Tag Archives: Sean McGinnis

Orica, Caterpillar to provide customers with high-fidelity rock property information

Explosives and blasting, IoT, Mining equipment, Mining services, Sustainable mining, , , , , , , ,

Orica and Caterpillar Inc have confirmed they are teaming up to improve real-time data exchange and integrate workflows across the mining value chain.

The collaboration is aimed at providing customers with intelligence to improve decision making and optimise their entire operations, with the announcement following a mention of this tie-up in Orica’s most recent FY2023 financial year results webcast.

The mining industry has started to unlock the potential of combining data, sensors and intelligence to optimise workflows for real-time decision making and value chain optimisation, the companies said. Digitally integrated workflows enable customers to achieve a step change in safety, productivity, recovery and sustainability outcomes for their operations.

“To realise the full potential across the entire value chain, technology domain leaders, customers and academia need to increase collaboration in an open ecosystem to develop integrated, end-to-end operational workflows which link orebody intelligence, drilling and blasting, material characterisation and processing,” they said.

Recognising this, Orica and Caterpillar have signed a memorandum of understanding (MoU) to explore opportunities to integrate key elements of their respective domains. The initial focus will be on the potential integration between Orica’s Rhino™, BlastIQ™, and FRAGTrack™ technologies with Cat® MineStar™ Terrain.

The goal of this integrated workflow is to provide customers with high-fidelity rock property information enabling significant improvements to on-bench safety, drilling and blasting program accuracy and productivity, along with higher quality blast outcomes that generate enhanced mill performance.

In the future, the two companies intend to extend their collaboration to optimisation of the entire value chain, from mine to mill. This approach aligns with both organisations’ ambitions to create sustainable solutions and services that will build the momentum for more intelligent and solution-driven mining ecosystems.

Sean McGinnis, Vice President of Technology & Global Sales Support, Caterpillar, said: “Our customers are looking for every opportunity to optimise the productivity and safety of their mining and processing operations. By combining and leveraging the insights unlocked by Orica and Caterpillar’s technologies, we will be able to provide customers greater access and visibility to the data and information they need to make, better real-time business decisions.”

Rajkumar Mathiravedu, Vice President of Orica Digital Solutions, said: “The mining industry requires greater collaboration amongst its leading technology players to build connected workflows across different domains to address the current issue of value-leakage arising from traditional and disconnected silos. Collaborative end-to-end ecosystems are critical to harnessing the full potential of advances in sensors, data processing and intelligence to enable the development of safer, more sustainable, and productive methods of resource recovery.

“Orica Digital Solutions is excited to be working with Caterpillar across a range of domains as we aim to better connect the digital and physical worlds to give our customers more timely and actionable insights across their value chains.”

Caterpillar surpasses 5 billion tonnes of material autonomously hauled

Automation, IoT, Mining equipment, Mining industry recognition, Mining safety, Mining services, Mining software, Sustainable mining, , , , , , , , , , , , , , , , ,

Roughly nine months after reaching the 4-billion-tonne (4.4-billion-ton) autonomously hauled milestone, trucks equipped with Cat® MineStar™ Command for hauling have now moved over 5 billion tonnes (5.5 billion tons), the OEM says.

Cat autonomous trucks are on pace to eclipse previous record totals of materials hauled in a calendar year, projected to be more than 1.4 billion tonnes (1.57 billion tons) in 2022.

Currently, more than 550 mining trucks are equipped with Command for hauling, operating across three continents. Over the last nine years, trucks equipped with Command for hauling have journeyed nearly the average distance between the Earth and Mars with zero loss-time injuries, according to the mining OEM.

Denise Johnson, Group President of Caterpillar Resource Industries, said: “In 2013, we placed our first fleets of autonomous trucks in Western Australia at FMG Solomon and BHP Jimblebar. Since that time, trucks using Command for hauling have safely travelled nearly 200 million km, more than twice the experience in autonomous operations of any automobile manufacturer. Caterpillar has grown the number of autonomous trucks in operation by 40% in the past two years.

“We believe that automation is one of many keys to implement technology that unlocks the value miners need when it comes to the energy transition toward more sustainable operations.”

One of the company’s recent contract wins on the automation front relates to BHP’s majority-owned Escondida mine, in Chile.

Marc Cameron, Vice President of Caterpillar Resource Industries, said of this agreement: “The new Cat 798 AC electric drive trucks replacing BHP’s entire haul truck fleet at the Escondida mine will feature technologies that advance the site’s key initiatives, including autonomy and decarbonisation. The agreement allows Escondida…to accelerate the implementation of its autonomy plans by transitioning the fleet with autonomous haulage system (AHS) technology.”

Caterpillar has enabled 13 customers at 23 different locations to succeed with full site autonomous haulage solutions. Starting with iron ore at Solomon (Fortescue Metals Group) and Jimblebar (BHP), its solutions now manage oil sands, copper, gold, coal, lithium and phosphate. Spanning the 190- to 370-t class sizes, the Cat 789D, 793D, 793F, 797F, and electric drive 794 AC and 798 AC mining trucks are capable of fully autonomous operation. Retrofit kits allow miners to expand Command for hauling to existing Cat mining trucks.

Since 2019, Caterpillar says it has won eight of nine greenfield autonomy sites on offer.

Sean McGinnis, Vice President and General Manager for Cat Mining, said: “In 2023, we will expand Command for hauling to the 139-t truck class at ioneer Ltd’s Rhyolite Ridge lithium-boron mine. This is the first greenfield project in North America to use an AHS. We are now seeing a shift toward autonomy requested on new Cat trucks. Whereas large mines with fleet sizes of more than 70 trucks were the early adopters of the technology, we are seeing economic viability for autonomy at smaller mines with a fleet of less than 15 trucks.”

Caterpillar says it continuously monitors the industry for opportunities to broaden the use of automation to help drive safety and efficiency.

Beyond expansion of Command for hauling to the Cat 785 for ioneer, Caterpillar sees potential for Cat autonomy in quarry and aggregates. Additionally, Caterpillar’s AHS technology has been deployed on the Cat 789D autonomous water truck (AWT) operating at Rio Tinto’s Gudai-Darri mine in Australia, the world’s first AWT, for automated watering of haul roads.

Caterpillar hits 2 billion tonnes hauled milestone with autonomous haulage system

Automation, IoT, Mining equipment, Mining safety, Mining services, Mining software, , , , , , ,

Caterpillar has again hit a significant milestone in autonomous haulage – achieving 2 billion tonnes hauled using Cat® MineStar™ Command for hauling.

The mining OEM’s autonomous haulage system (AHS) has doubled the amount hauled in the 16 months since reaching 1 billon tonnes hauled in November 2018, it said.

“In just a bit over six years, we’ve safely hauled 2 billion tonnes – a milestone we achieved significantly faster than our competitors,” Sean McGinnis, MineStar Solutions Product Manager, said. “This milestone makes Command for hauling the most productive commercially available solution, and it’s something mining people are noticing.”

Since commercially launching Command for hauling in 2013, Caterpillar has continued to improve the speed of implementation. “We’re launching Command on more sites and implementing it more quickly, so more of our customers can experience the safety and productivity gains that autonomous hauling delivers,” McGinnis said. In the company’s March quarter earnings call on April 28, Andrew Bonfield, Chief Financial Officer of Cat, said 282 trucks were running autonomously using Cat Command for hauling.

McGinnis credits input from Caterpillar customers for the success of Command for hauling. “One of the reasons that Caterpillar has been so successful in expanding Command and delivering results is because we listen to and partner with our customers. They identify features, functionality, and even the autonomous truck models they need for their operations.”

One of Cat’s latest AHS customers is Newmont’s Boddington gold mine, in Australia, which earlier this year announced it would become the world’s first open-pit gold mine with an autonomous haul truck fleet. This followed the signing of a deal with Caterpillar, which would involve adding some new AHS-enabled Caterpillar 793Fs to the haulage fleet and retrofitting some existing 793Fs with AHS capabilities, a Newmont spokesperson confirmed. In the same March quarter earnings call, Cat’s Bonfield said the company expected to start shipping the first of its new Cat 793F autonomous trucks to the miner next year.

Over the last six years, MineStar Solutions has also continued to grow its expertise in autonomous operations – not only in hauling but also with autonomous dozers, drills and underground loaders, the company said.

John Deselem, Global Autonomy Operations Manager, said: “The skills and knowledge of our MineStar team are unmatched in the industry. Beyond getting better at implementing the system, we’ve become trusted advisors for mine sites looking to take advantage of what autonomy makes possible. We listen to their needs, then work together to build the ideal solution for their mine.”

“The push toward autonomous mining doesn’t show any signs of slowing,” McGinnis said. “We have projects in the works with a number of large mining companies either looking to expand their current autonomous haulage operations or implement new ones.”

The Caterpillar autonomous fleet is made up of Cat 789D, 793D, 793F and 797F trucks, as well as a fleet of Komatsu 930Es. The Cat 794 AC electric-drive autonomous truck will be ready for autonomous haulage later this year. Command equipped trucks have driven over 67.6 million kilometers without a lost-time injury, according to the company.

“Command for hauling has proven its value to mining customers,” McGinnis said. “That value is reflected in the rate at which the Cat autonomous fleet achieved this milestone. The fleet is growing quickly and production continues to climb as mining companies benefit from greater truck productivity, increased truck utilisation, consistent truck operation, and reduced costs.”