Tag Archives: wheel loaders

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

Automation, Base metals, Mine operation news, Mining equipment, Mining services, Precious metals, , , , , , , , , , , ,

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.

Caterpillar boosts payload, performance with new 995 wheel loader

Automation, Mining equipment, Mining services, , ,

Building on the success of the 994K, the new Cat® 995 Wheel Loader features up to 19% increased productivity than the previous model with its higher rated payload and 6% increase in hydraulic force with equal hydraulic cycle time, Caterpillar says.

This new loader delivers up to 13% lower hourly fuel consumption and offers up to an additional 8% efficiency gain when operating in Enhanced Eco Mode compared with throttle lock mode, according to the company. It is also up to 19% more efficient than the 994K in equal comparisons of throttle lock operation.

Enhancements to the front linkage include an improved casting design, increased weld size, larger bearings and pins, and profile changes for increased service life. New, larger capacity buckets available for the 995 incorporate an extended floor for fast loading, high fill factors reaching 115%, and excellent material retention. Buckets are interchangeable between the 995 and 994K.  

Built to the same size as the 994K but offering a higher rated payload, the new 995 enables a one-pass reduction when loading Cat 785, 789 and 793 mining trucks. This equates to up to a 33% increase in production and efficiency when loading the 785, up to a 25% increase with the 789 and up to a 20% increase with the 793.

The new 995 meets the global industry’s demand for high production and greater payloads with its powerful Cat 3516E engine offering configurations based on regional needs, meeting EU Stage V/US EPA Tier 4 Final or US EPA Tier 1 equivalent emissions, the company says. Its 39% torque rise ensures high lugging forces during digging and acceleration in high rim pull conditions.

Comfort and visibility

The redesigned next generation operator environment for the new 995 has 50% more legroom and boasts features that improve operator confidence while reducing fatigue. Its pressurised cab reduces vibration feedback, lowers sound levels and includes automatic temperature control. Providing shift-long comfort, its new electro hydraulic speed-sensing steering with force feedback automatically stiffens when traveling at higher speeds and softens as speed decreases to boost operator confidence.

Designed for visibility, the cab’s taller windshield provides a 25% increase in glass surface area and a 64% increase in wiper sweep area to better see the bucket. Two 254-mm colour LED monitors display machine control, operating functions and the electronic operator’s manual. A third 203-mm screen offers a dedicated view of the standard rearview camera and is upgradable to a multi-view camera system that offers 270° vision with rear object detection.

Access and egress to the cab along with all service areas being accessed from either ground level or a platform improves safety on the job. Wide stairs with full handrails on each side are positioned at a 45° angle for easy access. An optional powered access system – raised and lowered from either the cab or ground level – enhances ingress and egress to and from the rear platform even further.

Confidence-boosting technology

Integrated with electronics, the new Cat 995 wheel loader offers flexible levels of information and technologies for a smart machine and more informed operator, maximising the productivity of both. Standard tip up prevention technology avoids unnecessary stress on the drivetrain and structural components by delivering full breakout forces while preventing the back tyres from significantly lifting off the ground.

New optional Autodig components automate three of the dig cycle’s most difficult parts in both rehandling and tough digging applications to improve productivity and reduce tyre wear.

Reducing tyre wear, Tire Slip Prevention reduces rimpull before the tyres are set and increases rimpull when downward force is applied. Auto Set Tires detects pile contact and automatically lifts against the pile to set the tyres and increase available traction, discouraging premature racking. Lift Stall Prevention manages rimpull in-dig to prevent hydraulic stall when lifting through the face, so the 995 spends less time in the pile.

An onboard interactive training tool, optional Operator Coaching measures and reports on individual operator behaviours that have an impact on efficiency, production and component life. Instructional videos provide training on measured behaviours, showing both the incorrect and recommended behaviours. Among 21 total monitored operating technique aspects, the system shows how to properly reduce tire rotation, avoid unracking in-dig, enter the pile with a level bucket, avoid excessive usages of the impeller clutch, reduce dump height and use the kick out.

Available Payload Overload Prevention improves productivity and efficiency by allowing a larger bucket to be used to achieve pass-match targets across a range of material densities without risk of overload. It is configurable to either stop or slow lift arms when the maximum allowed payload, including bucket weight, is exceeded.

Standard Vital Information Management System (VIMS) on the new 995 allows customers to connect directly to the machine to access a wide range of sensor information and enhanced machine data. Taking the guesswork out of asset management, standard Cat Product Link™ provides remote access to machine operating data via the easy-to-use VisionLink® interface. The 995 supports a variety of Cat MineStar™ solutions including Health, Guide and Terrain.

Reduced maintenance

Offering a 500-hour engine oil change interval and improved air filter life, the 995 spends more time working. The number of steering hoses has been reduced from 15 to 10 and tubes cut from 11 to one to improve steering system reliability. An enhanced service station provides access to functions like coolant and oil as well as level indicators, and it features a Cat battery charging connector and indicator lights for fuel tanks.

The loader’s redesigned pump bay improves access to transmission components, offers discharge ports on the side of the pumps and has simplified lines routed directly to the high-pressure screens. The bay includes a brake pump filter, implement pilot filter and implement discharge screens, and diagnostic ports are accessible from the front walk deck and pump bay. Ground line service now includes a steering pilot filter, transmission filters and steering pump discharge screen.

Volvo CE makes electric wheel loader investment in Arvika plant

Environmental, Mining equipment, Mining services, Power supply for mines, Sustainable mining, , , , , , , , , , ,

As part of its ambition towards industry transformation through sustainable solutions, Volvo Construction Equipment (Volvo CE) has announced an investment into the production of electric wheel loaders from its plant in Arvika, Sweden.

The SEK65 million (circa-$6.3 million) investment from Volvo Group will allow the Arvika factory in Sweden – which specialises in the production of medium and large wheel loaders – to expand its facilities with a new building and allow for the phased introduction of new electric wheel loaders.

It is not only a milestone in the plant’s almost 140-year history, but a significant moment for Volvo CE and its determination to be completely fossil free by 2040, the company said. This is in line with the aims of the Paris Agreement and as laid out in the manufacturer’s industry leading Science-Based Target goals. It is also a step forward in its ambition for 35% of its machines sold to be electric by 2030.

Coming soon after an announcement to invest in electric haulers from the company’s production facility in Braås, Sweden, the announcement shows Volvo CE is committed to achieving more sustainable solutions for customers across all its product lines. These announcements are part of an investment strategy that allows Volvo CE to advance electric solutions across its production facilities, including also the Konz facility in Germany, Belley in France and Changwon in South Korea, where other electric machines are made.

Site Manager, Mikael Liljestrand, says: “This is a clear signal of our commitment to building the world we want to live in. It is more than 40 years since we last invested in a new building and what better reason now than to invest in our future, our planet and the next generation. We know that this is not only important to our customers and stakeholders, who rightly have high expectations on us, but it is also close to our hearts to be part of something bigger in building our future.”

Volvo CE has already introduced compact electric wheel loaders to the global market with the L20 Electric and L25 Electric wheel loaders proving to be efficient, zero-exhaust emission solutions capable of driving down carbon emissions while maintaining high productivity across a variety of customer applications. Together with the ECR25 Electric, ECR18 Electric and EC18 Electric compact excavators and the mid-size EC230 Electric excavator, Volvo CE has one of the largest electric ranges on the market.

Thanks to the investment, Arvika will erect a new building, approximately 1,500 sq m, which will allow the facility to free up areas inside its assembly factory to be able to build electric wheel loaders. While it has not yet been announced which models will begin their electric transformation and exactly when, production of both electric wheel loaders and more traditional wheel loaders fitted with combustion engines will continue for now on the same production line.

Volvo CE will ensure a phased introduction model by model, taking into account all aspects of the electric ecosystem as it does so, including infrastructure requirements, charging solutions, battery handling and business models. The result will be reliable mid-size and larger electric wheel loaders that can easily be integrated into customers’ business, it said.

It is not the first sustainability initiative from the Arvika facility. Despite increasing production last year, the factory managed to reduce its internal climate footprint by 350 t of CO2 thanks to a variety of emission reduction efforts.

“Our goal at the factory in Arvika, as well as Volvo CE and the entire Volvo Group is to be climate-smart and to produce fossil-free machines,” Liljestrand said. “Together, we are quite clear that we want to lead this transformation and be the driving force of more sustainable ways of working for the benefit of our planet. This investment is Arvika’s exciting first step towards electrification.”

Building work is set to begin later this year, with further announcements on when production will begin to come.

Volvo CE to improve wheel loader operator safety with Collision Mitigation System

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

Delivering on its vision for zero accidents, Volvo Construction Equipment (Volvo CE) has launched its Collision Mitigation System for Volvo Wheel Loaders.

This automatic braking feature supports operator response and helps reduce the risk or consequences of collision when working in reverse, the company explained.

The first system of its kind from any OEM, it assists operators while working in reverse and automatically applies service brakes when the wheel loader approaches any obstacle, alerting the operator to take further action, according to Volvo CE. With wheel loaders spending an average of 40-50% of their time being driven in reverse, the Collision Mitigation System is a valuable solution for operators and site managers, it says.

While not designed to ever replace safe operator behavior, it is a smart tool to further enhance job site safety. As part of the Volvo Group, the company is committed to safety with its Zero Accident Vision which is delivered not only through its products, but also its operations.

Lars Eriksson, Global Product Manager for Wheel Loaders at Volvo CE, says: “We at Volvo CE continue to proactively develop intelligent solutions which not only mitigate the consequences of accidents but strive to avoid them altogether. This new Collision Mitigation System is one important part of our work to reduce the risk of accidents and help fulfil our commitment towards zero accidents.”

With this new system, customers are moving a step closer to not only eliminating accidents, but also reducing any unplanned interruptions that can be incurred during those avoidable knocks and bumps, the company explains.

“It works by identifying when there is a risk of collision and responding by automatically activating the brakes for 2-3 seconds to slow the machine down prior to impact or bring it to a stop to avoid it,” Volvo CE says. “This initiation of the braking alerts the operator to intervene.”

For seamless stockpiling operations, for instance, the system will remember the last slope the machine climbed, allowing operators to reverse down a pile without activating it. It can also be temporarily deactivated for specific site conditions.

Functioning only when the wheel loader is in reverse and driving at speeds of between 3-15 km/h, no matter what gear it is in, it serves as a facilitator to job site safety, Volvo CE said.

Developed in-house by Volvo CE, the patent-pending Collision Mitigation System for Volvo Wheel Loaders is a factory-fit option currently available on the L110H/L120H equipped with OptiShift, L150H, L180H, L220H, L260H and L200H High Lift wheel loaders.

Requiring a Radar Detect System to be fitted, it works as an additional system to the existing wide range of features, options and site services provided by Volvo CE for its line of wheel loaders, all of which have been designed to elevate job site safety and minimise unplanned interruptions.

Liebherr modernises its L 550, L 566 and L 580 wheel loaders

Automation, Equipment maintenance, Mining equipment, Mining software, , , , , ,

Liebherr is modernising the three largest wheel loaders in its series, the L 550, L 566 and L 580 models, with, among other things, increasing the tip load, bucket sizes and engine power.

The wheel loaders also feature a new electrohydraulic pilot control; a technology that forms the basis for various intelligent features to increase safety and productivity during daily use.

Liebherr has been offering a series of wheel loaders tailored to markets outside of Europe and North America since 2010. The L 550, L 566 and L 580 come with tip loads of 12.4 t, 15.9 t and 19 t, respectively, while the three boast 3.4 cu.m, 4.2 cu.m and 5.2 cu.m bucket capacities.

Liebherr has developed the three new models at the Bischofshofen plant, its long-standing Centre of Excellence for Wheel Loaders. Decades of experience in designing wheel loaders was one of the keys to success in the development process, according to Wolfgang Rottensteiner, Liebherr-Werk Bischofshofen GmbH Wheel Loader Series Head of Sales.

“We also analysed our international customers’ demanding wheel loader operations over a long period,” he said. “This included observing different mining operations around the world, some in Africa and South America, coal handling in India and timber work in Russia. Our customers’ experiences were crucial to the development of the new wheel loader series.”

The new L 550, L 566 and L 580 wheel loaders feature the hydrostatic Liebherr travel drive, which, the company says, is renowned for its great efficiency. Thanks to increases in engine power – approximately 17% for the L 550 – the travel drive is even more powerful while maintaining the same fuel consumption. This is advantageous when accelerating or penetrating material and lowers fleet fuel costs, according to the company. Liebherr has installed the diesel engine in the rear, where it also acts as a counterweight, thereby increasing the tip load for the wheel loaders.

Liebherr has three lift arm versions on offer for the new models. First, the z-bar kinematics, which come to the fore particularly in the lower lifting range and for the break-out force. Secondly, the industrial kinematics, which have been designed for working with heavy working tools such as high dump buckets and log grapplers. Finally, there are the High Lift arms – an extended version of the z-bar kinematics with, Liebherr says, the longest lift arms in this wheel loader segment. These ensure greater reach and more productive loading procedures at great heights.

The L 580 is the largest model in Liebherr’s wheel loader series for markets outside of Europe and North America

The working hydraulics of the wheel loaders have also been upgraded with larger components and new electrohydraulic pilot control. This latter technology also ensures responsive movements of the lift arms, independent of the size or weight of the working tool. Liebherr also offers a new, optional weighing device on the bases of the electrohydraulic pilot control, which automatically works as a check scale and provides real-time information about the loading procedure. This data helps machine operators precisely fill dumpers, lorries and railway wagons with the specified quantities, and to avoid overfilling.

The electrohydraulic pilot control enables operators to perform individual adjustments on the new wheel loaders. For example, they can set lift limitations and maximum tilt-out heights, thus reducing the risk of accidents in areas where space is restricted. The tilt-out speed can also be programmed to protect lift arm components and the installed equipment.

In addition to these optimisations for operating safety, Liebherr has also invested in the operational reliability of the new wheel loaders. Because they are faced with an abundance of challenges – remote operating areas, extreme climates, demanding loading materials and multi-shift operation over a long period – they demand a high degree of reliability. For this reason, Liebherr has installed larger axles than were fitted on predecessor models. Liebherr has also drawn on proven components from its other wheel loaders for the core components and steel construction.

The modern design of the new wheel loaders comes with particular functional advantages, in addition to a bold new look, the company says.

The clean lines on the rear as well as the large glass surfaces in the cab facilitate good all-round visibility. Furthermore, the new reversing camera, which is installed in a protected position in the engine bonnet, assists the machine operator to keep an eye on the area to the rear. Service work is also eased with, on the L 566 and L 580, an engine bonnet that opens to the rear to make the diesel engine freely and safely accessible.

A sturdy cab access leads to the redesigned and spacious operator’s cab. One of the special features of this cab is the height-adjustable 9-in (229 mm) touch display with intuitive menu navigation. The high-resolution display provides a clear overview of all the wheel loader’s operating information. The Liebherr control lever, meanwhile, enables the highly-sensitive control of work movements as part of the modern operating concept. Hydraulic working tools can also be precisely controlled with the optional mini joystick on the control lever.

Komatsu aims to improve operator efficiency with WA900-8R wheel loader

Automation, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , , , , ,

Komatsu has released an upgraded version of its 11-13 cu.m class mining loader, the WA900-8R, incorporating, it says, innovative technology features that deliver increased productivity and ease of operation, while reducing operating costs.

This new loader incorporates Komatsu’s “SmartLoader Logic” technology to provide the engine with precisely the right amount of torque for each part of the duty cycle.

According to Mark Summerville, Komatsu’s National Product Manager, this feature improves fuel economy by up to 10% compared with the previous model, while also increasing productivity.

Further productivity improvements include the addition of a modulation clutch for controlling speed and torque, along with faster boom raise speeds to increase cycle times and a tyre slip control system.

“These features, combined with automatic dig and a semi-automatic approach and dump system, means the WA900-8R can significantly improve an average operator’s efficiency,” Summerville said.

The new loader also includes a KomVision obstacle detection system that uses radar and 360° cameras to alert and prompt the operator to react if a person, vehicle or obstacle is detected – greatly improving the safety of personnel in and around the machine.

Replacing the WA900-3E0, the WA900-8R is powered by a Komatsu SAA12V140E-7 engine rated at 671 kW, and has an operating weight of 116.4 t. It is matched for loading 90 t dump trucks (Komatsu HD785 size) in standard configuration, and up to 140 t trucks (Komatsu HD1500) in high-lift spec.

SmartLoader Logic optimises engine torque across all applications to minimise fuel consumption, while always ensuring the loader has the torque and digging power it needs, according to the company.

“This system functions automatically and doesn’t interfere with operation, saving fuel without decreasing production,” Summerville said.

The system is matched to the loader’s automatic transmission, with an electronically controlled modulation (ECM) valve that automatically selects the correct gear speed based on travel speed, engine speed and other travel conditions.

“This ECM valve system also engages the clutch smoothly to prevent lags and shocks when shifting, for more efficient machine operation and a more comfortable ride,” Summerville added.

The WA900-8R’s powertrain has a large capacity torque converter designed to ensure optimum efficiency.

“This ensures greater productivity in ‘V-shape’ loading applications because the torque converter’s increased tractive effort means it doesn’t require full throttle,” Summerville said. “It also allows the loader to achieve higher gear ranges and maintain higher travel speeds when working in load-and-carry applications.”

The loader’s hydraulics are designed around Komatsu’s closed-centre load sensing system (CLSS) technology.

“This uses a variable displacement piston pump combined with CLSS to deliver hydraulic flow exactly when the task requires it, preventing wasted hydraulic flow, which further contributes to better fuel economy,” Summerville said.

A tyre slip control system, proven to be effective in extending tyre service life, Komatsu says, sees the modulated clutch applied to control the torque converter when it senses a potential tyre slip.

“All these features combine to reduce fuel consumption by up to 10% – while also increasing productivity – compared with the WA900-3E0,” Summerville said.

The new WA900-8R features Komatsu’s latest generation of cab to improve operator comfort and safety. This cab features low-effort control levers and an advanced joystick steering system, alongside an electronically controlled suspension system, according to the company.

Other features include the addition of a trainer seat, shockless stop cylinders, climate control air conditioning and modulated clutch.

These features, combined with ergonomic improvements, all contribute to higher operator productivity, easier and safer operation and reduced fatigue, Komatsu said.

Summerville said: “Our new automatic digging system actuates the bucket tilt and lifting operations by detecting the sensing pressure applied to the work equipment. It is designed to significantly reduce operator fatigue and improve efficiency ensuring optimum bucket fill every time the machine enters the pile, whether in rock or in loose materials.”

This system is designed to work in conjunction with the new semi-auto approach and dump system.

“This automates boom lift and bucket dumping when approaching a dump truck, particularly in ‘V-shape’ loading operations,” he said. “Combining this with our automatic digging system, loading operations from stockpile to dump truck is made much easier, and operator effort and fatigue greatly reduced.”

Maintenance and serviceability have been optimised through a high-resolution in-cab monitoring system, which works in conjunction with Komatsu’s KOMTRAX Plus remote monitoring system, the company said.

Side-opening engine doors, an easily accessible engine compartment with dual-side engine bay access ladders, along with a swing-out cooling fan – with reverse – and wide-core radiator (with modular core) all aid maintenance and servicing processes.

An adjustment-free braking system, along with service brakes mounted in-board from the final drives and brake on the sun gear (high speed, lower torque), ensure increased brake life, the company added.

Improved loader linkage and upgraded structures for the front and rear frame, meanwhile, provide a longer structure life.

“With our new WA900-8R loader, Komatsu has developed a best-in-class mining loader, while delivering significantly higher productivity and operating efficiency, combined with lower fuel consumption and reduced operating costs,” Summerville said.

CR enhances large mining wheel loader cast lip system offering

Equipment maintenance, Mining consumables, Mining equipment, Mining services, , , , , ,

CR Mining has launched a new mining wheel loader cast lip system that, the company says, can deliver a 33% reduction in total running costs.

DecaEdge DE1545 is a game-changer for companies seeking premium small to large mining wheel loader cast lip systems, CR said.

The new nine-station lip has the potential to last for up to 25,000 hours without major rebuilds, and as a result, can deliver that 33% cut in total running costs, the company claims.

The DE1545 suits small to large mining wheel loader buckets with 14-20 cu.m.

“A lot of applications on wheel loaders in mine sites are plate lips,” CR Mining Product Marketing Manager, Katie Edser, said. “These require maintenance teams to do a lot of hot work around those particular lips, which is a safety risk as well as a maintenance issue.

“Because the DE1545 has mechanically attached GET (ground engaging tools), our cast lips require less welding and less hot work.”

The DE1545 also has CR Mining’s first GET Trakka-enabled lip – or a digitally enabled lip – which allows customers to use CR’s digital products to enhance performance.

GET Trakka sensors can be inserted into the available sensor cavity. The sensor is activated while digging and, if the GET comes loose, breaks off or gets lost, the operator is immediately alerted and can stop to avoid any further lip damage. Lost GET can then be located using a small hand-held scanner and eliminates the risk of GETs entering a crusher and the inevitable damage resulting in a costly repair. This avoids the need to shut down mine sites which will impact overall productivity.

CR Digital’s Titan 3330 load haul optimisation system for wheel loaders offers customers another level of productivity data they haven’t had access to before, the company said.

“Combining Titan 3330 with the DE1545 DecaEdge can help customers monitor cast lip and bucket performance, machine health and truck and bucket payload accuracy that delivers benefits that continue to flow through a mine site’s entire production,” it said.

The DE1545 is a welcome addition to the DecaEdge cast lip range known to deliver up to 7% less downtime, 34% strength increase, 27% mass reduction and a 30% reduction in digging force, CR said.

Bis to provide tailored equipment solution for Anglo American Capcoal contract

Mining equipment, Mining maintenance, Mining services, Steel and iron ore, , , , , , , , , , , , , , ,

Australia-based Bis has secured a new multi-year contract for Anglo American’s Capcoal operations near Middlemount, in the Bowen Basin of Queensland.

The off-road haulage, materials handling and site services contract is the latest in an ongoing relationship between Anglo and Bis that spans more than 20 years.

The contract will see Bis supply a tailored high payload equipment solution for the operation’s rejects haulage. Additionally, the company will deliver site services including road maintenance, dust mitigation and run of mine equipment feed, as well as haulage of topsoil, rock and run of mine coal as required.

Bis Chief Executive Officer, Brad Rogers, said the company’s ability to provide a tailored haulage and logistics solution, specific to this operation, was a key factor in securing the new contract.

“We have a long history of integrating customisable OEM innovations and existing solutions to deliver against specific customer objectives. This competency continues to drive operational efficiencies and reduce costs for our customers. It’s a formula that works.

“For instance, the specific higher payload capacity solution put forward for this project delivers significant advantages for Anglo American. It means a reduction in the total equipment required, vehicle movements and fuel consumption; all three of which directly contribute towards improved safety, sustainability and productivity outcomes for the customer.”

The range of tailored equipment incorporated to deliver the project includes double trailer configuration haulers, wheel loaders, graders, water trucks and a compaction roller.

The fleet is fitted with the latest Bis safety and productivity management systems, including Trifecta, which is a new in-cabin artificial intelligence driver and vehicle monitoring software developed with EDGE3 Technologies. The system collects and analyses data in real time to improve both safety and productivity. The system collects, analyses and reports driver behaviours such as drowsiness, mobile phone use, smartwatch use, smoking, seatbelt and other violations. Trifecta then ‘learns’ over time to pre-empt high risk incidents in real-time through alerts to drivers and supervisors. Bis says it has exclusive rights to use and sell the system across a range of markets.

On site mobilisation for this new contract is expected to commence from August.

Second Cat 994K wheel loader arrives at Capstone’s Pinto Valley in latest innovation push

Base metals, Comminution of minerals, Environmental, Mine operation news, Mineral processing, Mining equipment, Mining services, Sustainable mining, Water management, , , , , , , , , , ,

Capstone Mining has brought a second Caterpillar 994K wheel loader to its Pinto Valley operation in Arizona, USA, as it looks to reduce its emissions and improve its operating cost base at the copper mine.

Last year, the mine added to its fleet a Cat 994K loader, which, the company says, burns circa-30 less gallons of fuel per hour (1.9 litres/min) than its current shovels. “This reduced our CO2 emissions and operational cost savings on approximately 116,000 gallons of fuel in 2020,” Capstone said.

The second 994K, added last week, will, in partnership with the first wheel loader, displace around 10,000 shovel hours a year and save approximately 410,000 gallons of fuel and millions in maintenance costs, the company claimed.

Capstone concluded: “Pinto Valley is innovating and optimising for exciting times ahead.”

This is not the only area of innovation the company is currently pursuing at Pinto Valley, an operation it acquired from BHP back in in October 2013.

In its 2020 results, released last month, Capstone said the implementation of phase one of its PV3 Optimization project at Pinto Valley had delivered a 10% sustainable throughput improvement compared with 2019.

The PV3 Optimization project has been designed to achieve safer, more reliable and higher capacity operations without major investments in new comminution equipment. It is doing this by leveraging new inexpensive technologies.

Phase one work, which included improved blast fragmentation processes, installation of a new secondary crusher and screen decks as well as a new mill shell, was completed last year. This saw the mine achieve throughput of 57,168 t/d in the December quarter, 10% higher than the annual 2019 average of 51,137 t/d. December 2020 mill throughput achieved 60,717 t/d, which represents a new monthly record in the mine’s operating history.

Phase two of the PV3 Optimization project is expected to be completed in the second half of 2021, upon completion of upgrades to a conveyor, mill auto controls, cyclone packs and retrofits to the thickeners, it said.

During the month of December, the company conducted a pilot plant test of Eriez HydroFloat coarse particle technology at Pinto Valley, with Capstone saying the results had surpassed expectations of a 6% improvement target to overall copper recovery. In fact, the tests showed a 6-8% increase in overall copper recovery was achievable, which, when combined with expected higher throughput rates, could result in an additional 9-12 MIb/y (4,082-5,443 t/y) of copper production at the operation, it said.

“Additional benefits to the technology include allowing the operation increased throughput by operating at a coarser grind size, which is expected to lower power costs, improve water consumption and lead to improved stability in the tailings storage facility,” Capstone said in its 2020 results. “The estimated $70 million expansionary capital, which includes the installation of Eriez HydroFloat and related equipment, if approved by the board of directors, is expected to be spread over half two 2021 and early 2022, with start-up expected in Q2 (June quarter) 2022.”

Capstone said it expects to release an updated NI 43-101 technical report that encompasses the PV3 Optimization Phase 1 and Phase 2 projects and improvements in the second half of 2021.

At the same time, it is also looking into a PV4 study at Pinto Valley.

Capstone explained: “Feasibility work on scenarios to take advantage of approximately one billion tonnes of mineral resource not currently in the mineral reserve mine plan, which is at similar grade to the current mineral reserves, will be conducted for Pinto Valley.”

The PV4 study is expected to be released in late 2022 and will contemplate using existing mill infrastructure rather than building new facilities, with higher mining rates, higher cutoff grades to the mill and increased tonnage available for leaching.

Extensive column leach test work in collaboration with Jetti Resources LLC will take place over 2021. Jetti’s patented catalytic technology, designed to allow for the efficient and effective heap and stockpile leach extraction of copper, has been a success at Pinto Valley’s leaching operation, where it expects to recover up to 350 million pounds of cathode copper over the next two decades from historic and new mineralised waste piles.

“Capstone is a pioneer in the application of this leach technology and we intend to use it to enhance the economics of a future expansion at Pinto Valley,” it said.

Komatsu iMC dozers, drone tech help RHT Contracting revolutionise tailings dam build

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When long-time friends Joe Riccardo, Mike Heddon and Mark Tyler set up RHT Contracting in mid-2018, they knew they needed a winning edge when bidding for contracts – so they went for the most innovative and technically advanced construction equipment available, a Komatsu Australia case study reports.

That saw them choose Komatsu’s intelligent Machine Control (iMC) dozer and excavator technology when bidding for a large contract to construct tailings storage facilities (TSFs) for a major mining operation in Western Australia.

Currently RHT runs four Komatsu iMC machines: two D65PXi-18 swamp dozers, a D155AXi-8 dozer, and a PC360LCi-11, as well as Komatsu wheel loaders, dump trucks, graders, and other excavators on the one site.

Not only does using iMC technology give RHT significant safety, productivity, efficiency and accuracy advantages in TSF construction, it also provides the company’s mining clients the security and peace of mind that their critical facilities have been built to the highest and most exacting standards.

Today that is essential for any mining operation, following catastrophic failures of tailings dams in South America in the past five years, which have killed many people and caused widespread environmental devastation.

To ensure their integrity and long-term performance, it’s essential that TSFs be constructed following an established process, which involves placing the dam material in 300 mm thick layers; these are then compacted, and the top 100 mm scarified to ensure a strong lock with the subsequent 300 mm layer.

Using Komatsu iMC machines in this application, each 300 mm layer can be placed, quickly and efficiently, within tight tolerances, ready for compaction.

And unlike conventional ‘bolt-on’ machine control systems, the iMC system prevents dozer blades or excavator buckets from ‘over-digging’ into the already compacted and scarified layers, ensuring they are not compromised during placing of the next layer.

When RHT was formed, Riccardo, Heddon and Tyler (the company’s name comes from their surname initials) saw the opportunity to use Komatsu’s iMC technology as a real competitive advantage.

“These days, you’ve really got to innovate,” Heddon says. “Clients want to see that you are innovative and you’re not a dinosaur.

“I’ve been going to shows like CONEXPO and BAUMA for years, and I see all the latest stuff, and I was wondering how good it actually was. Then we spent some time with Dean Jones and Colin Brindle (from Komatsu Perth), to find out what their iMC technology could do.

“We were convinced enough to buy a D65PXi-18 swampy and a PC360LCi-11 excavator, plus a Topcon base station, which were delivered in February 2019, and took them to the site.

“We also put on Fraser Mead, a young surveyor, who’s passionate about technology, plus he’s really into drones and how they can really help with the whole mine infrastructure construction process.”

As of mid-June, Mead and RHT are trialling Komatsu’s EDD (EveryDay Drone) technology, a high precision UAV (drone) survey system providing industry-leading super-fast on-site processing using Komatsu SMARTCONSTRUCTION’s Edge technology.

“Initially the operators weren’t convinced about the iMC machines; they said ‘stuff this, I’m an operator, I don’t need that’, but then after a few days of seeing what the technology could do, they were going ‘wow!’,” Heddon says.

“On the first dam we built, we never put a grader on it, did the whole batter with just our first D65EXi dozer and the PC360LCi excavator. I have never, ever done that before; they are exceptionally good. The dams look great, the batters look great, we’re never having to do rework, we get it right – from the start to the end. It’s always spot on.”

Expanded fleet

Following the success of its first D65PXi-18, RHT bought a second D65PXi-18 in September last year, and the D155AXi-8 in February this year.

“At the moment, we’ve got all these machines working on site, building up to three dams at one time,” Heddon says.

“With the dozers, we are using them for winning material from borrow pits, while the excavator is pulling up batters.”

Building tailings dams for larger mines requires large amounts of earthworks – with dam walls up to 4-6 km around, along with haul roads, so there is a lot of earth to be moved.

RHT’s two smaller iMC machines, with their swamp tracks, are proving ideal for the precision final trim work to millimetre level accuracy, while the larger D155AXi-8 (pictured) is being used for the bulk earthworks on the dams and haul roads, according to Komatsu.

“On the newer dams we are building, we are using clay oxide materials, which are heavier to work with, which is why we brought in the D155AXi,” Heddon says. “Plus, we can also use it for building haul roads. We can just map in a haul road route and design, and the machine can go out and build it, even in rock and clay.”

One thing RHT has found is that the D155AXi-8 has not so far been giving quite the final trim accuracy of the D65PXi-18s.

“Certainly, it is extremely accurate compared with any conventional dozer next to it, but because we have seen how precise the D65s are to a few millimetres, we were expecting that with the D155. However, because it is bigger, it corrects slightly differently,” Heddon says.

“It’s still good, still within coo-ee of what we need, but we know at the moment it’s giving a slightly rougher surface, so you’ve got to take things a bit slower, use a lower gear to get there.

“On the bulk side, Komatsu’s intelligent Machine Control works really well, absolutely on this bigger dozer. You can just set it, and it does exactly what we need. It’s on the fine control, where I think we can get it going even better.

“Because this is all so new, it’s something we are working with Komatsu to perfect.”

Heddon also says iMC ensures that rework and over-excavation never occurs – eliminating overruns and field survey work.

“With Komatsu’s intelligent Machine Control acting as a rover, we know we are always building to the exact specs; we are never over-building, and everything is always exactly level and ready for rolling.

“We don’t require anyone to go out there with a dumpy level checking levels and all that stuff,” he says.

No micro managemenent

The other big advantage is having all the works designs already in the machines, ready for the operators as soon as they need them.

“That’s a big saving because the operators have everything at hand in the machines to do the work,” Heddon says.

“In the old days, we’d have two teams out there pegging the site, one for the day shift, and another for the night shift.

“Now we just put in a couple of reference pegs, then once the operator has the levels, it’s all good to go.”

And, as each part of the job is completed, it can be immediately checked and audited – and the records remain readily available at any time in the future for clients or geotechnical engineers.

“This technology means that the as-built track mapping is all there from the start. When you’re building a tailings dam, it’s essential that layers go down in 300 mm lifts, before the next one goes on top,” he says.

“We can see all this on the computer and know that it was done precisely. So, in future, if there is ever a question with a dam, we can go back in there and show that it was done exactly right. There’s no need for anyone to go in and micromanage. It is a great system.

“The other great thing about these iMC machines is that essentially they act as a mobile rover because everything is done within the machine.

“So, the surveyor can be away on another mine site, and if the operator finishes a job, the surveyor can jump in remotely, and work together with the operator to set things up for the next job. So, people are not sitting around waiting for someone to get back after lunch to start up again.”

Greatly increased site safety is another huge advantage with iMC, according to Komatsu.

“Safety is paramount for us,” Heddon says. “And not having people working on the ground around dump trucks, excavators, wheel loaders, dozers and other machines, is a major safety component. It’s just unreal.”

Heddon has also observed interesting reactions from operators using the iMC systems, and RHT’s clients.

“When these machines first came to site, people said it was just more stuff to go wrong. But then after a few days, they all agree the benefits are countless.

“And our clients have been really impressed with the quality, efficiency and technology the iMC machines offer.

“With this technology, we have the trucks deliver to the site, the dozers push it out – and it’s so level that the trucks can keep working, whereas before we’d have to call in a grader to give the trucks access.

“Everyone is stoked with it, the whole concept. We’ve since bought a second base station, and we’re putting that in our second site.”

The future

Heddon sees tremendous potential for Komatsu’s iMC technology in future projects.

“This is really moving into the future, that’s the only direction we want to go now.

“And particularly after those catastrophic dam failures in Brazil, the more you can prove the quality of your work and show that to the geotechs and the clients, the more successful we can be.

“They really need the confidence that these dams are getting built correctly at all times, not just some of the time.

“It’s giving the mining companies that security and peace of mind that their dams are built right, so they know they have their dams constructed to worlds best practice.

“We’re very committed to this technology. We want to see it on all our earthmoving machines, and we are very keen to see it on the larger excavators, at least up to PC490 size,” Heddon says.