Muck shifting. IM looks at new excavators, best practice for wheel loaders, trucks, tyres and haul road maintenance, as well as fuel additives

Transcription

1 EARTHMOVING Muck shifting IM looks at new excavators, best practice for wheel loaders, trucks, tyres and haul road maintenance, as well as fuel additives The industry has seen a number of new loading tools come available recently, like Liebherr s new 250-t mining excavator, the R 9250 Litronic, the successor to the R 994 Litronic, which has been in production since 1986 and has enjoyed great success, with more than 260 units sold. Technologies already proven in the larger R 994 B Litronic, R 995 Litronic and R 996 Litronic models have been incorporated in this new mining excavator - in particular, the advanced electronic, electrical and hydraulic systems, which are designed to offer reliability and high performance, and the robust, durable specification of the mechanical sections such as the constructional steelwork. The standard version of this new large excavator is equipped with a 9-m gooseneck boom, a 4-m stick and either a backhoe or bottom-dump bucket, each with a capacity of 15 m 3. With a 15% larger bucket than the R 994 which it supersedes, 42% higher swing torque and exceptional digging capabilities, the R 9250 Litronic is set to deliver even greater productivity. Only three bucket loads are required to load an 80-t truck, or four to five bucket loads for a 120-t truck. Three of the new large excavators are already in operation, two in large Australian coal mines. The first tests confirm the superiority of the R 9250 Litronic in its size category, Liebherr reports, primarily due to its high hydraulic power and the quick working cycles it can thus achieve. Even newer, the R 9350 is a 300-t class upgrade machine replacing the 994B. It is available in either backhoe or face shovel configuration and, equipped with an 18m 3 bucket, is capable of filling a 100-t truck in around three passes, or a 150-t truck with five passes of its 32.5-t capacity bucket. The power source is a 1,120 kw Cummins engine. The operating weight of the R 9350 is 302, ,000 kg. Komatsu says its PC mining excavator is designed to minimize operating costs through excellent fuel efficiency and easy maintenance. Available in backhoe ( m 3 bucket capacities) and loading shovel (11 m 3 ) configurations, this is a 200-t machine. The highly fuel-efficient engine, a powerful Komatsu SAA12V140E developing 713 kw, combines with Komatsu s Total Power Management system (which minimizes power losses in the hydraulics, cooling fan and PTO) to dramatically reduce fuel consumption. For additional fuel savings, the machine is fitted with an idling caution, eco-gauge and adjustable E mode to help the operator work in the most fuel efficient manner possible. The engine complies fully with Stage II emissions regulations and the power module packaging Caterpillar s 16M motor grader started shipping in March and is the first of the mining-sized, joystickcontrolled machines to be made available commercially. The joystick controls simplify operation of what many claim is the most difficult earthmoving machine to operate. Field trials with experienced operators and inexperienced operators have shown that experienced operators appreciate the reduced work required to operate M-Series machines, and the inexperienced operators become proficient much more quickly than they did when operating machines with many control levers. All like the good sight lines to the blade and work area. The 24M (the other mining model shown here) will be available later this year. features large sound absorbing blades that help reduce noise to a very low level. For easy maintenance and repair, the new design uses fewer components, helping reduce parts costs. The engine, radiator, oil cooler and PTO are all packaged in the power module, which is easy to remove and install components. A catwalk around the power module and centre walkway provides easy access for inspection and maintenance. Komatsu says its new 91-t capacity rigid dump truck raises the bar for this type of machine. The HD785-7 offers best-in-class engine power and brake retardation, as well as 18 International Mining APRIL 2007

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3 EARTHMOVING The Liebherr R 9250 is powered by a 12-cylinder Cummins turbo-diesel engine rated at 960 kw. The Vehicle Health Monitoring System (VHMS) monitors all major components and enables remote analysis of the Komatsu PC excellent fuel efficiency. It has a Komatsu SAA12V140E-3 engine that delivers 879 kw at 1,900 rpm. This powerful and efficient engine provides impressive acceleration, low fuel consumption and a top speed of 65 km/h. The engine is fitted with a variable horsepower control (VHPC) to optimize performance and fuel consumption. This sets the maximum engine power to one of four levels to match the job being carried out and the working conditions. The operator chooses between power and economy mode, and the VHPC automatically detects whether the machine is loaded or unloaded. Consequently, the HD785-7 delivers excellent climbing ability when required and can reduce fuel consumption. Komatsu has recently won some big orders, including 64 units of large mining equipment for a gold mine in Mexico and 45 units for a coal mine in China. The total value of these contracts will be $280 million. Komatsu Latin- America won an order worth about $160 million from Minera Peñasquito, a Mexican subsidiary of Goldcorp. Komatsu will deliver E super-large dump trucks and five HD785 trucks, eight D375 dozers, two PC300 hydraulic excavators, three GD825A motor graders, and three WA1200, one WA600 and two WD900 wheel loaders to the Peñasquito mine, one of the largest undeveloped precious metal deposits in Mexico. The first equipment shipment was scheduled for February 2007 and Komatsu plans to deliver a total of 31 units worth $80 million by the end of 2007 and is scheduled to complete the total delivery by Furthermore, Komatsu is looking forward to receiving an order for a full repair-and-maintenance service contract in which Road Machinery Mexico, a distributor for the Komatsu Group, will provide the service. Goldcorp, North America's third largest gold producer, announced in June 2006 that it had doubled estimated gold reserves from 4.93 to 9.98 Moz at its Penasquito property. About the same time, the company also disclosed that it had revised its silver, lead and zinc reserves by expanding 86% to 575 Moz of silver and by doubling lead to 1.67 Mt and zinc to 3.62 Mt. In China, Komatsu and Toyota Tsusho Corp have won an order for 45 of the 930E superlarge dump truck (maximum payload 290 t), worth $120 million, from Pingshuo Coal Industry, a member company of China National Coal Group, which is one of the two major state-owned coal producers in China. Komatsu will deliver the 45 trucks from its Peoria manufacturing operation in the USA to China's two largest open-pit coal mines in Shanxi Province owned by China Coal. With the first shipment scheduled for June 2007, Komatsu plans to complete the delivery in one year. In late January, Komatsu completed the construction of its new Ibaraki plant for large wheeled equipment. Komatsu anticipates that 20 International Mining APRIL 2007

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5 EARTHMOVING Last June, P&H Mining Equipment announced its newest lines of electric mining shovels and rotary blasthole drills, known collectively as the C-Series. The shovel line comprises five models: the 4100XPC, 4100C BOSS, 4100C, 2800XPC and 2300XPC. The C-Series drills, the 300XPC and 320XPC, replace the 100XP and the 120A, respectively. P&H heralds the C-Series as delivering substantial improvements in three key areas: control, comfort and consistency. Mark Hardwick, Senior Vice President and Managing Director - North America, said, Foremost among the features that unite the shovel and drill lines, especially in terms of control and consistency, is the P&H Centurion Control System. The P&H Centurion Control System is the platform for P&H technologyenabled products that lower customers cost per tonne. Centurion's benefits include greater productivity, inherent safety, advanced diagnostics, and simplified maintenance. orders for its large equipment for mining will remain at a high level into the future. To meet accelerating growth in demand, Komatsu decided to build a new plant in Japan and started construction in April last year. For the Komatsu Group, this is the first new plant to start up in Japan in 13 years. It will produce large dump trucks and wheel loaders, over 90% of which will be exported to North America, Europe, Asia Pacific, Africa, Latin America and other regions of the world. Its monthly production capacity is 130 units. Equipped with a simple assembly platform and IT applications such as IC tags, the new plant features a high degree of flexibility for changes in the volume of production and product specifications. Furthermore, by using the adjacent Port of Hitachinaka, Komatsu will

6 04/07 be better positioned than before to ship products which are near completion, and will thus be able to further improve product quality and shorten delivery time. Komatsu established the Ibaraki plant as an environment-friendly model by reducing CO 2 emissions and power consumption through a substantial reduction of on-land transport distance and use of solar panels, respectively. OMZ (Uralmash-Izhora Group) plans equipment repairs worth $56.5 million and capital expenditures to the same amount in 2007 at its manufacturing plants. In 2006 OMZ recorded $28.2 million in capital expenditures, and invested around $1.1 million in scientific and research engineering developments. In 2007 the company will continue research on production related to new mining equipment development including ESH-15.90V and EKG-3000 excavators, DK-2000 extraction complex and crushing and milling equipment. The company will also develop new production technologies and will improve existing technologies. Hyundai is moving into mining with the R800LC-7A, a new 80 t excavator, presented for the first time at Bauma This workhorse for tough jobs is the company's latest edition to its Robex excavator range. This heavy-duty excavator has a power output of 343 kw from a common-rail diesel engine. To monitor and control the machine, Hyundai uses a new generation of its tried and tested CAPO (Computer Aided Power Optimization) system. It allows the hydraulic system to be controlled in exactly the correct function setting for any particular job. This provides extra power to the tools needed for any job: for particularly heavy work or faster working motions, 10% more breakout force, instantly at the push of a joystick button, with the Power Boost feature. Permanent monitoring of all the functions with self-diagnosis should anything go wrong completes the CAPO system s range of functions and increases the functionality of the excavator. Wheel loader use Based on studies at mines and in testing at its proving grounds, Caterpillar has developed recommendations for wheel loader applications and operating techniques. It also has determined benchmarks to use as an aid in assessing wheel loader performance. Of course mine design and conditions play an important role in wheel loader productivity. Favorable site conditions and mine design include: Hyundai s R800LC-7A offers a Level, dry, smooth, firm floors Sufficient cross fall and drainage in high rainfall areas to minimize tyre damage

7 EARTHMOVING The 992G and the 994F are the two primary mining loaders from Caterpillar. The 992G is four-pass match with 100-t capacity trucks and a six-pass match with 150-t trucks. It is especially popular in coal operations. The 994F is used for primary stripping or waste removal in some mines and ore loading in many mines around the world. It is a good match for the Cat 785 truck (150-t capacity) and the 789 truck (195-t capacity). In the high lift version, the 994F can work with 793 trucks (240-t capacity). The Super High Lift 994F is designed to load 793 and smaller trucks that have high-volume coal bodies. Both loaders have mechanical drive trains, and both use the Steering and Transmission Integrated Control (STIC) system that enables the operator to use small movements of a single hand to steer and to make direction and gear changes. The system tremendously reduces the amount of effort required of loader operators when loading trucks. Well-fragmented materials that minimize crowding time, particularly in the toe area of the cut Lower face profile optimum bench height is the bucket hinge pin height at maximum lift Multi face loading due to excellent mobility, wheel loaders are the only loading machine that can efficiently perform such duties. When selecting a loader/truck fleet, Cat recommends keeping in mind that the most efficient match for wheel loaders is four to six passes. Efficient operations should achieve a 90 to 110% bucket fill factor with wheel loaders. Conditions should allow cycle times of 32 to 42 seconds. Average cycle time observed in efficient operations is 38 seconds. Conditions that are particularly negative for wheel loaders include poor or very wet underfoot conditions and tight loading areas. It s also important that the loader operator keeps the pit floor free of rocks to minimize tyre 24 International Mining APRIL 2007

8 04/07 damage to both the loader and trucks. As with all loading tools, proper wheel loader operating techniques are critical to productivity as well as machine maintenance costs. Caterpillar recommends the following: Use truck exchange time to make the first pass a good pass by filling the bucket completely; ensure that the truck is correctly spotted by loader positioning or sounding the horn Enter the pile straight on, with the floor of the bucket parallel to the pit floor Keep the frame straight when digging Lift the bucket before crowding Fill the bucket by the time the lift arms are horizontal Keep the time in the face below 12 seconds Minimize non-productive floor contact with the bucket Maintain proper kick-out adjustment. Selecting and using the appropriate ground engaging tools (bucket edges and teeth) also is important to loader productivity and maintenance. Never operate with a bare edge. Lubrication Engineers International s BTU+ is a diesel fuel supplement that provides significant fuel savings in large equipment. A company in Wyoming, USA undertook a BTU+ study to evaluate the impact on its wheel loaders in late 2005/early Fuel consumption was recorded on two loadout ( a Komatsu WA Loadout Loader and a Cat 980G) machines and two quarry loaders (Caterpillars, a 990 and a 988F) for a two month period. BTU+ was then added to the fuel and fuel consumption was recorded again recorded for another two month period. The difference was an 11.98% fuel saving on the 990 (consumption down from 19.2 gallons/h to 16.9 gallons/h) and a whopping 22.8% saving on the 988F, with hourly consumption down from 14.0 to 10.8 gallons. The average fuel savings for the four loaders was 16.3%. The total fuel used at the quarry in 2004 was 277,672 gallons, at a total fuel cost of $399,848/y. Projected annual fuel cost savings when using BTU+ = $65,175 (16.3% of $399,848 less the cost of BTU+ treatment of the 277,672 gallons). proprietary High Pressure Direct Injection (HPDI) for the Cortez mine in Nevada in 2002 and of natural gas uses the diesel cycle combustion concluded that LNG haul-trucks looked to be process and therefore retains the diesel feasible from an operational and safety viewpoint, and had good emission reductions engine s high performance and efficiency characteristics. HPDI has been demonstrated in (primarily NOx PM and SOx were evaluated at on-road Class 8 trucks since 2001 accumulating that time). The next step identified was to develop almost 10 million km to date. The supply of a concept vehicle for demonstration at the mine, LNG fuel will be an essential parallel aspect in but we were unable to secure sufficient funding the introduction of HPDI to mining. LNG can to embark on this work at the time. Hodgins be transported to site as diesel is today, or may notes that at that time, oil was at something be produced at or near mine operations that like $15/bbl so the economics were less have access to methane sources or pipelines. compelling than they are today. At that time, Bruce Hodgins, Vice President, Market HPDI development was part of a Cummins Development with Westport told IM about the Westport joint venture (CWI), but in late 2003 company s progress with LNG power for haul the JV was restructured and HPDI technology trucks. The initial feasibility study was completed development was returned to Westport. Foot on the gas Westport Innovations believes that mine haul trucks, because they consume considerable quantities of fuel, are ideal candidates for the adoption of cleaner and cheaper fuels like natural gas. The company says impressive fuel cost savings will be realized in regions where liquefied natural gas (LNG) has cost advantages to diesel fuel, while also significantly reducing air contaminant and greenhouse gas emissions, compared to diesel fuel. Westport s APRIL 2007 International Mining 25

9 EARTHMOVING In 2005, Westport re-initiated the investigation into the application of HPDI to mine-trucks and worked closely with Energy Developments Ltd (Brisbane) and several major mining companies, Hodgins reports. An in-depth feasibility study, development plan, and business case was developed over about 18-months looking at the complete LNG cycle for producing LNG through to the trucks on the mine site. This business case showed very compelling economics for all parties (fuel provider, vehicle technology provider, and mine operator), and we are in the process of engaging the right partners to collaborate on product development and evaluation for HPDI trucks. We are optimistic that we will find a workable arrangement to commence on a development programme, but the timing of that has not been established. He says that where mine operations are located close to natural gas fields or pipelines, LNG can be manufactured directly from pipeline gas. This is attractive in countries like Australia where the cost of gas is cheap. Alternatively, LNG can be transported long distances (up to 1,000 km) economically by road. Furthermore, coal mining operations are increasingly interested in the option of using Ensham s Bucyrus dragline. their coal bed methane (CSM) gas in liquid form to power mining vehicles, as this provides a natural hedge against rising diesel costs. And its great for the environment. Westport suggests a mining operation of 30 trucks might consume in the order of 40 million litres RESISTORS ARE WHAT GRIDCOM DOES BEST! concentrates on building the most complete range of of braking resistors for off-road diesel electric electric mining mining trucks trucks and and LeTourneau electric loaders. LeTourneau electric loaders. Completed braking resistors Completed are always in braking stock: model, resistors B are model always (Poly-Zi), in stock: H model D model, andb model the newest (Poly-Zi), 33D model. H model Besides and the new newest units we 33D can model. also Besides repair new most units of failed we resistors. can also repair most of failed resistors. Gridcom also provides individual after-market parts (e.g. plates, plates, barriers, barriers, hardware) hardware) for all for makes all makes of off-road of off-road diesel electric diesel electric mining trucks, including mining Euclid, trucks, Komatsu including (Wabco, Euclid, Komatsu Dresser), (Wabco, Unit Rig Dresser), and others. Unit Rig We and will others. always We provide always effective provide effective solutions solutions fitting your fitting specific your specific needs. needs. Unit B Ave., Surrey, B.C. Canada V4N 4E6 Unit B Ave., Surrey, B.C. Canada V4N 4E6 Bus: Bus: (604) (604) Fax: Fax: (604) (604) sales@gridcom-mining.com gridcom@telus.net 26 International Mining APRIL 2007

10 04/07 of diesel per year. Applying HPDI natural gas technology to such a mine would reduce the GHG production by ~ 22,000 t/y. Tracks and tyres Considerable investments have been made in the Berco Mining Products area in recent years from the biggest mechanical maxi-press in the world (32,000 t) to heat treatment and machining lines for large-size, heavy components in order to complete the already extensive product range. Moreover, in mining, where products must ensure excellent safety, extremely high quality to avoid dangerous accidents or critical failures during the work process and good wear resistance for longer component life, it is essential that the products supplied guarantee high performance, Berco says. To this end, it has extended its range of forged mining products to replace corresponding cast products: the quality of forged items is much higher, guaranteeing a more The Detroit engine of the Terex TA40 is equipped with an effective engine or Jake brake, which provides additional retardation for opertation on steep slopes reliable, controllable, precise and long-lasting component. At Bauma, Berco is exhibiting its latest innovations, including a set of forged track shoes of lengths ranging from 800 to 1,150 mm for Liebherr mining excavators, forged sprockets for dozers (such as the Komatsu D375) and a number of forged track links for dozers (such as the D11R). The upgrade for the Komatsu D275 and D375 dozers and the undercarriage for the R994 excavator will be on show alongside the traditional D11R, D10R and D9R undercarriages (all with the BPR Berco Pin Retention system and rolled single-flange idlers), together with the maxi-roller for an 800 t excavator and a range of undercarriages for the largesize excavators frequently used in the mining industry. In 2007, the Michelin Earthmover Management System (MEMS) will be available for sale on a large scale. This tyre management solution for surface mining is the first of its kind avail- BEDELCO your OTR TYRE dealer BIAS RANGE 52/80 X PR E X PR E X PR E4 50/65 X PR L X PR E X PR E X PR E X PR E X PR E4 45/65 X PR L5 35/65 X PR L X PR E X PR E4 NEW RADIAL RANGE 1600 R25*** 23.5 R25** 26.5 R25** 29.5 R25** 1800 R25** 1800 R33** 2400 R35** worldwide delivery large stock OTR TYRES Rue de l Environnement Seraing - BELGIUM Phone : Fax : info@bedelco.com APRIL 2007 International Mining 27

11 EARTHMOVING able on the market, Michelin says, and enables users to monitor tyre temperature and pressure in real time, thereby enhancing productivity and improving safety. MEMS will be sold and installed individually on 49-in and larger replacement tyres. Market rollout will take place during In response to the tyre shortages, Michelin has increased its production capacity with a new plant at Campo Grande in Brazil for 25 to 49-in tyres, which will be operational starting November 2007 and will produce up to 40,000 t of tyres in In 2005 Michelin also announced an increase of production capacity of large mining tyres at its earthmover plant in Lexington, South Carolina, USA. Michelin is spending $85 million to increase the site s production capacity by 50%. Currently under construction, the new units will produce 51 to 63-in tyres. Production capacity has also been increased at Michelin s earthmover plant in Vitoria, Spain. These capital spending programmes will allow Michelin to increase its total earthmover tyre production capacity by 26% by year-end 2008 (or 40% by 2010) to meet strong global demand. World No 2 dragline Ensham Resources new 7,000-t dragline (known as Dragline 4) - the second biggest in the world - has left the construction pad on its 12 km journey into the nearby Ensham mine. It will replace a fleet of smaller shovels to take on the task of uncovering coal in a new area of the mine where the coal seam is deeper. Ensham Dragline 4 will move 20 Mm 3 of overburden in 2007 in its commissioning year and 28 Mm 3 /y after that. Ensham s General The Bell B50D, a very popular ADT. Manager Operations, Peter Westerhuis: That s more than two of the mine s existing draglines put together and underscores the sheer size of the Bucyrus and its 110 m 3 bucket. The decision to install the dragline was made back in 2004 to improve Ensham s ongoing sustainability and competitiveness in the global steaming coal market by reducing overburden Experience and Innovation are the keys to our successful products the right equipment for mining and tunnelling made by GIA, Sweden. Giamec ANFO Charge-Up Trucks Utility & Service Trucks Rocmec Scaling & Charge-Up Trucks Cable Bolter SwedVent Axial High Pressure Fans SwedVent High Pressure PVC Ducting Häggloader Shuttlecar Kiruna Truck Locomotive Rescue Chamber P.O. Box 59, SE Grängesberg, Sweden. Telefon + 46 (0) , fax + 46 (0) info@gia.se Tailor made solutions our speciality Service & Parts support our commitment

12 04/07 removal costs. We ve had an unusually high dependence on truck and shovel operations to meet our production targets over the past couple of years, but as the coal gets deeper this method is proving inadequate and too costly in moving the sheer volume of overburden which needs to be moved to access the coal. We have started planning and discussing with our principal contractor the reduction of truck and shovel fleets that the dragline will replace over the course of 2007 to allow them to redeploy those resources elsewhere. The demobilization of truck and shovel fleets would occur gradually, commencing this month and winding up around May as the new dragline is properly bedded down. This would reduce the number of contract truck and shovel fleets from eight to five in total. Each fleet employs approximately 35 people including fleet managers, machine operators and maintenance support. Ensham is employing an additional 20 people full time in 2007 to operate and maintain the new dragline. This is in addition to the 100 contractors who were involved in its construction over the past two years. Year of the ADT 2007 is the year of the ADT (Articulated Dump Truck) from Terex Equipment, which this year celebrates 25 years of manufacturing this successful range in Scotland. The Terex TA40 truck which has achieved quick success within the market, largely due to design focus on operator comfort and safety will also be shown at Bauma Maximized cab space, the ergonomic layout of operator controls and a new suspension system have developed the standard of the cab working environment, and the added visibility due to the centrally mounted cab enables the machine to be manoeuvred with ease. Improved retardation is an additional feature, both from the new oil-cooled service brakes and from an integral retarder working on the output shaft of the transmission. At Bauma Bell Equipment will be announcing its intention to manufacture its flagship ADT, the B50D at its German factory by the third quarter of Group CEO, Gary Bell says the decision to manufacture locally has been driven by the strong demand for the B50D in European markets. The B50D has developed a solid reputation in mining in various countries and in the UK we have already had our first customer who is changing out his B50D for new machines, which is a good sign, said Bell. In an interesting application in eastern Germany, Washington Group International is using Volvo ADTs at its Mibrag operations. These are traditional lignite operations using large, continuous mining equipment. However Mibrag has found the supplementary production provided by the Volvo units, loaded by hydraulic excavator, to be very effective, recovering coal that would otherwise be lost. IM will report on this in detail in a forthcoming issue. IM Do you need to keep up with the latest mining project news? Subscribe to International Mining Project News and save hours of collating news items and reports. Contact Emma Joseph for more information, on +44 (0) emma@im-mining.com APRIL 2007 International Mining 29