SURFACE LOADING
some time is in Russian gold mining . In early 2019 , RCT said it had successfully completed its biggest surface mining related project to date at the time for Caterpillar dealer Vostochnaya Technia which saw eight automation solutions deployed at Polyus ’ Olimpiada surface mine in Krasnoyarsk region , Eastern Siberia , Russia . The company ’ s bespoke department , RCT Custom successfully designed , manufactured and installed ControlMaster Teleremote solutions tailored specifically for this project for a fleet of five Caterpillar 777F trucks , a Komatsu 1 PC- 3000-6 hydraulic shovel and D-275A-5 dozer and an Atlas Copco DML drilling rig . Given RCT ’ s success in underground mining with applying its ControlMaster technology , represents a huge untapped market .
Polyus Gold told IM in November 2020 on the project : “ Polyus operates remote control systems for mining equipment at Olimpiada . This system is in place in order to improve employee safety in the most dangerous areas of the mine . The mining fleet is controlled using two mobile units with workplaces and server equipment installed . The mobile control units are safely located near to the location where haul trucks and drilling rigs operate , inside the mining pit itself , and the technology is currently in use at the most dangerous pit sites and ensures safe operations by the company ' s personnel , as well as increasing efficiency .”
Monitoring sensors are placed on all pit walls at Olimpiada to track potential movement of rock mass . Polyus developed a digital model of the deposit , which reflects the displacement of fixed sensors as well as the level of rock stress . The company uses the data from the monitoring system to decide on pit areas for further mining using the remotely controlled machinery . “ The mining fleet is equipped with a remote control system , and an on-board computer communicates wirelessly with a remote server , enabling remote control of the equipment using joysticks and tracking monitors .”
The company plans to construct a control room beyond the pit site . A separate control centre will be built outside the open pit , near to the minesite . In addition , Polyus says it will upgrade the data transmission system currently in place and upgrade the remote-controlled machinery by adding cameras and special equipment , as well as expanding its remotely controlled mining fleet .
Cat upgrades 7495 rope shovels
Caterpillar has updated its 7495 and 7495 HF electric rope shovels with the result it says being an up to 10 % increase in operating efficiency . Drawing from more than a century of rope shovel innovation , the 2021 Cat ® 7495 and 7495 HF Electric Rope Shovels ( ERS ) combine multiple
Komatsu says its 2650CX Hybrid is seeing a 40-50 % reduction in diesel fuel consumption versus large hydraulic shovels but also with greater efficiency and productivity
standard feature upgrades to improve machine productivity , while component enhancements , increased frame durability and improved serviceability help reduce cost per tonne of material moved by as much as 15 %. A new propel gear case for the 7495 and 7495 HF models nearly doubles the life of propel gearcases in some extreme operating conditions , Cat claims . Precise adjustments to gearing geometry and advancements in tooth hardening enhance gear case durability and productivity . The result is lower total cost of ownership of as much as $ 8 / h when the drive system is replaced at one scheduled time . Additionally , an ecology drain simplifies oil draining and enables kidneyloop flushing , which reduces abrasion-causing contaminants and oil change frequency . Updates to the 7495 AC electric drive system deliver greater reliability , improved maintenance access , enhanced safety , and expanded high altitude and temperature capabilities , the company says .
The standard Operator Assist – Enhanced Motion Control simplifies machine operation to promote high production while protecting the machine . This system is designed to yield more reliable crowd rope replacement schedules , full design life for hoist ropes , reduced wear on crowd brakes and longer life for hoist gear case components , according to Cat .
The first 2021 Cat 7495 mining shovel will be operating in October 2021 and the second in Q1 2022 . The elements of the 2021 machine that are retrofittable are currently operating successfully in the field . These elements include the outboard propel shaft and the improved propel gear case , Operator Assist - Enhanced Motion Control technology , improved hoist gearset , updated HydraCrowd cylinder , improved saddle block , and the fast propel transfer switch . In reference to the integration of the Enhance Motion Control ( EMC ) technology , data from a Chilean copper mine indicates significant improvements to shovel operations . In one year , the software detected 779,309 anti-swing in bank events across the mine ’ s fleet of shovels . Anti-boom jack year-over-year comparison indicated 60 % fewer incidents thanks to EMC . In addition , crowd overspeed was reduced by 80 %, from an average of 15 per month to three . Longer-lasting crowd and hoist running ropes reduced costs , increased reliability , and boosted production per set of ropes . Other improvements include hoist stall protection , crowd anti-impact and hoist rope
slack prevention . Ultimately in that period , the site saw overall production increase by 25 %.
Help from Komatsu hybrids
Komatsu Mining ' s 2650CX Hybrid Shovel pilot unit has operated at both the Asarco Mission copper mine and Climax Molybdenum moly mine . Luke Tolley , Product Manager – Hybrid Shovels told IM : " Hybrid shovels are designed to deliver the cost benefits of the high productivity of electric rope shovels with the flexible digging and manoeuvreability of diesel hydraulic excavator ; they fit into operations that run a similar class of hydraulic excavators or rope shovels . We are seeing a 40-50 % reduction in diesel fuel consumption and greenhouse gas emissions compared to hydraulic excavators . Over its life , the hybrid shovel can save 14,000,000 litres of diesel fuel and 37,000 t of carbon emissions ."
SR Hybrid Drive Technology is leveraged on the hybrid shovel to capture regenerative power that is naturally produced . Diesel energy is converted to electrical energy through a switched reluctance generator , which provides power to hoist , crowd , and swing motors . When the 2650CX lowers its bucket or decelerates swing speed , motors become generators , supplying energy to the machine and shutting off fuel supply . Engines do not burn fuel for about 17 % of a typical loading cycle , including dig , swing , dump and return swing , contributing to reduced fuel consumption and longer engine life . To maximise efficiency , the machine utilises electric power over hydraulic to enable regeneration . The result is 50-60 % less hydraulic fluids needed compared to hydraulic excavators . This translates to additional savings through reduced fluid costs , reduced hydraulic routings and fittings , and a reduced environmental impact .
With a payload capacity of 59 t enabling a four-pass match to 227 t haul trucks , it will accommodate trucks ranging from 135 to 360 t . Tolley adds : “ The P & H 2650CX leverages the hoist and crowd digging forces of P & H electric rope shovels and adds a third force , referred to as breakout force , ie bucket curl . Breakout force
30 International Mining | MARCH 2021