WORLD PROSPECTS
Komatsu ’ s 4800XPC starts to bed in
Designing , building and launching the next generation of the world ’ s largest mining equipment represents huge commitment , cost and risk . Komatsu Mining took that step in 2013 when it launched the P & H 4800XPC AC – then and now the world ’ s largest electric mining rope shovel with a 135 ton payload , designed to three pass load 400 ton ultra-class haul trucks . The design leveraged new Adaptive Controls technology with ultra-class machine structures to enable the larger payload and increase efficiencies .
The shovel is capable of up to 9,000 t / h with other attributes including very robust machine structures and systems such as a wider boom and handle , a new dipper with a higher weight to payload ratio and a new modular counterweight system . The first unit was deployed to Teck ’ s Fording River coal operation in British Columbia , Canada , in 2019 following detailed analysis to understand the potential ripple effect that increased production might have across the mine site .
Specifically , data was collected and assessed to determine how significant gains in shovel productivity might affect the truck allocation , lifeof-mine planning and ongoing maintenance . And it has performed very well there working with the 400 ton 980E , displaying high productivity with high availability .
Since then , there has been no news of the 4800XPC AC until now – IM can report that the second unit of the shovel will be going to Anglo American Platinum ’ s Mogalakwena platinum mine in Limpopo Province , South Africa , in 2024 . Beyond that a larger order for multiple 4800XPC units has also been placed by a Tier 1 copper miner – on which more details will emerge in the coming months .
Back to the unit for Mogalakwena ; first off , how did this come about ? The mine ’ s existing large shovel is a Chinese TYHI WK-55 shovel which restarted operations in June 2023 after an extensive upgrade and partial rebuild to increase its performance levels . This machine has been operating at the mine for a number of years but in 2021 Anglo American also began looking for a second large shovel to help meet the needs of its ongoing expansion project .
Initially discussions with Komatsu centred on the 4100XPC AC – this unit weighs 1,500 t and has a payload of 109 t so is more than capable of three pass loading the mine ’ s 321 t class Komatsu 930E trucks . The 4100XPC would be able to produce around 6,000 t / h with a 930E truck fleet .
But Komatsu South Africa had a novel solution to handle the challenging hard rock mine conditions at Mogalakwena – why not deploy the 4800XPC instead , and take advantage of its considerable extra power – 20 % more – but with a scaled down 4100XPC sized dipper to achieve a 7,400 t / h production rate ?
Essentially it is still three pass loading the 930Es – but doing so faster with better dig performance . So , the higher initial cost is quickly justified in this application . An order for the machine was placed in March 2022 after detailed simulations and TCO determinations , with handover of the units – the second 4800XPC ever built , the first outside North America and first in Africa – due in April 2024 .
And these were not the only considerations in Anglo American Platinum opting for the 4800XPC AC . Charl Coetzer , Strategic Account Manager , Mining at Komatsu South Africa , said : “ The 4800XPC AC leverages new Adaptive Controls technology with optimised machine structures to enable its larger payload and increase efficiencies . Adaptive Controls is a series of control functions that optimise shovel power usage in different phases of the dig cycle ie crowd , hoist and swing , leading to improved shovel performance while lessening the effect of operating impacts on the machine . Adaptive Controls combined with a stable , optimised structural platform in conjunction with efficient sight lines and refined ergonomics contribute to improved operator effectiveness and reduced operator fatigue . Through the application of innovative engineering and advanced technologies , Komatsu has designed the 4800XPC to be the industry ’ s most productive electric mining shovel .”
He adds : “ The need for the new shovel was a direct requirement due to the mine ’ s ongoing expansion . The shovel will load ore and waste , but its main focus initially will be on waste . The major factor was the higher production rates available from the 4800XPC shovel , especially with the down-sized dipper . The digging conditions at Mogalakwena are very challenging , due to the nature of orebodies and formations found in the region .”
Going forward the future for the 4800XPC AC seems bright – in recent months and years , large commitments have been made worldwide for new electric drive 400 ton class truck fleets , especially in Latin America , plus Komatsu has just launched its highest powered truck to date – the 980E-5SE equipped with a Cummins QSK95 4,400 hp engine . www . komatsu . com
Sandvik makes truck delivery to Zone 5 copper-silver mine
Sandvik Mining has successfully delivered a 63 t class TH663i truck to the Zone 5 copper-silver mine , owned by Khoemacau Copper Mining in Botswana , in partnership with mining contractor Barminco . The operation is in the heart of the Kalahari Copper Belt .
The Khoemacau operations are comprised of the Zone 5 underground mine and associated infrastructure , and the upgraded and expanded Boseto processing plant . The current operations can deliver 60,000 t / y copper and 2 Moz / y of silver in concentrate at full run rate . A planned Phase 2 expansion will more than double production to 130,000 t / y of copper and 5 Moz / y of silver in concentrate .
Sandvik says Zone 5 is set to experience a game-changing transformation with the arrival of the TH633i truck . “ Sandvik Mining ’ s commitment to innovation and excellence is evident in this delivery , as the TH633i boasts state-of-the-art features designed to tackle the unique challenges of mining operations .”
The TH663i is engineered to deliver exceptional hauling capacity , optimised fuel
efficiency and reliable performance even in the most demanding conditions . Equipped with stateof-the-art safety features and advanced automation capabilities , it enhances the wellbeing of miners and the overall operation , according to Sandvik .
It also incorporates cutting-edge technology that enables real-time monitoring , remote operation and data-driven insights . This translates to better decision-making and improved operational efficiency . With reduced emissions , efficient energy consumption and environmentally conscious design , it also aligns with the industry ’ s evolving sustainability goals . www . sandvik . com ; www . barminco . com . au ; www . khoemacau . com
10 International Mining | SEPTEMBER 2023