The Load Factor

Transcript

SURFACE LOADING:proof 28/8/12 13:23 Page 1 SURFACE LOADING The load factor A dragline operating at Peabody NARM, Wyoming Paul Moore looks at the current status of the surface loading machine market, where demand remains strong in most regions and in most commodities, with ultra-class faring particularly well he current upswing in mining activity has been particularly positive for the most pivotal types of capital mining equipment such as large mills, but it also applies to mining excavators – from hydraulic machines to rope shovels and draglines. Lead times for the largest loading tools tend to be long anyway hence the effect of the 2008 downturn was minimal and now a distant memory. The hotspots in terms of hydraulic excavator and rope shovel orders remain the same – coal, iron ore, copper/gold and oil sands – with relative demand for ultraclass machines especially strong. In addition, several new models and new variants of existing models are expected to be announced at MINExpo in Las Vegas. In new rope shovel deliveries, Taseko Mines has provided an update on its GDP3 expansion project that will increase the Gibraltar concentrator capacity to 85,000 t/d. Gibraltar is a copper-molybdenum mine, located in southcentral British Columbia, Canada. The expansion has also meant investment in the surface mining fleet, including a new Caterpillar 7495 shovel which will be operational in November. Elsewhere, Allied Nevada Gold is to use three Caterpillar 7495 shovels at its major Hycroft gold mine expansion which will be delivered in 2013/2014. In the dragline market, North American Coal’s Freedom lignite mine recently commissioned its third Bucyrus Erie 2570W dragline (now part of Caterpillar). The dragline was purchased from T 164 International Mining | SEPTEMBER 2012 CONSOL Energy in 2003, and years later disassembled and transported to the assembly site near Beulah, North Dakota. The dragline is needed to handle the increased overburden depth at the mine and has a 126 yd3 bucket. Some 15 Mt/y of lignite is supplied to the Antelope Valley, Leland Olds and the Great Plains Synfuels power stations. The high cost of new draglines has meant that for many years there has been a very active market for the global supply of idled, pre-owned draglines, where they are disassembled, relocated and reassembled: at huge cost but still well short of the capital expenses of a new machine. This supply route it seems is coming to an end due to a lack of available machines so some major new orders for draglines are expected in the coming year. In upgrades, Armstrong Coal has used the Flanders Electric AC Drive System to upgrade an old Bucyrus Erie 770 dragline from DC drive. Flanders believes that is the first company in North America to successfully upgrade a DC powered dragline to AC power. The dragline is being used at the Lewis Creek mine in Kentucky. Other AC upgrades have been completed elsewhere in the world – these include the well documented ABB retrofit of two Russian ESH15/90 draglines with AC drives at the Narva oil-shale mine in Estonia. Flanders offers a complete line of mining machine electric-drive upgrades, including rope shovel DC drive and controls upgrades, rope shovel DC to AC retrofits, dragline DC control upgrades, and dragline DC to AC retrofit. It offers several distinct options for mining machine upgrades, namely complete recondition of existing rotating equipment, replacing MG sets with upgradable DC drive technology, complete replacement of existing DC drives, and replacement of DC system with AC drives and 'drop in' AC replacement motors. Key developments Caterpillar states that it will reveal “a number of innovative mining systems and machines” at the event including what is described as ”an unprecedented, efficient means to step up production loading of ultra-class haulers.” The company says the new loading tool makes the best use of size and energy storage technology. Possibilities include an electric and/or backhoe configuration version of the former O&K RH400 or finally a completed and updated version of the Bucyrus 795 rope shovel for which an older design has been around for years but never actually built. Its release would also be significant in terms of the In-Pit Crushing and Conveying (IPCC) market. Loading tools that Caterpillar will have on display include the 994H Extended High Lift designed to efficiently load 250 short ton size class trucks and the 6030B FS hydraulic face shovel representing the extensive line of SURFACE LOADING:proof 28/8/12 13:23 Page 2 SURFACE LOADING shovels. The 6030B is the first of the Cat B Series hydraulic shovels and features a state-of-the-art new cab and operator environment with productivity enhancing onboard electronics. Mining specialist Hargreaves this year invested in a totally new fleet of Caterpillar equipment in a UK-first, £60m, seven year deal with Finning Equipment Solutions. This is the first time in Europe Africa and the Middle East (EAME) that a mining project has chosen a total solution from the newly extended Caterpillar mining range. The deal includes four new Caterpillar 6030 hydraulic excavators. Customers for the 6090 FS (former RH400) include Vale’s Moatize mine in Mozambique which was one of the first in new Caterpillar colours. Its assembly started in March 2012 and it is now operational. A 6090 FS is also operating at Xstrata Coal’s Ravensworth coal mine in the Hunter Valley. The 994H is the largest of the Caterpillar wheel loader line, and features four loader linkage configurations and a range of buckets to tailor the machine to the application. While optimally matched to Cat 785, 789 and 793 mining trucks, the company states that the 994H has the design flexibility, capacity and durability to deliver reliable, low-cost production in any operation. The fuel efficient 994H has 1,092 kW of installed power and an operating weight of 195.5 t. It also features Caterpillar's Rimpull Control System, Positive Flow Control hydraulics and Vital Information Management System. Lift configurations for the 994H include standard, high lift, extended high lift and super high lift, providing dump clearances at maximum lift that range from 5.58 m to 7.08 m. Bucket choices include heavy-duty rock, highabrasion rock and coal— available in narrow and wide widths to suit the application—and ranging in capacity from 15 to 36 m³. To ensure durability that will sustain multiple life cycles, the 994H uses solid-steel lift arms that work though a powerful Z-bar linkage, which features a greased pin design and an automatic lubrication system. The 994H rear frame is a fullbox-section fabrication designed to resist torsional shock and twisting forces, and the machine's cast axle-pivot mounting areas disperse stress loads for added overall durability. For fuel efficient operation, a Cat 3516B HD engine works through a Cat planetary powershift transmission specifically designed for mining applications. An integral Impeller Clutch Torque Converter and Rimpull Control 166 International Mining | SEPTEMBER 2012 South American mining corporation Masering is expanding its current comprehensive fleet of 13 Liebherr excavators by another four large excavators. An agreement was concluded between Masering SAS and Liebherr-Colombia SAS to supply two of each model, namely the R9250 BH and R9350 BH. Colombia as a whole possesses the largest coal mines in South America and is currently using a total fleet of 34 Liebherr mining excavators. Given the growing importance of this market, Liebherr founded Liebherr-Colombia SAS, a new sales and service company for mining equipment, in July 2011. The head office in Barranquilla includes administration offices, as well as a spare parts store and a modern repairs workshop. The mining excavators are supported from one of the service centres affiliated to the El Hatillo mine. Originally planned as a sales company for mining equipment, LiebherrColombia SAS set up an additional office in Bogota in January 2012, to support Colombian customers in special civil engineering machinery. Another key Liebherr market is Australia, where the company’s largest R9800 machines have been delivered over the past few years. In April 2011 Thiess commissioned a second R9800 backhoe excavator at the Burton coal mine in Central Queensland. This additional machine was purchased as part of the mine expansion known as the Burton Deeps Project. This massive project involves removal of 275 Mt of overburden. The first R9800 backhoe was commissioned at Burton in December 2009. Additionally there are four R996 and one R994 backhoe excavators operating at Burton. With Thiess as the lead customer, the second R9800 customer is contract mining group Downer EDI. It has an R9800 backhoe in operation at Fortescue Metals Group’s Christmas Creek mine, recently visited by IM. Also at the mine are four R9400 backhoe machines. The R9800 is working in overburden and is equipped with a 42 m3 bucket and is loading 225 t trucks in three passes. The R9800 is equipped with twin MTU 4000 engines and is the first unit equipped with them. Downer EDI Mining also made an order for a further R9800, which was shipped earlier this year. To support the machines on site, Liebherr has a sub-branch operating out of Downer EDI Mining premises, staffed by two parts personnel and a project manager. In addition, there is a factory technician from the lead manufacturing facility While Russia’s own shovel manufacturers have been doing well, there have also been deliveries of other machines, such as this P&H 2800XPB System allow the operator to precisely adjust power at the wheels to specific loading conditions by modulating rimpull from 100 to 25 %, reducing potential for tyre slippage without diminishing hydraulic capacity. The 994H Positive Flow Control (PFC) implement hydraulic system uses four, electronically controlled, variable-displacement pumps, delivering up to 1,460 litres/min at a main relief pressure of 32,800 kPa, “assuring fast, consistent response as well as fuel economy and low heat generation.” The PFC system also integrates concurrent valve control, providing precise, proportional command of loading functions with electro-hydraulic loader controls, electronically controlled cylinder stops and automatic kickouts set from the cab. The Steering and Transmission Integrated Control System (STIC) combines control of travel direction, steering and gear selection in a single controller, and the spacious, pressurised cab features automatic climate control and a quiet, 71 dB(A) sound rating. The 994H also features a powered access ladder and reduced stairs angles for easy access and egress from the operator station. For enhanced operator awareness of the area around the loader, the Cat Detect Vision rear vision camera system is standard, and Cat Detect Object Detection is available. Object Detection includes radars that detect objects around the machine and notify the operator of these potential hazards. Integral with the 994H Vital Information Management System (VIMS), which allows realtime assessment of machine performance, is the Payload Control System that enables on-the-go weighing, payload recordkeeping and analysis of parameters such as utilisation, cycle time and fuel usage. In addition, the available Cat MineStar System provides a suite of integrated mine operation and equipment management technologies that can enhance 994H operation and maintenance. Earlier this year, Liebherr announced that SURFACE LOADING:proof 28/8/12 13:24 Page 3 SURFACE LOADING in Colmar on site, who is assisted by the local Perth technical services department. Hitachi Construction Machinery (HCM) launched two new ultra-large hydraulic excavators in February 2012. Designed to increase production on large-scale mining projects, the EX5600-6 and EX2600-6 have succeeded the EX5500-6 and EX2500-6 models. The company stated that the launch of the new excavators coincides with an increase in demand for resources on a global scale. HCM also said the move is a response to requests from its international mining customers for ultra-large excavators with a greater capacity for excavation and loading. To increase production, the bucket capacity for both models has been increased: from 29 m3 to 34 m3 on the EX5600-6 and from 15 m3 to 17 m3 on the EX2600-6 on the backhoe version; and from 27 m3 to 29 m3 on the loading shovel version of the EX5600-6. The reach of the front attachment has also been shortened. Higher productivity has been achieved, with a cycle time equivalent to the original machines, by boosting the engine output. As an example, the backhoe EX5600-6 uses four rather than five bucket passes to fill a dump truck with a nominal payload of 220 t, significantly increasing production capacity and efficiency by reducing the loading time. Both new models have the same type of engines as their predecessors, namely two Cummins QSK50s. The cooling performance of the radiator and oil cooler has been increased to protect the engine and hydraulic devices. In addition, all undercarriage and hydraulic cylinder parts can be replaced with those from the original models. The EX5600-6 and EX2600-6 are also both equipped with a spacious working environment that provides good visibility for the operator. The cab is fitted with LED lighting, an airsuspension seat, user-friendly control levers and a large LCD monitor. For easy maintenance, the EX2600-6 has an additional walkway, which enhances access to the machine. The EX5600-6 and EX2600-6 are both suitable for operating in extreme temperatures, from tropical regions to cold environments and high altitudes. They can also be supplied with an optional interface for mine management systems, such as Wenco Fleet Management Systems, provided by Wenco International Mining Systems, a subsidiary of HCM. Electrical motor-driven versions of the EX5600-6 and EX2600-6 will also be made available. The company states that these are popular in Russia, the CIS countries and China due to the availability of existing power supply facilities and because in some situations they can offer versatility compared to rope shovels. These models will also be promoted to companies operating in newly developed mines 168 International Mining | SEPTEMBER 2012 An IZ-Kartex shovel at the Taldinski coal operation, Russia in North and Latin America. Greg Smith, Manager Heavy and Mining Equipment for Hitachi Construction Machinery (Europe) said: “The two new machines complement the Hitachi EX8000-6, EX3600-6 and EX1900-6 models, which are highly valued by major mining companies for their high levels of productivity, availability and reliability. Total sales of the EX5600-6 and EX2600-6, including both engine types and the electrical motor, are expected to reach 100 machines a year.” Hitachi has also announced plans to significantly boost its global production capacity for mining machines, including large and ultralarge hydraulic excavators. It will not only expand two of its existing plants, but will also construct new facilities in Hitachinaka City, Japan. The manufacturer also intends to invest in its Indonesian and Canadian locations to further increase production and improve efficiency on a global basis. The total cost will be approximately €430 million. Sales of mining machinery are expected to continue to grow due to the substantial demand for resources around the world. As of 2013, HCM predicts annual production of 170 units of large hydraulic excavators up to 120 t; 240 units of ultra-large hydraulic excavators between 190 and 800 t; and 260 units of dump trucks with a loading capacity of 190 to 300 t. Hitachi believes the quality of the machines will be enhanced and costs will be reduced by focusing on production plants close to its development base at Tsuchiura Works, located in Japan’s Ibaraki Prefecture. Hitachinaka-Rinko Works will be extended by 9,950 m2 to create space for assembling large and ultra-large excavators and dump trucks, plus a new training centre. In March 2012, HCM acquired 78,312 m2 of land adjacent to both the harbour and the Hitachinaka-Rinko Works for the construction of a 29,297 m2 plant. The new facility will produce frames of large and ultra-large excavators and dump trucks, and accommodate employee facilities and an office. Hitachinaka Works will also be extended by 29,900 m2 for the machining of the components required by mining machines. In addition, HCM has acquired 224,335 m2 adjacent to the Hitachinaka Works for the construction of a 37,155 m2 plant. Components previously manufactured at Hitachinaka Works will be transferred to the new plant, where they will be assembled to form modules (a functional group of components). The new plant will act as a main distribution base, transferring the modules to HitachinakaRinko Works and shipping them to the plants in Canada and Indonesia, for efficient machine assembly. Work has already begun on the extension work at the two Japanese facilities and is due for completion by the end of 2012. The two new plants will be fully operational by October 2013. More than 500 new jobs will have been created in Japan by 2015. In Indonesia, work on the Cibitung plant in Bekasi is now underway – the Hitachi Construction Machinery Indonesia facility will be extended by 11,118 m2. A new 20,280 m2 plant will also be built on a 100,000 m2 site in West Cikarang. They will be used to manufacture components of undercarriages, frames and front attachments of large and ultra-large excavators. The leading ultraclass hydraulic mining excavator remains the Komatsu PC8000 of which the number of installed units is approaching 100. The company estimates its ultra-class share of the market at 75% and 20% for machines from the PC3000 and above. Recent PC8000 deliveries include three machines to Pascua Lama, operating at 5,200 m above sea level, which has required a unique engineering approach to the machines, all of which are now operational. The company told IM that the conditions required engine and SURFACE LOADING:proof 28/8/12 13:24 Page 4 SURFACE LOADING Komatsu PC8000 at Yakutogol, Russia. This model is the leading ultraclass hydraulic excavator and the 100th delivery will be made to Drummond in 2013 hydraulic pump adjustments, a general cold weather package to cope with ambient temperatures down to -40°C including radiator, hydraulic oil and engine oil pre-heating; an additional operator cab heater; special sealing packages, steel and casting tests; screws and bolts material changes; pump drive gearbox/cab/cab base preheating; and finally engine pre-heating and ether start. Most PC8000s have been shipped with face shovels but the market for backhoes is picking up following Liebherr’s introduction of the R9800. Komatsu is shipping a diesel backhoe PC8000 to BHPB Escondida by the end of the year, a diesel machine with a 42m2 bucket. Electric operation is not so suited to backhoe machines – but electric machines remain popular for face shovels. Aside from US and Colombian coal, Canadian oil sands as well as iron ore in Brazil, and copper/gold in Chile/Peru remain important ultraclass markets. The PC5500 is the most ruggedised machine and is popular in the copper-gold markets for abrasive hard rock operations. The 100th PC8000 will be the third of three electric face shovel machines on order for Drummond’s Twin Pines coal operation in Alabama. It is due to be shipped ex-works in April 2013 and operational by July/August 2013. Elsewhere, Drummond now has no less than 13 PC8000s working at its Colombian sites. Komatsu Brasil, a wholly owned subsidiary in Brazil of Komatsu Ltd is to begin direct marketing and product support (such as direct parts sales and technical support) of Komatsu mining equipment to its mining equipment customers in Brazil effective April 2013. For this purpose, KBI has been setting up its own facilities, parts operation, systems, and hiring and training necessary personnel. Komatsu will continue to engage in the marketing and 170 International Mining | SEPTEMBER 2012 product support of Komatsu mining equipment through existing dealer, Distribuidora Cummins Minas Ltda (DCML) until that point. Komatsu states: “In Brazil, the machine population of Komatsu mining equipment has been growing. In this light, it is becoming ever more important for Komatsu to improve machine utilisation rate and thereby help its customers further enhance their mining productivity. The more direct involvement of Komatsu will reinforce its technical support capability and product support services such as timely overhaul and parts supply.” KBI has also agreed with Mason Equipmentos Ltda, an affiliate of DCML, that Mason Equipmentos will continue its distributorship of Komatsu construction and utility equipment in the state of Minas Gerais. The new L250G wheel loader from Volvo Construction Equipment fills the needs of the market for a machine in the 35 t weight category. The L250G shares the sleek design of the rest of the new G-Series from Volvo, as well as a new engine and driveline system for improved productivity, lower emissions, greater smoothness, serviceability and operator comfort. The L250G also features a powerful ZBar loader linkage that allows for high breakout force for digging in hard materials. Its heavyduty linkage, lift arms and cylinders also offer high lift capacity and rapid hydraulic reaction, resulting in faster work cycles. The L250G is also fitted with a fuel efficient Tier 4i/Stage IIIB compliant engine that is married to drive train, hydraulics and lifting systems that are all designed and produced by Volvo. Fitted with Volvo’s 13 litre, six cylinder turbocharged V-ACT (Volvo Advanced Combustion Technology) off-highway diesel engine, it features cooled gas recirculation and a particulate filter with active regeneration. One of the first mining customers is Löderburger Baustoff + Transport (LBT), which has a limestone operation in Stassfurt, Germany. Part of the larger Ferdinand Wesling Group, LBT owns a number of rock and sand operations scattered across northern Germany. The Wesling Group is a major Volvo CE customer, running a fleet of 35 wheel loaders across Germany - 10 of which are at work in the Stassfurt quarry - and purchasing two or three new machines each year. According to Volvo, the L250G has “revolutionised efficiency” for LBT by providing a perfectly sized machine for loading semitrailer trucks in rehandling applications and rigid haulers at the rock face. IM was present at the first day of Intermat 2012 in Paris to see the official launch of Hyundai’s new mining class excavator, the 120 t R1200-9. The company said it had sold the first machine to a mine in Russia, with others having been delivered to mining operations in Myanmar, New Zealand, Indonesia and South Africa. The company states: “Underlining its intention of competing on a broad front in all sectors of the construction and mining equipment business, Hyundai’s introduction of a new top end excavator in the 100 t plus sector endorses the company’s commitment to large scale investment in developing new products and new market opportunities. Building on Hyundai’s experience with the successful 50 t and 80 t high capacity models, the all-new 120 t R1200-9 has been conceived with an eye on the expanding worldwide mining and quarrying sector, where the demand for efficient, largescale mass excavation in minerals extraction and overburden removal has fuelled an increase in sales of large mining trucks and the equipment to load them.” The R1200-9 is powered by the highperformance 23 litre, 6-cylinder Cummins QSK23-C engine, rated at 567 kW. Particular attention has been paid to the insulation to achieve low internal and external noise levels. This first version of the new 120 t machine is equipped with a heavy-duty, 7.55 m boom, 3.4 m dipper-arm, and 6.7 m³ bucket – a combination which gives a maximum digging depth of nearly 8 m, an outreach of 13.76 m, and a load-over height of 7.8 m. Maximum breakout force at the bucket is 64.9 t. The company adds: “With three selectable power modes (power, speed and economy), this is clearly a machine designed for extra-heavy digging duties and loading of large capacity dump trucks.” The 120 t weight puts the machine up against the likes of the Hitachi EX1200-6, the Komatsu PC1250, the Caterpillar 6015 and the Liebherr R9100 or R984C. The R1200-9 excavators are also equipped with Hyundai Construction Equipment’s Hi-Mate remote management system that provides operators and dealers with continuous access to service and diagnostic information on the SURFACE LOADING:proof 28/8/12 13:24 Page 5 SURFACE LOADING machine from any computer with Internet access. Users can pinpoint the excavator’s exact location using digital mapping and set machine work boundaries to reduce the need for multiple service calls. For added production, controllability and versatility, Hyundai also improved their current hydraulic systems. Fuel consumption has decreased as a result of improved pump-flow control that reduces flow when controls are not being used. Spool valves in the control valves have also been improved to provide precise fuel flow to perform each function with less effort. Developed with input from customers and in collaboration with truck manufacturers, the flagship of the P&H shovel line is now the heavy-duty P&H 4100XPC. Incorporating the P&H Centurion Control System, the P&H 4100XPC provides a 104.3 t nominal payload capacity specifically designed to operate in mines for high production loading of 218 t to 363 t haul trucks and larger. P&H states that the 4100XPC “stands alone as the preferred ultraclass shovel choice for high production mines around the world.” A proven 120 short ton option is also available. Iron ore miner, Cliffs Natural Resources, recently commissioned a new AC drive 4100XPC shovel at its Tilden mine, which adds to its new fleet of Komatsu 930E4SE trucks, which it can load in three passes. Cliffs has stated that it will use the shovel in The new Volvo CE L250 wheel loader both the Empire and Tilden operations. The shovel is now the largest electric shovel Cliffs operates in North America. Other users of the 4100XPC include Codelco Andina, Rio Tinto Coal’s Mount Thorley Warkworth and Hail Creek operations, the KRU Taldinski coal mine in Russia, and China National Coal Group Corp’s Pingshou. One feature of the 4100XPC is a modular “rear room” enclosure for major AC drive components including the inverter units and auxiliary transformer. Assembled in the factory instead of at often-harsh new shovel field assembly sites, the modular rear room assembly strategy helps streamline electrical routings, speeds installation time, and helps improve shovel serviceability. Electrical components are wired in the easier-to-control environment of the factory with the wires and cables terminated, wrapped and made ready for roll-out and quick installation at the mine site. Russia and China Russian manufacturers have also shipped new models this year. The Krasnobrodskiy coal mine recently commissioned its new EKG-32R THE EASIEST WAY TO BE MORE PRODUCTIVE ZSLPWULYÄZSLPWULY'ZSLPWULYÄ with the clever and simple Sleipner system. SEPTEMBER 2012 | International Mining 171 SURFACE LOADING:proof 28/8/12 13:24 Page 6 SURFACE LOADING excavator, produced by IZ-Kartex, part of OMZ Group. The EKG-32R has a bucket capacity of 32 m3 and weighs 950 t. It is the most powerful face shovel ever produced in Russia. Its development was part of the framework of excavator family renewal that went hand in hand with the modernisation of the IZ-Kartex production facilities near St Petersburg, financed by Gazprom, the company’s strategic partner. During the pilot production period, which lasted 6 months, the company tested the excavator’s functionality. The machine is stated to have met all of its required performance specifications and in January 2012 recorded its highest daily output of 29,400 m3 of material. IZ-Kartex also signed a contract this year with iron ore giant OJSC Stoilensky for the manufacture of four excavators with various bucket capacities; namely one EKG-10 excavator, two EKG-8US excavators and one EKG-5U excavator. Production of the EKG-10 model began in 1984 and today the electromechanical excavator EKG-10 is the leading loading machine in Russia and the CIS countries. Earlier this year, IZ-Kartex delivered its 500th EKG-10 to the Olympiadskiy mine. Stoilensky accounts for some 12% of the saleable iron ore produced in Russia. IZ-Kartex has cooperated with Stoilensky plant for almost 50 years with the first excavator delivered in 1968. IZ-Kartex machines still compose the main part of the fleet for overburden removal and iron ore extraction. Elsewhere in Russia, Ekaterinburg-based Uralmash recently shipped an EKG-12А shovel for the Kovdorsky GOK iron ore mine. Erection of the mining shovel started in May 2012 and the machine was put into operation in August. A second machine is to be delivered in early 2013. Uralmash EKG-12А shovels have also been put into operation at Evraz-owned Kachkanarsky GOK. The EKG-12А is equipped with a new electric drive system with static converters. This will contribute to energy savings, and extend service life and production efficiency while also improving noise and vibration characteristics. The design of the boom has also been strengthened in accordance with expected operating conditions. An improved automatic protection system and a prototype cabin with double-glazed windows and air purification system have also been included in the machine. China’s SANY is also making its presence felt in the loading tools market, albeit in specific mines that use smaller machines. The company completed the shipping ten SY365C mining excavators in 2012 to nickel miner Century Peak in the Philippines. Together with dealer VLFS Enterprise, SANY Philippines has established on-site support at the remote Dinagat Islands to 172 International Mining | SEPTEMBER 2012 better serve the client. Prior to the delivery, SANY’s engineers custom tailored the machines for work in the unique conditions of Philippine nickel mines. Modifications included a larger 1.8 m3 bucket to accommodate the low density of loads as well as extended tracks to increase machine stability. “The SY365C mining excavator is an excellent choice for use in the Philippine nickel mines, and we expect to sell another 20 units by the end of this year,” said Zhang Tao, director of SANY Philippines. SANY HE’s excavator sales volume in China exceeded 20,000 units in 2011, though the vast majority of these are working in construction. The SANY HE range extends up to the 68t, 4 m3 bucket SY700C. In Chinese electric rope shovels, December 2011 saw the signing ceremony for the export of four WK-35 large-scale mining excavators to Russia. The manufacturer, Taiyuan Heavy Industry (TYHI) is based in Taiyuan, capital of north China's Shanxi province and has supplied the machines through China National AeroTechnology International Supply Corporation. It had previously supplied a similar machine to Russia via the same company in 2010. According to THYI, the Russian customer had ordered four excavators from other country, but opted to purchase the machines from TYHI based on their performance. TYHI also recently produced its largest ever machine, the WK-75 shovel. The WK-75 is 37.5 m in length, 17.3 m in width, 23.5 m high and weighs 2,000 t. It is capable of producing 5 Mt of coal in a month and can achieve rates of 12,000 t/h, according to Wang Chuangmin, President of THYI. The company claims to have the dominant share of China's mining excavator market and has sold products in Russia, Peru, India, South Africa and Mongolia. New solutions In surface loading technology, funding from the Australian coal industry's research program ACARP has seen CSIRO collaborate with the Cooperative Research Centre for Mining, to develop automated swing loading technology for electric mining shovels. The system has been tested onboard a working electric rope shovel at the Bracalba quarry, near Caboolture in Queensland. CSIRO’s contribution to this project is the development of a system which takes input from a variety of sensors (including lasers and a mm wave radar) and uses this to construct and maintain an accurate model of the shovel's environment capturing the shape and form of the face, the position and location of the crusher-conveyor or truck and the shovel itself. The Queensland Centre for Advanced Technologies (QCAT, a CSIRO division) Mining Automation team has also been developing high-technology systems to assist dragline operators and mine planners. They have demonstrated their research with their cruise control and Digital Terrain Mapping (DTM) technologies on a scale model dragline in Brisbane A separate Excavator Guidance project aims to develop and demonstrate a system that is able to simultaneously track the bucket of a mining excavator and map the terrain under the boom. Trials at the Blair Athol mine in Central Queensland demonstrated that the Excavator Guidance was able to generate dynamic Digital Terrain Maps (DTM) while tracking the location of the bucket teeth within 10 cm. GE Energy this year announced the introduction of a new AC excavator solution which consists of drives, controls and motors designed specifically for challenging surface mine applications and environments. GE already has a long history of designing, installing and maintaining direct current (DC) excavator systems worldwide. “Mining owners and operators are migrating to AC systems in general,” said Nimesh Sharan, GE’s senior product manager for motors. “AC excavator systems are more energy efficient, and because they utilise less mechanical parts, AC systems tend to require less personal care and maintenance.” The AC Excavator Solution is a complete electrical drive solution comprised of a family of AC motors, drives, controls, engineering and field services. Heavy equipment original equipment manufacturers and earthmoving equipment owners can apply this solution in their draglines, shovels and blasthole drills. The company stated: “GE AC excavator solutions, based on an advanced AC drive, control and motor system technology, will help deliver the reliability and productivity necessary to help mining operators meet their goals.” Justin Forbes, GE’s senior marketing manager for motors commented: “Our solution offering is truly unique in the industry. GE’s endto-end solution includes up-front application engineering, rugged, field-tested equipment and field engineering support for installations.” New Liebherr excavators at MINExpo 2012 Along with the new T284 and T264 trucks, Liebherr will have two hydraulic excavators at MINExpo 2012. The new R9150 hydraulic mining excavator is ideally matched for 50 t trucks and is the successor of the Liebherr R984C. Offering the largest bucket capacity in its class combined with its high digging forces and optimal cycle time, Liebherr states that the R 9150 is “the most powerful excavator in the small class mining market.” The R9150’s new modern cab design has a one-piece windscreen with a panoramic view over the entire machine and loading area. The machine is also equipped with SURFACE LOADING:proof 28/8/12 13:24 Page 7 SURFACE LOADING a new monitoring system that is also used on the R9800. Liebherr states: “By providing complete monitoring functionality and textual maintenance information, this system enables easy machine operation management and quick dysfunction diagnostics.” The R9150 is equipped with the same Liebherr V12 diesel engine as the R9100, specifically designed to withstand extreme exterior temperatures and fluctuations in atmospheric pressure. Integrating the latest engine management system, the R9150 engine also complies with US EPA Tier 2 emission limits. The R9400 is “built for ultimate performance in the medium class mining market” and is ideally matched with 150 t trucks as well as being available in two configurations, either The Liebherr R9400 and all new R9150 are being showcased at MINExpo 2012 diesel or electric. The R9400 is powered by the Cummins QSK50 Tier 2 compliant engine with the electric drive version offering an alternative for applications that do not require frequent machine relocation. The production-tailored attachment kinematics combined with a mining-optimised bucket shape ensure the highest crowd and breakout forces. Liebherr states: “Even under tough conditions the R9400’s high digging force allows easy bucket penetration and high bucket fill factors to achieve high productivity. The machine is available with a wide range of buckets and Liebherr Ground Engaging Tools to cover all mining applications.” Optimising electrical, mechanical and hydraulic power distribution, the Litronic Plus System allows for easier control even when simultaneous movements are required. Every attachment cylinder is fitted with the patented Liebherr Electronic Damping System which provides controlled end-cushioning for fast and smooth machine motions. In addition, the R9400 is equipped with the “Pressureless Boom Down Function” to enable fast cylinder retraction without the need for pump energy. “Intelligent and power-oriented energy management” diverts the pump flow during boom lowering, allowing other cylinder motions to operate unimpeded. IM Drill More with RockMore t s a 1343 u # e Se No. 2012 h po ot Bo inex M Bits B its Rods Rods Couplings Couplings Shanks S hanks DTH D TH ® Mining M ining Construction Construction Quarrying Quarrying Tunneling T unneling Water-well Water-well R o c k M o r e® International Rock Drilling Drrilling Tools Toools Wilsonville, Oregon USA Wilsonville, Tel +1 (503) 682-1001 Tel [email protected] Judenburg, Austria T el e +43 3572-86300 Tel [email protected] www.rockmore-intl.com www w.r . ockm more-intl.com SEPTEMBER 2012 | International Mining 173