SURFACE LOADING
Komatsu highlights decarbonisation , productivity & safe maintenance
To get some insight into the large mining excavator market , IM spoke to Dr Thomas Jordan , Head of Marketing & Sales Support at Komatsu Germany – Mining Division , which manufactures the complete range of hydraulic mining excavators in both electric and diesel drive configuration from 300 t PC3000 to 800 t PC8000 at its manufacturing facility in Düsseldorf . He commented : “ For hydraulic mining excavators , there are three major topics that are currently important to our mining customers and therefore also for us . These are first decarbonisation , second efficiency & productivity ; and third the elimination of live work on the machine .”
Starting with decarbonisation , Jordan said : “ Our customers have clear emission targets to hit by 2030 and beyond . At Komatsu , we are dedicated to supporting them through strategic partnership , with a particular focus on electrification . We offer electric power options for all our models manufactured in Germany , ranging from the PC3000 to the PC8000 . This year marks a significant milestone as we celebrate over four decades of electrified hydraulic mining excavators . Since our inaugural electric mining excavator deliveries in 1983 , we ' ve supplied over 260 units , serving our worldwide customer base . Up to now , our electrified machines in the market have accumulated more than 12.5 million operation hours , showcasing our commitment to sustainable and efficient solutions in the mining industry .”
Komatsu additionally offers an automated cable drum to optimise cable management and simplify the operation and serviceability of its electric machines . Introduced in the mid-1980s , this feature is available for all excavator models . The system is based on the tension on the cable , and winds it up or down depending on the specific need , eliminating the need for manual intervention by the operator .
Is there a ramp up in electric excavator interest and orders ? “ The general level of interest has noticeably increased , particularly in markets that have traditionally emphasised conventional diesel machinery – Australia is a noteworthy example of that . Furthermore , in terms of product deliveries , there is an observable growth in the proportion of electrified machines compared to diesel-powered ones . Although the percentage increase is modest , it represents a gradual shift in the market over the last three to five years .”
Jordan added that in certain markets there is a great deal of interest in converting from diesel to electric during the shovel life . “ At Komatsu , we offer solutions that exemplify our commitment to sustainability . A notable example occurred in 2019 when we undertook a significant project involving the conversion of three PC8000 units to
A PC8000 converted from diesel to electric in Zambia
electric drive at a copper mine in Zambia . Since the conversion , each unit has accumulated close to 30,000 operating hours . Subsequently , the customer decided to invest in further new electric machines . For many customers , conversion is likely to be a first step – a starting point before investing in new equipment . This approach allows them to explore the benefits of an electric drive while giving their machine a second life with a lower TCO . In two ways it is a win-win situation : reducing operational expenses as well as contributing to a much lower carbon footprint .”
He adds : “ Our high-quality steel structure is made in-house and uniquely robust . We therefore suggest that our customers consider converting to an electric drive when undertaking a major midlife overhaul . The benefit here is that most of the main structure , undercarriage and boom plus attachment can remain in place and only the diesel specific parts need to be replaced . In practice , the diesel engine is removed and instead an electric motor is installed . This goes hand in hand with further changes to controllers and harnesses , as well as replacing the fuel tank for the switch cabinet , enabling a second life of the machine .”
Has there also been more interest in electric excavators in metallic mining whereas in the past , demand was dominated by the coal industry , with these open-cast mines already having electric infrastructure in place ? “ Definitely , we are registering increased interest now in hard rock applications , across copper and iron ore particularly . In view of the growing general interest in electrification of those industries , this represents a great opportunity . This interest is particularly pronounced in cases where customers have the capability to procure renewable energy from various sources . Additionally , in certain regions , the electrification trend is being propelled by regulatory permitting requirements , as exemplified in the Scandinavian countries .”
On efficiency and productivity , the – 11 variants are available for all our machines ranging from PC3000 to PC8000 , which feature safety improvements , such as the improved access and egress system with a 45-degree access ladder , plus two emergency egresses on the cabin- and machinery house-side of the machine . Komatsu also incorporated the latest EMESRT findings to enhance serviceability and safety during
maintenance ; these machines are also equipped with the KomVision 360-degree birds-eye view of the machine .
“ Beyond all that , the – 11 technology allows for performance improvements such as higher availability thanks to a simplified electrical schematic – a lean electric system with Komatsu pumps and controllers to minimise the number of components and therefore downtime . We also have the option to extend machine settings via the Komtrax Plus monitor inside the cabin . Our Komtrax Plus upgrade enriches the data and machine status visualisation in the cabin and offers storage of real time machine monitoring data . You can assess downtime information and R & M status to maximise product & component life .”
Another digitalisation option includes a payload meter system to improve the digging process . Finally , a further -11 focus is the reduction of cost per tonne through a more advanced and lean electric system as well as fuel efficiency improvements for diesel-driven machines through the latest Tier 4 Final-certified engines .
On to elimination of live work – this refers to taking service engineers out of higher risk operations and situations . One example of that is the recently introduced Komatsu Valve Adjustment Device ( K-VAD ) which facilitates the safe and secure adjustment of main and secondary relief valves on hydraulic mining excavators . It allows for remote operation from within the operator cabin , eliminating the need for service engineers to work next to highpressure areas . This increases safety in the workplace and prevents work on the running machine in the high-pressure area . It can be operated via Wi-Fi or via the 7-in touchscreen . The set includes everything needed for valve adjustment : pressure sensors , adjustment motors with tool heads and allen keys . The device can be operated by laptop , tablet , or smartphone . It enables the control of up to six tool heads and displaying up to four pressures . Moreover , the engine power check can be carried out with the K-VAD tool .
34 International Mining | MARCH 2024