Engineering & Mining Journal

APR 2013

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VDMA Surface Mining Technology: Mining Machines for all Applications Few other companies in the world have comparable expertise in designing and building surface-mining machines to those based in Germany. While it is true that two out of the three major suppliers of hydraulic mining excavators with production plants here are foreignowned, the undisputed fact remains that the technology involved is fundamentally German, representing decades of continuous research and product development. German companies have also been at the forefront of developing continuous mining technology, with systems that encompass the full mining, transport and waste-handling process. Indeed, according to companies interviewed by Best of Germany, there is an increasing trend toward further applications for continuous mining systems, especially where mines are being operated in remote locations where infrastructure and fuel are expensive. This chapter looks specifically at loading and hauling equipment: materials handling is covered separately in the following section. Of course, it is important to remember that open-pit operations cover a much wider range of equipment than just shovels, trucks and surface miners. Take, for instance, hydraulic hammers which—in the right applications—offer a genuine alternative for niche extraction, as well as for handling oversize effectively. Produced in Essen, Atlas Copco's hammer range runs up to 10 mt in weight, providing more than enough impact for most mining and quarrying applications. New Excavators and Mine Trucks from Liebherr Liebherr AG took the opportunity afforded by last year's MINExpo show in Las Vegas to launch new mining excavators and haul trucks, which are made in Colmar, France and Newport News, U.S., respectively. The face-shovel version of its R 9400 excavator was one of the machines featured, while the introduction of the R 9150 came as a replacement model for the earlier R 984 C. Of the two trucks, the T 284 replaces the company's former top-of-the-range T 282 C, while the T 264 marks its return to the 240-ton class of hauler after a number of years. With an operating weight of 353 mt, the R 9400 is matched to loading 150 ton-class trucks. It is available in both diesel and electric versions, and carries a 22 m3 (28.8 yd3) bucket in standard configuration. Power for the diesel version comes from a 1,250 kW (1,675 hp) Cummins QSK50 Tier 2-compliant engine, with Liebherr The face-shovel version of Liebherr's R 9400 excavator. VDMA 22 suggesting that the electric drive option is an efficient alternative for machines working in cold climates. The company says the 130 mt R 9150 has been built to outperform all competitors in the small-class mining market. It uses a Tier 2-compliant 565 kW (757 hp) Liebherr V12 diesel engine equipped with a state-of-the-art engine-management system; when less power is required, "Eco-Mode" can be selected via the machine monitor panel to reduce the engine load, thereby improving the fuel efficiency and reducing carbon emissions. The R 9150 carries an 8 m3 bucket. Both new excavators have been designed for maximum performance by improving the efficiency of all the individual subsystems, the company states, and have been engineered for straightforward serviceability to give maximum uptime. Liebherr claims the T 284 offers the highest ultra-class payload in the industry, combining the benefits of a low empty vehicle weight and an electric drive system. Developed and built by the company, the Litronic Plus AC drive determines the optimal way to extract power from the engine, it says, so that more power is available to accelerate the truck and climb grades. The system also conserves fuel when the engine is idling, minimizing fuel consumption and maximizing performance. The T 284 supports engine options with power ratings up to 3,000 kW (4,023 hp), allowing customers to select an engine that will deliver productivity targets under their specific conditions. It also supports high-capacity tires. Meanwhile, the T 264 is sized to match the R 996 B and R 9800 hydraulic excavators, as well as electric shovels and wheel loaders. It can be fitted with engines up to 2,013 kW (2,700 hp), with an advanced traction-control system that helps operators to maintain steering control and truck stability, even in wet or icy haul-road conditions. KMG: Mining Excavators for Tough Conditions With its headquarters in Düsseldorf, Komatsu Mining Germany GmbH (KMG) is part of the worldwide equipment manufacturer, Komatsu of Japan. Within the group, KMG is responsible for the development, production and marketing of super-large excavators for open-pit mining. KMG's history goes back to the early 20th century. In 1907, Carlshütte AG built the first electrically driven rope shovels, with the company later being taken over by Deutsche Maschinenbau AG (Demag). The current production plant was built in 1939, and over the years, Demag repeatedly set new milestones in developing mining equipment. In 1949, the BL 335 rope shovel was the biggest in the world and five years later the company introduced the world's first fully hydraulic, diesel-driven excavator. Demag followed this in 1972 by developing the first hydraulic excavator with a total machine weight of more than 100 mt. Following a 20-year period when Demag was part of the Mannesmann group, in 1999 the company was bought by Komatsu, and was renamed Komatsu Mining Germany. Today, it is a global player, claiming a near-30% share in the international market for extralarge excavators for open-pit mining. It also claims market leadership in the 700 mt-plus class of excavator, reporting that the 100th PC8000 machine is scheduled to leave the factory during the first few months of this year. KMG produces four different types of super-large hydraulic excavators and shovels at its Düsseldorf plant, with machine weights VDMA MINING SUPPLEMENT • 2013

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