Tag Archives: RCT

Costerfield gold-antimony mine firing on all cylinders thanks to RCT solution

Automation, Communications in mining, Equipment maintenance, Explosives and blasting, IoT, Mine operation news, Mining equipment, Mining maintenance, Mining safety, Mining services, , , , , , , , , , ,

Removing personnel from underground loading operations at Mandalay Resources’ Costerfield gold-antimony mine in Victoria, Australia, through RCT’s ControlMaster® Teleremote and Guidance Automation, has led to time and cost savings, as well as maintenance and safety benefits, according to a recent case study from the automation specialist.

Costerfield produces ore via a single portal underground mine with narrow vein mining carried out to extract vertical veins of ore. The mine produces up to 80,000 gold-antimony-equivalent ounces per year in a concentrate comprising around 54% antimony and 60 g/t gold.

The nature of narrow vein mining dictates that ore drives are quite thin to reduce the amount of waste material that is captured, with Costerfield’s drilling and blasting program designed to maximise ore recovery by throwing the ore towards the draw point. Historically, however, the site could only recover 75% of the ore, according to RCT, due to the remaining ore sitting in the stope void out of reach of the underground LHD as manually operated loaders could not exceed the stope brow.

Looking to increase productivity, Mandalay investigated implementing a loader that could be managed remotely to extract additional ore and to safeguard equipment operators from hazardous situations at the mine face. This led to it, in 2015, engaging RCT to implement its ControlMaster Teleremote and Guidance Automation product on a Sandvik LH203 LHD.

The automated loader enabled Mandalay Resources to retrieve significant amounts of ore that were previously unreachable, RCT said.

In recent years RCT has increased the autonomous fleet at Costerfield by commissioning ControlMaster Teleremote and Guidance Automation on a second Sandvik LH203 as well as a Sandvik LH151D.

The machines are managed from Fibre Optic Control Stations at secure locations in the underground mine protected by Laser Guard Containment Units as well as stations on the mine’s surface.

Jayson Guzzo, Major Projects and Innovation Manager – Costerfield, Mandalay Resources, said removing operators from the machine is the “best outcome” as it eliminates their exposure from one of the highest risk jobs, which is working at a stope brow.

“The small loaders we use are very rigid which has the potential for repetitive strain injuries,” he said. “They also have open cabs and, in this environment, dust, machine exhaust and debris can be an added safety concern.”

In mid-2019, Mandalay made the decision to implement a digital mine communications network to accommodate future technological growth.

Guzzo said: “Given that we are a narrow vein operation we may have to access ore a significant distance from the mine access point so we are looking at going to a digital platform so we can run a fibre backbone and autonomously operate machines over a vast distance.

“In a traditional mine, you might spend a whole week bogging a single stope before moving, but at Costerfield we might bog three or four headings in one shift, so the number of sites that we have to have set up at any one time are multiple, hence a digital system will significantly speed up the process of commissioning new drives.”

Mandalay has reported that ControlMaster Guidance Automation enabled them to carry out bogging and firing operations simultaneously, saving them substantial time which was previously spent clearing personnel to a safe distance, RCT said.

Guzzo said the solution has enabled the company to reduce shift changeover time by two thirds – which is a significant cost saving – and the site has also experienced less unplanned machine downtime.

“At Costerfield, the drives are roughly 2 m wide so Guidance Automation keeps the machines off the walls and stops them bouncing around the tunnels, so the damage to the machines is a lot less and results in significantly reduced unplanned maintenance time,” he said.

Guzzo concluded: “Relocating operators from the cab of our loaders to safer environments on the mine’s surface is essential and being able to continue bogging during firing as well as significantly reducing shift changeover time is critical to improving site productivity.

“Plant automation is definitely the way of the future in the mining industry and RCT are the leaders in that area, which is why they are our preferred supplier with this equipment.”

RCT and Northern Star carry out ‘history-making’ trial in WA’s Goldfields region

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RCT and Northern Star Resources have recently completed an autonomous technology trial in Western Australia’s Goldfields region that bodes well for the future of underground remote operations centres in the state.

In early October, RCT set up a ControlMaster® Automation Centre at the Western Australian School of Mines (WASM) in Kalgoorlie with a network connection to an underground LHD equipped with ControlMaster Guidance Automation at the East Kunduna Joint Venture (EKJV) mine.

EKJV is a joint venture between Northern Star, Tribune Resources and Rand Mining, managed by Northern Star  and located around 40 km away from Kalgoorlie.

The mining method at the Kundana operations is from underground using up-hole longhole stoping with paste backfill.

The project to set up a Remote Operating Centre (ROC) was a combined effort by technical specialists from RCT and Northern Star Resources, RCT said.

Once operational, a Northern Star Resources equipment operator controlled the ControlMaster Guidance Loader from the WASM Kalgoorlie facility and resumed site required remote production rates.

Northern Star Resources currently uses ControlMaster Guidance Automation on its underground LHD fleet at the EKJV from an onsite Surface Control System.

RCT said: “The trial is a history-making event for the Goldfields region and represents an exciting opportunity for both Northern Star Resources and RCT and what can be achieved through the use of smart technology.”

RCT Kalgoorlie Branch Manager, Rick Radcliffe, said: “This trial has helped both businesses to understand what future opportunities there are in autonomous technology, which is not only exciting for both business but the local Goldfields community as well.

“To conduct the trial from the WA School of Mines is also a story worth sharing with the wider mining and METS (mining equipment technology and services) community, to showcase the great innovation coming from the Western Australian Goldfields region.”

ROCs represent great job opportunities for members of the labour force who traditionally would not be able to work on a mine site due to various lifestyle or personal factors, he added.

Chief Executive Officer of Northern Star Resources, Stuart Tonkin, said: “ROCs are proven for surface operations, but this advancement for an underground application is a significant development led by RCT in the Kalgoorlie Goldfields.”

He added: “Northern Star Resources encourages continual improvement and innovation, and we are very pleased with RCT’s commitment to developing practical mining solutions.”

RCT brings teleremote options to Hindustan Zinc’s Rampura Agucha mine

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Autonomous solutions specialist RCT has entered into its first automation project in India, commissioning its technology on machinery at Hindustan Zinc’s Rampura Agucha zinc-lead mine in Rajasthan province.

The agreement with Hindustan Zinc Limited and its mining services provider Barminco will see ControlMaster® Guidance Automation installed on two Cat R2900 underground LHDs at the mine. These loaders will now undertake teleremote mining in open stopes developed by Barminco.

Barminco, in February, was awarded a three-and-a-half-year underground mining services contract at Rampura Agucha. The mine, meanwhile, is currently undergoing an expansion to boost production to 5 Mt/y of ore.

RCT will install two underground ControlMaster Automation Centres, as well as four ControlMaster Area Access Cabinets into mine stopes, as part of this package. These will collectively enable machine operators to safely manage the machines away from the mine face, according to RCT.

The Automation Centres will also be equipped with Multiple Machine Selection and Multiple Machine Control options, enabling a single operator to manage both machines at one time, according to RCT.

The project represents the first time RCT has deployed its proprietary digital communications network RCT Connect into a mine site anywhere in the world, the company said, adding that RCT will carry out training programs to empower local operators and maintenance personnel then machine servicing works on an ongoing basis.

Chinova goes autonomous with RCT at Osborne mine

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RCT says it has entered into a project with Chinova Resources to install and commission autonomous technology at its Osborne copper-gold underground mine in Queensland, Australia.

The project involves RCT installing its ControlMaster® Guidance Automation packages on two CAT 2900 LHDs at the operation, which comprises mining, processing facilities and exploration tenements.

RCT will also provide an underground Teleremote Cabin complete with a Laser Guard Containment Unit and analogue communications as well as a Fibre Optic Control Station located on the mine’s surface, it said.

Osborne is a 2 Mt/y (5,500 t/d) copper-gold flotation operation that has recently transitioned from open-pit to underground mining.

RCT said: “ControlMaster Guidance offers consistent machine operation and cycle times by reducing unplanned machine downtime from operator errors and improved safety for operators who can manage the machines from remote locations.”

RCT’s Brisbane and Mount Isa branches carried out installation and commissioning works in mid-2019 and will deliver operator and maintenance training to site personnel, it said.

RCT deploys ControlMaster at Westgold mine sites

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RCT says it is finalising a major automation project for Westgold Resources at five of its gold mine sites in Western Australia’s Murchison region.

The package of works involved the autonomous solutions provider installing and commissioning its ControlMaster® Guidance Automation technology to 10 of Westgold’s underground loader fleet across its mining operations, including CAT R2900Gs and Sandvik LH517 LHDs.

RCT will also deliver its latest surface-based ControlMaster Automation Centres equipped with Multiple Machine Selection and Multiple Machine Control options aimed at driving further mining production efficiencies at each site.

Guidance Automation encompasses a fully automated tramming cycle between production level locations, which includes proportional braking and automated steering and speed control, RCT says.

“The technology also includes features such as G-Dash which empowers operators by presenting a graphical dashboard of the machine telemetry and diagnostic features to ensure optimal loader performance,” the company said.

Implementing the ControlMaster Guidance Automation solution across Westgold’s Big Bell, Paddy’s Flat, Comet, South Emu and Starlight operations standardised the company’s production technology and will deliver significant efficiencies and synergies, according to RCT.

RCT Business Development Manager Mining – APAC, Ryan Noden, said each delivery is being tailored to site-specific requirements.

“Over the past few months, RCT has been working in a staged approach to upgrade Westgold’s existing systems and consolidate the operating system across all operations to ControlMaster,” he said.

“The introduction of RCT’s technology will offer Westgold a proven and successful pathway to mine digitalisation, with the ability to adopt the latest technology offerings as and when required and applying shared learnings across its operations.”

He continued: “RCT is excited to be working closely with Westgold as a technology provider to achieve operational excellence.”

David Noort, Executive General Manager – ACM at Westgold Resources, said he was delighted to be working with RCT.

“We made the decision to implement the ControlMaster Guidance Automation solution due to RCT’s proven productivity and technological reliability and proactive support services,” he said.

“Being able to implement Multiple Machine Selection/Multiple Machine Control is an added advantage as it will support staged growth and specialised applications where geotechnical constraints require a period of standoff before re-entry after blasting.”

RCT has been upskilling Westgold site personnel by implementing operator and maintenance training courses and will carry out after sales support and field servicing on an ongoing basis, it said.

RCT on the importance of autonomous technology training

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As an OEM-agnostic facilitator of autonomous solutions, RCT has vast experience in training up personnel and companies on how to best use this technology. Training Coordinator, Sunil Kumar, shares his thoughts on the subject.

Across the global mining industry there is an ever increasing take-up of smart technology. Gone are the days where miners worked in isolation, digging up earth and hoping to strike pay dirt. Now every stage of the mining process is jam-packed with technology designed to improve the mining process and safeguard mining personnel.

With the inevitable uptake of smart technology, advanced communication infrastructure and autonomous machinery, comes the need to ensure employees are suitably trained and confident in utilising this technology. At RCT, we categorise employee training needs into two streams; equipment operators and maintenance personnel.

Our comprehensive operator training is focused on functionality and designed to impart all necessary knowledge to get the most out of mining equipment. Our maintenance training goes a little bit deeper into the underlying technology of RCT’s proprietary products. We offer a regular maintenance package which teaches mine site personnel to replace components and conduct other minor maintenance works.

We also have an advanced maintenance package for select customers, which teaches suitably qualified mine employees to service individual components and carry out the type of activities that RCT’s specialised Field Service Technicians would carry out on a site visit.

Personal safety has been one of the key drivers behind an uptake of training programs in the global mining industry. Most countries that RCT works in have stringent laws governing people working in hazardous environments. Further to this is a cultural shift inside mining companies, which want to protect their workers and safeguard their operations.

Use of autonomous technology in this sort of hazardous environment is a no-brainer because a lot of the work involves people coming into contact with dust, smoke, extreme weather, chemical particles and long working hours often in confined working spaces such as underground operations.

Therefore, in order to use autonomous technology properly, they need to be informed about the standard operating procedure otherwise it can result in serious incidents involving machines and people. Properly trained personnel contribute significantly to operational efficiency and productivity because technology is only as good as how it is used. Most people underutilise the technology that they possess.

The most common example is the smart phone which can improve personal productivity multi-fold if used optimally, however most people only use about 10-15% of the features and capabilities. The same principle applies to autonomous technology in the mining industry, which, if properly used, will enable the mine site to increase productivity multi-fold, which in turn increases profits.

Training is equally essential for both younger workers who are traditionally more technologically savvy and older workers who are adapting to new technologies in the mining industry.

Autonomous technology is going into every mine so the technology is becoming part and parcel of new mine infrastructure. Therefore, it is important that the entire workforce be upskilled so they have some level of understanding of autonomous technology.

Going forward, RCT will continue to offer face-to-face training packages delivered on mine sites or in our offices. This will be complemented by an online training portal which will enable us to reach very remote mine sites that are difficult to access physically and will focus more on repeat trainings and refresher modules.

RCT and GBF reflect on decade-long automation partnership

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RCT and underground mining specialist, GBF, have marked 10 years of working together to implement autonomous technology into underground mining operations.

Since 2009, when GBF & RCT conducted underground trials of the ControlMaster® Guidance Automation system at Gold Fields Caves Rock mining operations, RCT has delivered 19 autonomous systems including Sandvik LH203s, CAT 2900Gs, R1700s, R1700Gs and R1300Gs at multiple GBF-run mine sites throughout Western Australia’s Goldfields, according to RCT.

The work collectively amounts to roughly 15,000 hours of machines operating on Guidance Automation within GBF-run operations.

“ControlMaster Guidance Automation has seen numerous software iterations over its product life starting with dynamic operator engagement, surface control to independent autonomous tramming and, more recently, multi machine control via RCT’s latest automation offering,” RCT said.

GBF Maintenance Superintendent Alan Moyle, who played a key role in the initial trials and has seen the Guidance Automation system evolve over the last 10 years, said RCT’s technology has significantly improved safe machine operations by removing personnel from the mine face as well as better operator fatigue control.

“Greater control features have reduced the amount of machine damage due to operator errors with consistent machine cycles enabling us to improve productivity and it provides us data when tendering for new contracts,” he said

“RCT have also provided multiple opportunities for GBF apprentices to gain experience with their latest modern technology which they have subsequently applied to their work.”

RCT Product Manager Automation & Control, Brendon Cullen, said GBF’s early adoption of RCT’s technology meant its operations have benefitted consistently as the product has evolved.

“GBF has been influential in driving features and improvements to the system over time and develop new features such as G-Dash which empower operator’s decision making by presenting a dashboard of the machinery in relation to its surrounding in real time,” he said

“GBF’s operators have also consistently provided feedback over time, resulting in improvements such as faster tramming times, better cornering speeds, more efficient braking and the evolution of the fully automated tramming cycle.

“As the mines are becoming deeper the drive to operate the machinery from the surface is becoming a key requirement to maximise production times. RCT continues to work in partnership with GBF to allow them to reach their goals as cost efficiently as possible using the technology available onsite at the time.”

RCT brings automation to MATSA underground operations in Spain

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RCT says it has finalised a major automation project at MATSA’s Aguas Teñidas and Magdalena mines in the Huelva province of Spain.

The project involved installing ControlMaster® Guidance Automation on four CAT R2900G underground LHDs and one Automation Centre Surface Control Station at MATSA’s Aguas Teñidas copper-lead-zinc mine.

MATSA is a jointly-owned company by Mubadala Investment Co and Trafigura. It owns and operates three mines in the Huelva, including Aguas Teñidas, Magdalena and Sotiel, on top of a 4.4 Mt/y copper and polymetallic processing plant.

RCT’s automation centre at Aguas Teñidas is fitted out with RCT’s Multiple Machine Control feature enabling a single operator to remotely control multiple machines at the same time via the mine’s digital communications network.

RCT also commissioned two Sandvik LH621 underground LHDs with ControlMaster Guidance Automation at the nearby Magdalena copper mine. These Sandvik LHDs can operate on a digital network via RCT’s Area Access Cabinets which act as an extension of the automation centre and interfaces between the work areas and the machines.

This instalment builds on a previous project to mount ControlMaster Teleremote and Guidance Automation solutions on three of the site’s CAT R2900G LHDs, which operated on an analogue network via two surface control stations, according to RCT.

Guidance Automation allows machines to tram between two predetermined points on a mine site with the push of a button by operators who also receive real-time information including machine speed, rpm, direction, pitch and roll, RCT said.

“The automation centre consists of an ergonomically designed operators chair facing up from screens, which feed real-time information from sensors and machine-mounted cameras to the operator,” the company added. Teleremote, meanwhile, enables the operator to remotely manage the machine from a control station in real time.

A MATSA spokesperson said: “This system not only allows us to operate in hazardous conditions safely from the surface, but also increases productivity by permitting us to operate during shift change and smoke clearing. We also have the capability to simultaneously operate more than one piece of equipment with the same teleremote operator.”

RCT Account Manager, Shane Smith, said the Guidance Automation products would provide solid benefits for MATSA. “ControlMaster Guidance Automation has a proven track record of improving operator safety in a traditionally hazardous working environment by removing them from the mine face,” he said.

“The faster tramming speeds will also help to boost site productivity on site and limit unplanned machine downtime due to repairs from machinery accidents while the new automation centre will reduce operator fatigue due to improved comfort and ease-of-access on the mine’s surface.”

RCT fuel cap protection system finds its way to Northern Territory gold mine

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RCT has recently completed a project to install its fuel cap protection system at an underground mine in a remote part of the Northern Territory in Australia.

The gold mine’s fleet of 17 Epiroc MT6020 underground haul trucks are now equipped with RCT’s Muirhead® Fuel Cap Isolation system, which has been devised to prevent incidents when refuelling.

This protection system helps clients eliminate damage to refuelling bays and save money in downtime costs associated with operators accidentally driving off with the nozzle still attached, according to RCT.

“The implementation of the Fuel Cap Isolation system is just another way of safeguarding operators,” the company said.

RCT’s Kalgoorlie branch makes quick work of automating Sandvik LH621i LHD

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RCT says it has successfully installed its autonomous technology on the recently released Sandvik LH621i underground loader for one of its clients in Western Australia’s Goldfields.

Earlier this month, RCT’s Kalgoorlie branch received the loader and commissioned the ControlMaster® Guidance automation technology package only weeks after the machine was first released to the Western Australia market.

The ‘i’ series represents Sandvik’s latest iteration of its underground loader range and, according to Sandvik, is the LHD of choice for rapid mine development and large-scale underground production. It is a matching pair with the previously introduced 63-t payload Sandvik TH663i truck.

ControlMaster Guidance Automation means machines can automatically tram between production level locations at higher speeds while also providing real time, graphical machine information to operators situated in remote automation centres, RCT said.

RCT Kalgoorlie Branch Manager, Rick Radcliffe, said the company could install and commission the Sandvik LH621i loader and deliver it to site within a relatively short lead time.

“Now that we have documented the new LH621i, all future ‘i’ series loaders can be commissioned in exactly the same amount of time as traditional Sandvik 621 loaders,” he said.

“This work follows on from a previous project where we commissioned two Sandvik LH517i loaders in the Kalgoorlie workshop for clients in the region.”