Engineering & Mining Journal

JUL 2018

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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JULY 2018 • E&MJ 61 OPERATING STRATEGIES more effi cient dig cycle when looking at energy usage per ton of material moved." The shovel also features the PreVail re- mote health management system, which Singleton described as an "early warning system," and the Track Shield collision de- tection and mitigation system. The latter, he said, involves sensors that "allow the machine to detect where it is operating on a geometric plane." That and other planes "can, at times, intersect, and the specifi c intersection being discussed represents a collision between the dipper and the crawl- er shoes," Singleton said. "By being able to predict, based on operator inputs, the situations where the dipper and crawler shoes will hit, we can take minimal yet ef- fective evasive action, which will lead to maintenance effi ciencies by not having as much damage to the dipper and latchkeep- er and a minimization of damage to crawler shoes and connecting pins over time." The dipper is perpetually assessed by P&H Payload, a monitoring system that relays to the operator the weight of the payload. An upgraded system being tri- aled features "ease-of-confi guration," as an anchor feature, Singleton said. Since 2013, the company has been fi eld-testing the shovel's various systems to include the new dipper, the direct-drive crowd and the Adaptive Controls. The machine is 15.2 m long by 15 m wide by 3.3 m high from the ground to the bottom of the counterweight slabs. Work- ing ranges include a cut height of 18.9 m, a cut radius of 24 m, a max dump reach of 19.4 m, and a dump height of 10.8 m. The dipper capacity maxes out at 77.6 m 3 . It requires at least a 3,750-kilo- volt-ampere supply transformer. The company said the shovel can in- crease production by as much as 20%, which Singleton attributed to its ability to load trucks in three passes. "One of the keys to capturing this production po- tential is having enough trucks for the machine to effectively load, and also the speed with which the trucks can be load- ed," he said. With the upgraded swing system and the Adaptive Controls, it can handle a dig cycle "as fast or faster" than the 4100XPC AC, he said. "So, the shov- el isn't simply a slower machine with a larger dipper designed to three-pass load ultra-class haul trucks," he said. "Rather, it is an optimized machine with a larger dipper that will load as aggressively as the market standard 4100XPC AC." Komatsu said the shovel could de- crease cost-per-ton by as much as 10%, which Singleton attributed to the ma- chine's optimized performance. "The per- formance improvements, enabling high- er production, are proving to more than offset any increase in overall machine costs," he said. The key requirement for adopting the shovel is an adequate electric grid. De- ployment mandates only minimal infra- structure or logistics changes, Singleton said. "Because the envelope of the ma- chine is so similar to the 4100XPC AC, there is not a tremendous requirement for signifi cant differences in approach, and there is also a signifi cant level of machine commonality shared with a 4100XPC AC, which will help drive effi ciencies in in- ventory management and understanding from similar maintenance processes." So far, the shovel has been received with "guarded optimism," Singleton said. Due to "the shovel being so early into its life with the fi rst unit beginning manufac- turing," he said. The "optimism" is in- spired by "the smart upgrades that were made to the machine, which they trust will drive the 4800XPC to deliver on the brand promise of a P&H electric mining shovel."

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