buckets of energy - Joy Global · buckets of energy Ailbhe Goodbody ... cated to introducing new, produc- ... As part of that, the company will be introducing the next-generation

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loAd & HAul

buckets of energyAilbhe Goodbody examines the current trends in the underground load-and-haul sector, including the effect of emissions regulations

I n the current climate of the min-ing downturn, mining companies have a strong focus on regaining

their productivity to improve their position on the cost curve relative to their competitors – in addition, the increase in productivity must be safe, sustainable and cost-effective, so for example energy efficiency is important.

In terms of underground load and haul, this means that mines are look-ing for products that transport more tonnes per energy unit, provide a safe workplace for mine personnel and benefit the overall productivity of the mine.

Marcus Eklind, product line man-

ager – underground material han-dling at Atlas Copco, says: “This means strong partnerships with a focus on automation. Automation is not just about autonomous opera-tion but also about optimisation and control, coming from effective moni-toring. So it’s not just about the equipment collecting data, but about sending data in real time to be able to act and plan based on the data sent.”

Mines are seeking technology integration, with the flexibility to scale features from basic automation to fully autonomous operation, resulting in safety as well as produc-tivity gains.

Daniel Hawkins, technical market-ing representative, underground hard-rock vehicles at Caterpillar, tells Mining Magazine: “The primary goal is to remove personnel from poten-tially dangerous applications.”

Data acquisition allows mine oper-ations to measure the health and performance of the machinery, increasing reliability. Bill Maki, prod-uct manager – loaders & trucks at Joy Global, says: “Reliability is only second to safety in importance, as reliability has a direct effect on over-all productivity and utilisation.”

There is also an increased focus on total cost of ownership (TCO), with a higher pressure on OEMs to lower

The Joy LT-650 is ideal for

narrow-vein applications

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costs and increase productivity. Customers are putting more

focus on profitability and also on the overall partnership with the suppliers rather than just buying machinery for their operations, and are asking for long initial machine life and the capability for the machine to be rebuilt for a second life to reduce TCO.

Jarkko Koskinen, sales support manager, loading and hauling at Sandvik Mining, notes: “Customers have started to look for complete packages with leasing, financing and aftermarket services. There is also more interest in upgrades, repair kits and retrofit kits to increase the current fleet’s lifetime.”

EmissionsUS EPA Tier 4 and EU Stage IV die-sel engines are becoming available on load haul dumper (LHD) vehicles, providing a significant reduction in hazardous emissions and improving the underground work environment.

However, they carry additional

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complexity that can increase mainte-nance requirements.

Eklind says: “We are now stretch-ing the diesel technology to the limit, increasing the complexity of the equipment, which adds com-plexity to our product offering since we must offer a lower emission-rated engine alternative to markets out-side Europe and North America.

“There is a big difference between a Tier 2 and Tier 4 Final installation on a machine, complicating the man-ufacturing and support processes (with different parts to stock and forecast), as well as increasing the portfolio maintenance requirements.

“The increased complexity and requirement for clean, low-sulphur fuel have definitely made our cus-tomers look at alternatives such as electrically powered vehicles.”

GE believes that there are several challenges in using Tier 4 engines in underground mines, including: diesel particulate matter (DPM) versus nitrogen oxides (NOx), bigger foot-print, urea injection, increased tech-nical challenges and maintenance, exhaust-gas recirculation (EGR) expense, platinum/palladium cata-lyst in selective catalytic reduction systems (SCRs), and the added heat through the exothermic process of catalyst and regeneration.

Sid Gaitonde, senior product man-ager, underground propulsion at GE Mining, explains: “The exothermic

challenge specifically impacts mine ventilation as heat management increases the load on the mine’s ventilation and cooling system. Elec-tric machines have a much higher heat efficiency when compared with their diesel counterparts, and are gaining traction in the underground mining market.”

Alternative power sources for load-and-haul vehicles can allow for a better use of energy to move tonnes of ore, while also significantly reducing the cost for ventilation.

GoinG dEEpErMines are going further under-ground as orebodies are being found deeper– and as excavations go deeper, the cost of installing and operating fans, heating and cooling grows significantly, resulting in addi-tional strain on the existing ventila-tion and cooling systems and requir-ing expensive upgrades. Gaitonde says: “Most underground mines in North America and Europe have a typical ventilation rate between 100ft3/min and 125ft3/min (2.8-3.5m3/min) for every installed horsepower of diesel engine – a rate that is largely mandated by legislature.”

The Centre for Excellence in Min-ing Innovation (CEMI) states that the cost of operating underground ven-tilation systems is the single largest underground mine expense, at up to 40% of total running costs.

Gaitonde states: “Reducing the

ventilation requirement provides mine operators with the option to reduce ventilation power costs or use the same ventilation to simulta-neously mine at more locations. That is a significant benefit, providing both operational efficiency and pro-ductivity.”

As a result, there has been an increased demand for electric rather than diesel-powered vehicles in underground mining.

Carl von Hohenthal, sales at GHH Fahrzeuge, says: “Seen from a TCO point of view and with a strong focus on diesel particulate matter as well as heat in the section, we do see very strong benefits for this technol-ogy. In the end it becomes clear that the best way is not to generate any emissions underground at all. This is the safest and eco-friendliest way to muck ore.”

He adds: “Furthermore, demand is strong in regions where energy is cheap and diesel quality, especially sulphur content, is too low to run Tier 4 Final compliant engines. It becomes clear that the total TCO of electric LHDs is lower than diesel when analysed holistically.”

Underground electric vehicles may be powered by batteries or by teth-ered trailing cables. However, Koski-nen cautions: “The switch to teth-ered electric LHDs requires modifications to the mine infrastruc-ture and also only specific applica-tions can utilise eLHDs – those with a fixed loading location and no other traffic on the route.

“Customers using the diesel-driven LHDs normally prefer the flex-ibility provided by diesel LHDs but are also interested in upgrading the units into low-emission models to improve air quality, achieve cost sav-ings and in some cases even reduce the ventilation requirement for fur-ther savings.”

The GE 7T LHD comes with all

the standard options of the

company’s current diesel

LHDs

The soft-rock low-profile

version of GHH Fahrzeuge’s LF21 loader

“There is a big

difference between a Tier 2 and

Tier 4 Final installation

on a machine”

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AtlAs CopCoAtlas Copco provides a compre-hensive line of equipment for underground load and haul in a wide range of applications, with its Scooptram loaders ranging from 3.6t to 18t tramming capacity (both diesel and electric), its Minetruck trucks ranging from 20t to 60t payload capacity as well as the Häggloader continuous loaders with capacity from 3.5m3/min to 5m3/min.

Eklind explains: “Safety is always our number-one priority, which can be seen in our products and the many smart features they offer. Min-imal operator fatigue is ensured by the ergonomically designed and spacious operator compartment.

“The best-in-class power-to-weight ratio ensures good speed on grade for high productivity. Com-pared with on-highway equipment,

our trucks offer high reliability and low running costs.”

Atlas Copco states that it is dedi-cated to introducing new, produc-tive and technology-leading prod-ucts that bring value to its customers’ businesses.

As part of that, the company will be introducing the next-generation large underground Minetruck at the MINExpo International trade show in Las Vegas, US, in September.

Eklind says: “The new Minetruck comes as automation-ready, which is enabled by the modern Rig Con-trol System (RCS). The new Mine-truck has got a new efficient hydraulic system and offers unparal-leled productivity in underground haulage.

“The all-new telematics solution CERTIQ from Atlas Copco ensures real-time feedback for accurate planning.”

CAtErpillArCaterpillar has a full line of under-ground LHDs and articulated trucks ranging from 6.8t loaders through to 60t dump trucks specifically designed for underground mining in hard-rock applications. The truck line has application-specific options available, including ejector bodies for backfill applications.

Optional payload-management systems for the trucks allow custom-ers to monitor production material being hauled and identify areas for improvement.

Selected underground loaders feature ejector buckets for low drift heights where a traditional dump application is not possible.

“All Cat underground hard-rock LHDs and articulated trucks feature one common thing; they are all built, designed and manufactured by Cat-erpillar,” comments Hawkins. “These

Equipment providersThere are several companies that supply equipment for underground load and haul – Mining Magazine spoke to some of the main players about what’s available and what will be launched later this year

“Safety is always our

number-one priority,

which can be seen

in our products and the

many smart features

they offer”

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products all use proven Cat power trains and Cat components.”

This gives Caterpillar’s customers a single source to contact for help, and it provides parts commonality with other Cat machines owned by the company.

Hawkins says: “We see MINExpo as a significant opportunity to dem-onstrate Caterpillar’s deep commit-ment to underground mining. It allows us to showcase the invest-ment, innovation and technology solutions that we either continue to improve on – or will launch at the show.”

GE mininGIn 2012, GE acquired Fairchild Inter-national and Industrea, both manu-facturers of underground soft-rock mining vehicles. Since the acquisi-tions, GE’s Fairchild developed and began offering complete lines of battery-powered scoops, tractors, multipurpose vehicles, longwall shield haulers, maintenance vehicles, contin-uous miners and haulage systems.

Gaitonde tells MM: “GE believes battery-powered vehicles are leading the way towards green mining by eliminating emissions of diesel partic-ulates without sacrificing perfor-

mance or flexibility, cutting ventila-tion costs and outperforming diesel machines on productivity.”

GE’s new 7t battery-powered LHD for underground hard-rock mining combines GE’s existing mining pro-pulsion systems with the technology from Fairchild to form a greener min-ing vehicle for underground hard-rock mining.

“Ventilation will always be a chal-lenge in underground hard-rock min-ing – with orebodies becoming deeper, the cost of installing and operating fans, heating and cooling will grow significantly,” says Gai-tonde. “In other areas, mines are being reopened but have to exploit the orebody using infrastructure already in place, sometimes making ventilation management nearly impossible. The requirement for ven-tilation is mostly driven by regulation, and the industry expects the require-ments will increase as the potential health hazards related to poor venti-lation where diesel particulates are present in underground space become better understood.”

As a result, GE is bringing forward its know-how in battery-powered

A Cat LHD equipped with Command for hauling

“Ventilation will always be a challenge in underground hard-rock mining

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vehicles in coal mining to the hard-rock industry through a battery- powered LHD. Its advantages include ventilation and maintenance savings as well as healthier condi-tions for underground miners.

“Many mining companies want to be greener and reduce their carbon footprint while maintaining produc-tivity and cost reduction. GE’s goal is to eliminate underground diesel par-ticulate,” explains Gaitonde.

“Battery-powered technology has improved dramatically in the past ten years. Electric motors are par-ticularly good in certain applications due to their torque curve versus internal combustion engines – this has been demonstrated on locomo-tives and surface haul trucks. How-ever, it eventually comes down to cost. Battery-powered LHDs not only eliminate diesel particulates, making it safer for the workers, but also reduce operating costs.”

GE Mining will be launching the 7T-BLHD battery-electric loader for underground mining at MINExpo. The 7T-BLHD has a length of 9,378mm, maximum width of 2,242mm; and maximum height with canopy of 2,229mm. Its outside turn-ing radius is 5,762mm and inside is 2,932mm, and the maximum bucket reach at the pin is 3,234mm. Its tramming capacity is 6,800kg with a lift breakout force of 134kN for both lift and tilt. The maximum travel speed (loaded and level) is 17km/h.

The GE 7T LHD comes with all the standard options of the company’s current diesel LHDs. Gaitonde says: “In addition, the electric propulsion system enables the seamless integra-tion of telemetric data capture, help-ing customers monitor operating con-ditions and duty cycles. This enables customers to better monitor their maintenance intervals, reduce operat-ing cost and improve availability.”

GHH FAHrzEuGEGHH Fahrzeuge develops and manu-factures LHDs and articulated dump-ers as well as scalers and mixers for mining and tunnelling. Its special- purpose vehicles are manufactured to the customer’s specifications for dif-ferent requirements, whether for soft or hard rock. Its products support mining houses worldwide in the haul-age of base metals, precious metals, rare earths and other commodities, and the most important mining regions for the company include Africa, South America, Russia as well

as Germany and North America.Based on its modular machine

approach, GHH can quickly adapt and create customer-specific solu-tions for individual requirements.

“Our strengths are customised solutions, such as application-specific vehicle designs,” comments von Hohenthal. “Likewise, we offer spe-cial cabins and modifications for operators as well as engine variants. Other solutions are hydrostatic drives for highest efficiency, low fuel con-sumption, reduced maintenance cost and best handling.”

Furthermore, GHH modifies vehi-cles for extreme conditions, such as corrosion, extreme temperatures, water and gradients, along with semi-autonomous operation. Von Hohenthal says: “Based on GHH standard machines, we design explosion-proof versions for environ-ments with methane hazards.”

GHH meets the trend for larger machinery with its 21t LF-21H loader, which comes in several different ver-sions for hard- and soft-rock applica-tions. Von Hohenthal notes: “The approach utilises the largest possible machine that adapts to the size of the gallery, not vice versa. Therefore we offer this machine in several height options, for example a super low- profile cabin and z-linkage with a height of only 2,300mm.”

Joy GlobAlJoy Global offers five underground hard-rock loader models and five underground hard-rock trucks. Maki says: “Our machines’ simple and robust designs offer ease of use and low maintenance with features and options that help drive down operat-ing costs. All models are engineered with a focus on operator safety, pro-ductivity and reliability.”

The company’s four-wheel drive, articulated loaders range from 0.7t to 10t and the trucks range from 6.4t to 31.8t. The Joy LT-350, LT-270, LT-210 and LT-650 are all ideal for narrow-vein applications, and the Joy LT-1050 is ideal for load-and-carry and truck-loading applications.

Maki states: “Our newest model, the 16TD truck, is based on the pop-ular DT-1804 model, a stalwart unit in our product line for many years. The new and improved design features lower hood lines for improved visibil-ity, a digital operator display, shorter turning radius, ground level mainte-nance and faster ramps.”

Joy Global also offers a complete range of haulage products that are used in both room-and-pillar and longwall entry development. The Joy shuttle car is used for batch haulage – it comes in a wide array of heights and widths to match most mining conditions. Its latest developments include a variable-frequency drive (VFD) conveyor drive for smoother conveyor starts and longer reducer life. Joy shuttle cars have a rated load capacity from 8t to 30t.

Joy battery haulers come in three models. The 11.4t capacity BH10 is designed for low-seam applications, the 16.4t BH18 is ideal for medium seams and the 18.2t BH20 is for high seams. Maki says: “All Joy AC battery haulers feature a patented lift-from-grade battery-change system and can be equipped with an optional video camera system to reduce operator blind spots.”

On the continuous haulage side, Joy offers a true continuous haulage flexible conveyor train (FCT). The FCT eliminates bottlenecks between the continuous miner and feeder-breaker. This single operator system allows the miner to operate at maximum

“Our strengths

are customised

solutions, such as

application-specific vehicle

designs”

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sAndvikSandvik has a wide range of load-and-haul products available for underground mining. This includes 1-21t diesel-driven LHDs for narrow vein and mass mining applications, 3.5-25t tethered electric LHDs, 5-9.6t low-profile LHDs, 15-63t trucks and an 80t truck for horizontal hauling.

The main features of Sandvik’s LHDs are high breakout forces thanks to the box-constructed boom and sophisticated geometry, optimised

operator safety and comfort and high productivity with reliable design.

Sandvik’s trucks are designed to match the LHD sizes to ensure three-pass loading for faster loading phases and the highest available capacity. Koskinen adds: “High reliability and fast ramp speeds, due to minimised own weight vs. load, ensure high long-term hauling productivity. Oper-ator safety and comfort has been taken to a completely new level in the latest TH551 and TH663 trucks.”

Sandvik is currently introducing a complete fleet of eco-friendly LHDs and trucks equipped with ultra-low Tier 4 Volvo Penta engines. Koskinen says: “There are already about 100 pieces of Sandvik load-and-haul units equipped with Tier 4 (interim or final) engines in operation, and the cus-tomer feedback has been very posi-tive. The air quality underground has improved quite a lot, and on the other hand low fuel consumption is creating customer savings.”

The company also states that the Sandvik booth at MINExpo will show-case a lot of new interesting units and technology, but couldn’t give further details at this time.

capacity. Maki tells MM: “This all-electric, single-operator, truly contin-uous haulage machine can replace a small fleet of diesel haul trucks. This can significantly reduce the amount of diesel particulates released during the mining process, and it also elimi-nates the need for costly diesel fuel and the special handling required.”

Joy Global’s continuous haulage offering also includes two chain haulage options. The CHS-AC35 is rated at 22.7-31.8t/min, while the CHS-HT25 hydraulic tram is rated at 15.4-22.7t/min. Maki says: “Both sys-tems feature that same dependable, field-proven OptiDrive VFD traction drive system used on our 14CM con-tinuous miners.”

Joy Global’s new underground hybrid loader family, set to debut this year, features its proprietary Switched Reluctance (SR) hybrid drive technol-ogy to significantly reduce fuel con-sumption. Maki explains: “It allows power generation that is fully regen-erative, resulting in very efficient wheel-loader operation. During brak-ing or retarding, electrical motors become generators and feed power back into the generator connected to the engine. The Joy SR hybrid drive system allows for 100% capture and utilisation of all braking energy during the loading cycle.”

The new Joy 16TD underground hard-rock truck is based on the popular DT-1804 model, which was a stalwart unit in the product line for many years

A Sandvik TH551 truck being loaded by a Sandvik LH517 LHD

“This all-electric, single-operator, truly continuous haulage machine can replace a small fleet of diesel haul trucks