Tag Archives: SME MineXchange Annual Conference & Expo

Caterpillar Safety Services looks to build safety resiliency with newest updates

With safety no longer being a box-ticking exercise but a true measure of employee engagement, Caterpillar Safety Services says it helps build a strong culture where safety practices are embedded across an organisation. To aid this, the company has launched two updates to its programs contributing to resilient safety cultures.

The updated Safety Perception Survey and a program focused on human and organisational performance that have recently been announced leverage Caterpillar Safety Services’ 50 years of operation, along with the latest research and approaches to address safety excellence within organisations.

Today, Caterpillar Safety Services says it assists companies with improving the four components of a resilient safety culture, where safety is approached proactively, and all team members take ownership of safety. This expands to programs featuring equipment from all OEMs – not just Caterpillar. The components include:

  1. System – clearly defined safety expectations embedded in policies and procedures to identify and mitigate risk;
  2. Mindset – a shared mindset that safety is everyone’s responsibility, people make mistakes and an environment of openness that makes people feel safe to speak up;
  3. Leadership – specific, consistent leadership behaviours at all levels of the organisation that positively influence people toward safe work; and
  4. Ownership – occurs when all levels fully engage in the creation and continuous improvement of the safety system.

Trinnie Cortez, Industry Consultant, Caterpillar Safety Services, said the latest updates reflected ongoing trends in the industry that are relevant to safety people and operators on the front line in mining.

“We, at Caterpillar Safety Services, are close to our customers and, with these updates, are recognising not only feedback from the field but also from our technicians working with equipment on a daily basis,” he told IM on the sidelines of the SME MineXchange Conference and Expo, in Phoenix, Arizona. “The updated Safety Perception Survey, for instance, is a product of continuously communicating with safety steering teams and the facilitation of working groups. We continue to evolve our offering in line with what the market tells us.”

The Caterpillar Safety Services Safety Perception Survey analyses an organisation’s safety culture. Building on 35 years of research and study, the new survey updates language and modern concepts of safety culture excellence, adding questions related to psychological safety and human and organisational performance.

The new survey’s reports are streamlined with more modern visualisation of the data. They measure five safety activities – hazard identification, event learning, inspections, near miss and safety meetings – and address 11 cultural indicators, including caring climate, employee involvement, feedback, management credibility, training effectiveness and risk reduction. Importantly, they also show how safety is perceived differently among employees, supervisors and managers.

Human and organisational performance is a framework concept for talking about safety and creating a resilient safety culture, Caterpillar Safety Services explains. It is a mindset that allows organisations to build more error-tolerant systems by teaching leaders that expecting perfection from workers, processes, or procedures is not realistic.

Caterpillar Safety Services says traditional methods of managing safety systems centre around designing policies, standard work and processes assuming work happens in a straight line. Management sets the expectations, tells workers what to do and the workers do it the same way, every day.

“This method, however, does not account for organisational factors that can disrupt the system, such as employees not having the right tools for the job and adapting or making tradeoffs because they are still required to meet production targets,” it said. “Nor does it account for the individual factors that impact a worker’s awareness, or lapses in attention due to events in his or her personal life, such as a family emergency.”

When workers deviate from the safety plan or make mistakes under the traditional model, they may be scrutinised or punished to attempt to improve safety, but this can have the opposite effect and lead to a weaker safety culture.

Using human and organisational performance principles, Caterpillar Safety Services applies a new understanding of human behaviour to safety, it says. Leaders create an environment where employees feel empowered to speak up to share their ideas, struggles and mistakes. The organisation learns to improve its safety system continuously.

“With this framework concept, we are recognising what real leadership is within a safety context,” Cortez said. “Building and promoting such leadership is key to getting the whole workforce engaged with programs for continuous safety improvements.”

This results in a more engaged and proactive safety culture with improvements in morale, retention, efficiency and profitability, according to Caterpillar Safety Services.

Caterpillar Safety Services assists organisations with implementation of human and organisational performance principles through its Leadership Development and Coaching program.

“Tailored to the specific needs and objectives of the individual leaders, the program includes a mix of workshops, assessments and individual face-to-face sessions,” Caterpillar Safety Services said. “It helps each leader understand their strengths and areas for development in safety management, demonstrates how a leader impacts the safety culture, and creates personalised development plans for all leaders that align with organisational goals and processes.”

Caterpillar gears up for SME and CONEXPO-CON/AGG shows

Caterpillar has a busy few months lined up on the conference circuit, with major product releases, service options and technologies to be highlighted at the SME MINEXCHANGE 2023 event in Denver, Colorado, and CONEXPO-CON/AGG 2023 in Las Vegas, Nevada.

Focusing beyond the iron, the Caterpillar MINEXCHANGE 2023 exhibit will highlight the company’s innovation, technological advancements, and how Caterpillar is solving mining challenges today and innovating for the future. With its “Big Difference” theme, the company will showcase how it positively impacts miners and offers a range of careers within the mining industry at the event, which runs from February 26-March 1.

This includes:

  • Big Innovation – details how Caterpillar commits significant R&D investment to technology and automation that help mining customers succeed and contribute to a better, more sustainable world; and
  • Big Opportunities – covers career opportunities at Caterpillar for creating high-tech solutions.

Inside the Cat exhibit, a Cat D8 simulator will allow conference attendees to experience operating the dozer in a virtual environment. A video wall features the themed “Big” messages that include more details on Caterpillar and its mining solutions, autonomy leadership, a real-world sustainability journey and testimonials from Cat employees. Subject matter experts will be on hand to discuss Caterpillar’s latest technology, autonomy and equipment solutions for the mining industry. In addition, seven Caterpillar subject matter experts have been selected to present eight technical abstracts at MINEXCHANGE covering diversity in the workplace to technology and automation to implementing change management.

In Las Vegas at CONEXPO-CON/AGG 2023 from March 14-18, meanwhile, Caterpillar will highlight its latest products, services and technologies while paying tribute to those who build the world’s infrastructure in what is its largest exhibit to date at the event.

The company’s 6,500 sq.m outdoor demonstration arena will anchor the massive display known as Operator Stadium (visualisation pictured below)

New Caterpillar Technology, Services and Sustainability hubs provide visitors the opportunity to look for ways to increase operating efficiencies and improve machine uptime, while new and current models and battery-electric machine prototypes will be highlighted.

The extensive Cat® equipment display in the Festival Lot is set to include more than 30 machines, including model unveilings and battery-electric model prototypes with charging stations. Visitors will see two main equipment demonstrations each day; one focused on the latest Cat technology, and one that will spotlight the company’s full equipment line up. Additionally, Caterpillar will be providing daily spotlight demonstrations that will take a deep dive into key industry topics including improving fuel efficiency and job site efficiency, the evolution of technology, and convenient, scalable solutions for all customers.

The new Cat 950 medium wheel loader on display offers, Cat says, premium performance and simple-to-use technologies to help boost operator efficiency and increase productivity, while extended service intervals help lower maintenance costs. Visitors will be treated to a preview of the Next Generation Cat 926, 930 and 938 small wheel loaders – slated for production in late 2023 – which feature new technologies designed to make work easier, a reimagined operator environment and extended service intervals.

Caterpillar Industrial Power Systems Division, meanwhile, will exhibit a wide and rapidly growing portfolio of high-efficiency Cat industrial power solutions. The exhibit includes the unveiling of a new high power internal combustion engine, as well as lithium-ion battery technologies under development. Engines on display, such as the C3.6 IPU, C7.1 and C9.3B, meet EU Stage V, U.S. EPA Tier 4 Final emission standards and are compatible with biodiesel up to B20 and hydrotreated vegetable oil (HVO) to EN15940. The booth will also showcase Caterpillar’s technical services and market expertise leveraged by the global Cat dealer network to maximise the efficiency and extend the lifecycles of off-highway equipment, including Cat remanufactured and service replacement engines.

Caterpillar says it offers a range of service options that are easy, convenient, flexible and sustainable, and will be featured in the Services Hub at the event. The new Cat Central app is the latest tool for convenient access to genuine Cat parts and support. Another new service-related solution is the new Cat SIS2GO app which, Caterpillar says, takes the guesswork out of maintaining, troubleshooting and repairing Cat equipment. Both apps are available on Windows, iOS and Android platforms.

Team members from Cat Financial will also be available to discuss the latest leasing and financing programs.

The Caterpillar Technology Hub will offer attendees the ability to experience a range of new and existing Cat technologies – VisionLink, Cat Command, VisionLink Productivity, Cat Detect, Cat Grade and Cat Payload. Caterpillar SMEs will be on hand to assist each customer in finding a scalable solution designed to fit the business’s needs and budget.

Its centerpiece exhibit, the “Looking Glass” cube, displays and interactively showcases the five key capabilities of the new Cat VisionLink® application – Geofence & Location, Fuel Theft Alerts, Diagnostics, Idle Time/Fuel Burn, and Maintenance. An interactive wall will invite visitors to explore the full suite of VisionLink capabilities for both Cat and non-Cat equipment and non-machine assets.

The hub’s multiple Cat Command stations allow attendees to remotely operate Cat machines located more than 640 km away at the Tinaja Hills Demonstration and Learning Center. They are positioned to allow attendees to better experience and learn more about the Command for Dozing, Excavating and Loading technologies.

The Caterpillar Sustainability Hub will spotlight fuel efficiency and alternative power sources; technologies to fit every operation and budget; and parts and service designed to make uptime fast and easy, the company says. Plus, customers will learn about sustainability benefits they can choose today and plan for tomorrow.

Outside the Sustainability Hub, exhibit attendees can view components of Caterpillar’s total site solution for the energy transition, including four battery-electric machine prototypes – the Cat 301.9 mini excavator, 320 medium excavator, 950 GC medium wheel loader and 906 compact wheel loader – in addition to AC and DC charging solutions. The Caterpillar-designed batteries powering these battery-electric machines are built on lithium-ion Cat technology with a modular design that offers flexible configurations across multiple applications.

Marks reveals Resolution copper concentrator details at SME

There’s some good news for mineral processing equipment suppliers looking to win business from the Resolution copper mine in Arizona, USA: the Rio Tinto/BHP-owned project already has a preliminary concentrator plan in place.

The sticking point is that, according to Anita Marks, Principal Advisor, Process Engineering, Resolution Copper, the plant ground-breaking is not likely for another eight years!

Speaking at the 2020 SME MineXchange Conference & Expo, in Phoenix, Arizona, on Tuesday, Marks revealed the plans for the concentrator at the mine, which when operational could become the largest copper producer in North America.

The project, situated close to the former-operating Magma mine, is currently in the process of deepening Shaft 9 down to a level of 2,086 m deep. The project partners will have spent over $2 billion (Rio Tinto share $1.1 billion) by the end of this year to develop and permit the project, including $302 million of additional expenditure approved earlier in 2019. Marks’ long timeline to groundbreaking is a reflection of the lengthy permitting process the project will have to go through.

Following the shaft deepening – expected to be completed in 2021 – and if the project receives the required approvals, development work for the block cave mine could start to take place.

At the same time as the company is focused on these aspects of the project, Resolution is leveraging the drill core it has obtained to calculate all-important metallurgical information and come up with a preliminary concentrator design.

The project has delineated indicated and inferred resources totalling 1.97 Bt at 1.53% Cu and 0.036% Mo from drilling, so there are many datapoints to draw from when it comes to generating a process flowsheet. It has used 79,000 ft (24,079 m) of core – including 38 full holes and 10 partial holes – 527 grindability samples, 646 rougher/cleaner kinetic tests and three pilot projects to come up with these plans, according to Marks.

Ahead of the concentrator, ore will be crushed underground – possibly with a gyratory crusher – and conveyed underground before being hoisted to surface.

The concentrator looks like having a SAG and ball mill configuration without a pebble mill (at least in the initial stages), plus a large cell bulk flotation circuit with columns for cleaning. It would have a separate float for tailings separation and produce both a copper and molybdenum concentrate.

This has the potential block cave mine producing 120,000 t/d of ore, with plant availability expected to be 92%.

And water consumption and recycling are high on the priority list for the project, with Marks saying the company is trying to reclaim as much water as possible. A tailings thickener is expected at the concentrator itself, with the aim to capture 80-85% of the water used in the process, she said.

ABB’s Bonvicini argues the OPEX case for grinding mill installations

ABB’s Leandro Bonvicini is urging mining companies to think outside of the capital expenditure box and conduct numerous tradeoff studies when deciding on their grinding circuit of choice.

Speaking about the Toquepala copper expansion project in Peru (pictured), specifically, in a talk titled, ‘SPCC Toquepala Expansion: Designing a reliable grinding circuit’, at the SME MineXchange Annual Conference & Expo, in Phoenix, Arizona, Bonvicini said the mine owner, Southern Peru Copper, was keen to employ a solution that was not only affordable from a capital cost perspective, but also energy efficient and came with low operating costs.

The $1.2 billion expansion, which saw throughput rise from 60,000 t/d to 120,000 t/d, involved the addition of two new thyssenkrupp-made ball mills, with ABB providing the gearless mill drives (GMD) technology. This came on top of the 33 mills the miner already had up and running as part of the existing 60,000 t/d plant at the operation.

GMDs are the grinding solution of choice in challenging environments, according to ABB. By eliminating bolt-on mechanical components such as ring-gears, pinions, couplings and gearboxes, GMDs offer ore producers unrivalled availability, efficiency and durability, while reducing operating expenditure, the company says.

Unlike more traditional ring-geared mill drives – where a ring-shaped gear encircles the mill and drives it through one or two pinions followed by conventional motors – GMDs work by mounting rotor poles directly to the mill body and surrounding it with the stator ring, meaning the mill itself is incorporated into the motor.

The necessary torque to turn the mill is transmitted between the GMD motor and the mill via the magnetic field in the tiny air gap between the stator and rotor. Because this type of motor system requires no gearing or direct contact transmission, GMDs boost efficiency by reducing frictional losses, while fewer mechanical critical components means less maintenance downtime is required due to wear and tear, according to ABB.

Bonvicini said SPCC weighed up numerous drive options during the due diligence phase but settled on GMDs even though the mill power required was as low as 11 MW. He said this was one of the lower power installations the ABB GMD team had employed, but the operating economics stacked up.

The project team was focused on choosing a solution that, even if it cost slightly more to install, would provide the lowest operating costs over the life of the mine, according to Bonvicini. This convinced the company to employ GMDs for the very first time in its grinding circuits.

In addition to the GMDs on the ball mills, ABB supplied two 2.65 MW motors for the high pressure grinding rolls working at the operation, according to Bonvicini.

GZ Consultants’ O’Brien engineers case for new approach to mine access tunnel work

In his SME MineXchange presentation on Tuesday, Timothy O’Brien of Gall Zeidler Consultants, displayed how using an engineered tunnel approach in the construction and repair of mine access tunnels could result in extended life of mine and an effective risk management process.

During his talk, ‘An Engineered Tunnelling Approach for Mine Access Tunnels’, in Phoenix, Arizona, he revealed details about an ambitious project recently carried out at Rio Tinto’s Bingham Canyon copper mine, in Utah, USA.

With the C-6 tunnel at the mine – used to transport crushed ore from the open pit – suffering from decay, Gall Zeidler Consultants was drafted in to not only inspect the tunnel, but also carry out rehabilitation work on the ground support system to restore access to the tunnel. It chose a system made up of yielding steel sets for this project, knowing that this could cope with the varying condition of the 4.57 km-long tunnel that was built in 1959 originally as a rail tunnel.

The biggest challenge for the consultants was this support system needed to be constructed without interrupting the conveyor system working underneath, which sees 70,000 t of crushed rock conveyed daily.

The engineers came up with a solution that was elevated above the conveyor, allowing crushed material to keep running through the tunnel, according to O’Brien.

The consultants also developed a two-year ground control management plan, including a monitoring and instrumentation program and trigger action response plan to monitor tunnel structural integrity in response to future mining activities.

Newmont turning to software for Peñasquito TSF planning

Newmont is looking to leverage planning software already used in the oil sands industry to create a safe, stable and well-planned tailings storage facility at its Peñasquito gold mine, in Mexico, according to Ross Hunsaker.

Hunsaker, the gold miner’s Tailings and Fresh Water Manager, is due to present ‘Newmont Goldcorp Peñasquito Mine – How Technology has Enhanced Tailings Planning’ at the 2020 SME MineXchange Annual Conference & Expo, in Phoenix, Arizona, on Tuesday, with a presentation abstract revealing more about his talk.

As he said in this abstract, the oil sands industry operates large, complex tailings storage facility (TSF), with these operators taking advantage of tools generated for mining and using them for planning and scheduling TSFs.

“Several different software packages are needed to handle this planning due to beach slope changes, mature fine tailings and water management,” he said. “Mining lags behind the oil sands industry when it comes to tools for tailings planning.”

At the Peñasquito mine, which produced 272,000 oz of gold in 2018, the TSF dam spans 11 km and, at completion, will be 150 m high. It has a centreline raise for three sides and a downstream raise for the fourth side, according to Hunsaker. It is being constructed using a mine fleet of Komatsu 930Es for a buttress, and a fleet of Cat 777 haul trucks for a sliver fill, with 20-ton (18 t) dump trucks for rock fill and cycloned sand, he added.

According to Hunsaker, the Peñasquito team is implementing planning software to integrate all construction activities into one plan, with scenario planning enhanced by software to optimise resources, activity duration and constraint identification.

Back in 2018, Goldcorp (which later merged with Newmont) achieved commercial production at Pyrite Leach project (PLP) at Peñasquito, a project that has seen tailings reprocessed for metal recovery.

The PLP plant processes the existing plant tails, feeding a sequential flotation and leach circuit with precious metals recovered through a Merrill Crowe process, producing doré as the final product. Tails from the new plant report to the existing TSF.

Hunsaker concluded in the abstract: “The overall software implementation is a work in progress with the overall goal of a safe, stable and well planned TSF.”

Kibali automation journey to be discussed at SME Conference

One of the most autonomous underground mines in the world, Barrick Gold’s Kibali operation in the Democratic Republic of the Congo (DRC) recently hit another annual production record.

The mine soared past its 2019 production guidance of 750,000 oz of gold, with 814,027 oz being delivered. This topped the previous 2018 record of 807,251 oz.

At this year’s SME MineXchange Annual Conference & Expo, in Phoenix, Arizona, on February 26, Ismali Traore, Kibali Technical Services Manager, is to reveal more about how the operation has continued to surpass expectations and how safety has become front and centre at the mine, owned 45% by Barrick, 45% by AngloGold Ashanti and 10% by SOKIMO.

In his conference abstract, Traore said, in recent years, the mine has made significant progress by implementing a fully automated production level and material handling system (MHS) at the underground mine.

This sees up to three LHDs operated simultaneously from ore passes to the crusher and multiple LHDs from the stope to the finger raises. The entire automation system is remotely operated from a control room located on surface.

In a recent presentation, the Kibali partners said the system was designed to have autonomous Sandvik LH621 LHDs work in combination with a Sanvdik AutoMine loading system (ALS). The ALS Mission Control System is incorporated with features such as traffic management, auto-loading and tipping with real time tonne-kilometres/h, and a real-time bucket weighing system that is within 3% accuracy level for each bucket trammed to the coarse ore bins (COB) at the operation.

The MHS, meanwhile, uses data obtained from the ALS to interface with SCADA via an OPC interface, according to the partners. COB levels from the SCADA system are then interfaced with ALS to manage the loading of the bins.

All information is interfaced to achieve the nameplate capacity of the hoisting system – which WorleyParsons provided the operating philosophy for and Winder Controls (member of the SIEMAG TECBERG Group) provided the winder design for – while taking into consideration the availability of the ALS to equate the total MHS availability, they said.

In its objective of becoming one of the most efficient Tier One mines globally where safety is a focal point of the operation, a significant amount of time was spent on the traffic management and human interaction with the autonomous mining equipment, Traore said.

This is something Barrick President and Chief Executive, Mark Bristow, picked up on last month, saying the mine is continuing its technological advance with the introduction of truck and drill training simulators and the integration of systems for personnel safety tracking and ventilation demand control.

Traore is to expand on the important safety protocols implemented to mitigate the risk of collision between this equipment and humans within the automated system during his presentation.