BEVs), including trucks, loaders and drills, for its McIlvenna Bay project in Saskatchewan, Canada.

Set to be one of the world’s first carbon-neutral copper development projects, McIlvenna Bay will be powered by clean hydroelectric power and designed to take advantage of Sandvik’s latest technological advances in sustainable mining, the OEM says.

Sandvik’s biggest BEV fleet to date will include seven Sandvik 18-t-payload LH518B loaders (pictured dumping into a TH550B), six Sandvik 50-t-payload TH550B trucks, four Sandvik DD422iE jumbo drill rigs, two Sandvik DL422iE longhole drills and one Sandvik DS412iE mechanical bolter. Delivery of the equipment is scheduled to begin next year and continue into 2025, Sandvik says.

Sandvik will also provide on-site service support and Battery as a Service by Sandvik at the underground copper-zinc mining project located in east-central Saskatchewan.

Jakob Rutqvist, VP Strategy and Commercial for Sandvik Mining and Rock Solutions’ Battery and Hybrid Electric Vehicles (BHEV) Business Unit, said: “This record contract is the culmination of a year-long collaborative effort between Foran Mining and Sandvik and demonstrates a shared vision that electrification will drive the future of sustainable mining. BEVs have enormous potential to reduce a mining operation’s carbon footprint, and Canada continues to be the epicentre for mining electrification and a blueprint for what to expect in other major mining regions very soon.”

Copper and zinc are critical metals for the transition to a low-carbon future as essential elements of electrical grids, solar panels, wind turbines and batteries. The McIlvenna Bay project intends to supply those minerals in a way that will not only be carbon neutral but ultimately have a net positive impact on the climate, according to Sandvik.

Dave Bernier, Chief Operating Officer of Foran Mining, said: “This is a very exciting period for Foran as we continue to execute on our initiatives to permit, construct and operate McIlvenna Bay. Sandvik is a global leader in industrial battery technology and we look forward to working together on our project. Utilising battery-electric equipment with semi- and fully-autonomous capabilities can help us achieve carbon neutral targets and provide a safer working environment, which is part of our Net Positive Business strategy as we look to deliver critical metals essential for global decarbonisation in a responsible and socially-empowering way.”

Foran Mining conducted a thorough analysis during its 2020 prefeasibility study to determine the investment case for BEVs compared with diesel. The company determined that BEVs would deliver better financial results at McIlvenna Bay when considering the savings generated through lower ventilation capital and operating costs.

That report, authored by AGP Mining Consultants Inc, envisaged the potential use of 7 Sandvik LH517i LHDs and 11 Artisan Vehicles (Sandvik) Z50 battery electric trucks for a 3,600 t/d of polymetallic ore operation.

Stefan Widing, President and CEO of Sandvik, said: “I am very pleased that Foran Mining has chosen Sandvik to deliver our leading battery-electric solutions for the pioneering McIlvenna Bay project. We see very strong momentum for our mining electrification offering, which offers great potential in driving more sustainable mining, helping customers to boost productivity, reduce greenhouse gas emissions and improve workers’ health.”

A dedicated on-site project team will be jointly working with the mine’s operations team to ensure the products and services in the delivery scope support the alliance on Foran’s journey towards more productive, efficient and sustainable mining, Sandvik said.

“Battery as a Service by Sandvik will enable McIlvenna Bay to get the most out of its battery-electric equipment by relying on unrivaled expertise to manage the capacity and health of batteries and chargers throughout their long lives,” it added.