coal · 2013. 5. 15. · president, caterpillar global mining viewpoint is a publication of cat...
TRANSCRIPT
finding technology solutions to combat
operator fatigue
mining boom leads to increase in
Greenfield OperatiOns
a publication of Caterpillar global Mining
component Rebuild centers:the flexibility Of a service shOp with the
prOcess cOnsistency Of a manufacturer
www.cat.com
© 2007 Caterpillar | All Rights Reserved | Printed in USA
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
AEDQ0036
2007: issue 2
viewpoint is published in english.
text-only versions in chinese, french, portuguese, spanish and russian are available at www.cat.com/viewpoint.
viewpoint es publicado en ingles.
versiones en chino, francés, portugués, español, y ruso disponibles en texto únicamente a www.cat.com/viewpoint.
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viewpoint est publié en anglais.
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viewpoint é publicado em inglês.
versões somente em texto em chinês, francês, português, espanhol e russo encontram-se disponíveis no site www.cat.com/viewpoint.
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Ravensworth to successSteady and straightforward approach drives
For a subscription, please e-mail your contact information to [email protected]
asphalt reclamation paves way for
efficient underground haulage
Coal: Solution for an energy-dependent world
c cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 1
mining boom leads to increase in
Greenfield OperatiOns 2
As always, our primary focus is on safety. In this
issue we address operator fatigue—one of the
most prevalent causes of accidents within the
mining industry and the focus of a new study by
Caterpillar. We share practical advice for operators
and report on some promising new technologies
that help mining companies manage this
important safety issue.
This issue includes two articles focusing on one of
Caterpillar’s most important markets: Coal. Our
mine profile features Xstrata’s Ravensworth mine,
located in the coal-rich Hunter Valley in New South
Wales, Australia. And our energy story highlights
coal’s critical role in meeting the growing global
demand for power.
We head underground for a feature story on
CVRD Inco’s Coleman McCreedy East mine in
the Sudbury Basin of Ontario, which shares best
practices for building and maintaining roads in
these challenging conditions. Our story on a new
Component Rebuild Center (CRC) operated by
Cat® dealer Sotreq in Brazil shows how CRCs help
mine sites achieve optimum component life and
reliability. And finally, we learn about the obstacles
and advantages to starting a greenfield operation,
featuring the best practices exhibited by Newmont
in its startup mines in Ghana.
Thank you for the positive response to Viewpoint.
This magazine is for and about you—so please
continue to share your feedback.
cOmpOnent Rebuild centers 20
Caterpillar editorial Board Dan Hellige, editor; erik elsmark, wheel dozers and loaders; John enderby, china and india; greg gardner, europe, africa and middle east; Chris gehner, underground mining; larry gregory, trucks; Dan Hellige, safety; Kent lynch, tractors; Keith Malison, latin america and the caribbean; patrick Mohrman, field support; glenn Morrison, australia, indonesia and new Zealand; Shane o’Brien, north america; David Schricker, 6 sigma. news frOm cat 33
asphalt reclamatiOn paves way fOr efficient undeRgRound haulage 24
Welcome to Viewpoint, a magazine produced by Caterpillar to address the issues facing our mining customers today—and to share what we’ve learned from our industry partners around the world.
Chris Curfmanpresident, caterpillar GlObal mininG
Viewpoint is a publication of Cat global Mining, producer of the mining industry’s broadest line of equipment and technology. caterpillar serves the worldwide mining community through its vast dealer network and a single division called caterpillar Global mining, headquartered in peoria, u.s.a., with additional offices worldwide.
table of Contents
finding technology solutions to combat OperatOr fatiGue 28
steady and straightforward approach drives
RavenswoRth to success 12 cOal: sOlutiOn fOr an enerGy-dependent wOrld 6
2 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 3
Exploration programs in recent years have
yielded rich discoveries of mineral deposits. With
commodity prices strong and sustained, mining
companies are opening greenfield operations in
remote areas. The current boom has led to new
operations in the gold mines of Mali, Tanzania,
Commonwealth of Independent States (CIS) and
Ghana; the copper belts of Africa and Mongolia; the
coal fields of Mozambique and Botswana; and the
diamond mines of Angola, Democratic Republic of
Congo and CIS.
the challenges
“There are serious considerations that go
into a company’s decision to mine in remote
environments,” says Caterpillar’s Gregory Gardner,
an account manager in the Global Mining division.
“ sometimes it means developing infrastructure and support for equipment and staff in a part of the world that hasn’t been exposed to the financial, environmental and population impact of a high volume mining operation.”
Greenfield operations in remote areas face a host
of challenges:
Transportation issues. Remote locations often lack
adequate infrastructure and are far from major
cities—resulting in higher transportation costs.
Care for workers and their families. In remote
locations, mining companies may need to build
schools, medical facilities, sanitation facilities, shopping
areas, etc. In some cases towns must be relocated.
Lack of necessary skills. Local work forces
generally lack technical skills and education.
Mining companies must provide training to
develop equipment operators, technicians and
plant workers and often provide basic education
for local communities to develop the language
skills necessary to understand operating and
safety instructions.
Pilferage. Fuels, minerals, tools and spare parts
may not be secure on site. This creates major
expenditures on local security and additional
infrastructure costs.
Harsh conditions. The geographies where greenfield
mines are being developed may experience very low
or very high temperatures, high or very little rainfall,
high altitudes, dust and wind.
Unstable governments. Corruption, inefficient
bureaucratic administrations and civil unrest
are key deterrents to investment and corporate
compliance requirements.
Assessments and permitting. The development of
new mines requires elaborate studies of the potential
environmental and social impacts before a permit is
issued, covering topics such as:
• Reclamation
• Air and water quality
• Noise and vibration
• Animal and plant life
• Cultural aspects
• Safety and health
• Compensation
• Relocation and resettlement
Mantrac Ghana Ltd. has been the Caterpillar
equipment dealer in Ghana since 1937. The dealer
also shares challenges when working with new
mines in remote locations.
“Certain government sectors can hinder operations,”
says Andy Sarson, managing director of Mantrac
Ghana Ltd. “Our company, compared to U.S. or
European Cat dealers, holds very high inventories
due to delays in customs and excise procedures—
making it very costly to operate because of high
working capital requirements. Equipment will
simply stand idle if we do not have stock.”
Skilled staff shortages also are a problem. “We have
two major mining contracts in Ghana that employ
over 250 staff members—of which 80 percent were
newcomers to the business,” says Sarson. “We face
major challenges in recruiting and training.”
the benefits
For companies that can overcome the drawbacks
to development of a new site, there are significant
advantages to mining in these remote environments.
“Greenfield developments in remote locations are
usually welcomed by the local community instead of
being criticized for their effect on the environment,”
greenfielD operationS
Mining BooM leaDS to inCreaSe in
neWmont is moVing toWard suCCess in ghana
the world’s voracious appetite for the products of mining is sending companies to the four corners of the earth to develop new deposits. developing new sites not only allows mining companies to expand their operations; it also creates opportunities to improve the quality of life in undeveloped communities.
2 cat Global mining / viewpoint / 2007: issue 2
hiring local workers is a priority for newmont, which provides training to help workers perform their jobs in the mining operation as well as to develop marketable skills that can be transferred to other jobs when operations close.
4 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 5
“With the dealer being responsible for the
maintenance and repair of the mining equipment,
that allows the customer to do what he does best—
mine materials,” says Sarson.
Mantrac Ghana has four branches strategically
positioned in Ghana to support the mining
industry, providing:
• Production analysis and machine application studies
• Machine sales/rental options
• After-sales parts and service support
• Full Maintenance and Repair Contracts (MARCs)
• Machine assembly and commissioning
• Full warranty support
• Engine and component repair capabilities (5-star Caterpillar facilities)
“Large greenfield operations do not happen
overnight,” says Gardner. “Mining companies
often do exploration for years before taking the
project to a feasibility and developmental phase.”
Once a site reaches the feasibility phase, dealers help
calculate and manage equipment needs. The dealer
can provide the customer with product technical
data, product support alternatives, capital and
operating cost information and more.
Cat dealers help mining companies with many
considerations:
• The number and types of machines to achieve production targets.
• Order and delivery scheduling so machines are ready to work when needed.
• The range of support equipment needed.
• National, local and site regulations that drive modifications to the machine, including emissions, environmental, ergonomic, operator comfort and safety.
• How the terrain and climate will affect equipment.
• How Cat Financial and Cat World Trade can play a role in equipment and project financing.
• What facilities are necessary to support and service mining equipment.
• The manpower required to meet the needs of the site—from on-site technicians to a full maintenance department.
• How to build and operate a safe site.
sustainable development
While Newmont is pleased with achievements so
far and confident in future success, leaders are
most proud of the strong relationship the company
has built with the local community.
“I want Newmont to be one of the first gold mines
in history to have a successful partnership with
the community,” says Chris Anderson, director,
corporate and external affairs.
Newmont has partnered with a number of
government and social organizations to improve
the quality of life in Ghana today—and to prepare
its citizens to maintain their improved community
long after the mine has closed.
Collaborations and partnerships with community
development experts continue to feature prominently
in Newmont’s programs. These partnerships have
led to programs that are transforming the lives of
people within the mining communities by promoting
agribusiness growth, improving quality of life through
resettlement and relocation, and partnering in a
community health and well-being initiative.
“ i want us to be known as a good neighbor, a good corporate citizen in ghana and as one of a new breed of mining companies,” says gordon nixon, managing director and vice president of african operations for newmont ghana gold ltd.
“This involves taking Newmont Ghana to the highest
possible levels in all areas: safety, financial return,
production, environmental stewardship and social
responsibility,” Nixon continues. “Specifically, in
the near future, our vision is to bring to fruition at
least one other project as big as Ahafo and eventually
produce two million ounces a year out of West
Africa. We are developing a strong management
team of Ghanaians to take us further into the future
as Newmont Ghana in Africa.”
says Gardner. “The goal of today’s major mining
corporations is to operate with absolute respect for
local communities, the environment and future
generations. The high level of scrutiny by the
industry, government and NGOs ensures that
today’s mines comply with and exceed the
highest available standards.”
Greenfield operations benefit from:
Welcome from locals. Many greenfield sites are
located in undeveloped areas lacking jobs and quality
of life—making mining companies a welcome
generator of wealth and improved living standards.
Less competition for resources. Because other
mining companies may not be willing to take the
risks associated with development of a new site,
there is less competition for the resources.
the success
One of the world’s leading gold companies,
Newmont Mining Company, headquartered in
Denver, Colorado, USA, recently marked its first
year of operation in Ghana, West Africa. Newmont
purchased both the Ahafo and Akyem projects
as part of the Normandy Mining acquisition in
February 2002.
The Ahafo operation, which is broken into two
stages, is located in the Brong Ahafo region of
Ghana, approximately 290 kilometers (180 miles)
northwest of Accra. The Ahafo project represents
Newmont’s first African and Ghanaian project and
together with the Akyem project forms Newmont’s
newest core district.
Africa is rich in mineral resources, including
gold, diamonds, platinum, copper, coal, bauxite,
iron ore, zinc and manganese. In Ghana, the
main resource is gold with small operations in the
bauxite, manganese and diamond industries.
Newmont reports that exploration success at both
of its Ghana projects has been exemplary. Reserves
have grown from a combined 94,000 kilograms (3.3
million ounces) in 2002 to 575,000 kilograms (20.3
million ounces) at year-end 2006.
The Ahafo mine poured its first gold on July 18,
2006, and commenced commercial production in
August 2006. Ahafo sold 5,700 kilograms (202,000
ounces) of gold in 2006 and is expected to produce
between 11,700 kilograms (410,000 ounces) and
12,800 kilograms (450,000 ounces) in 2007 as the
mine enters its first full year of production and
optimization.
Newmont currently operates two open pits at Ahafo. The
process plant consists of a conventional mill and carbon-
in-leach circuit. Ahafo reserves as of Dec. 31, 2006,
were 357,000 kilograms (12.6 million equity ounces).
The company is collecting stakeholder feedback on
Stage 2 of the Ahafo project. The Akyem project
continues to evaluate options to maximize value.
the suppoRt
Caterpillar dealers are uniquely qualified to help mining
companies with new operations. In fact, Caterpillar
produces a Greenfield Guidebook that outlines best
practices for providing equipment, service and support
to companies developing greenfield sites.
the brong-ahafo Region is located in midwestern Ghana, between the ashanti region and the côte d’ivoire border. its capital is sunyani.
this region contains many cultural and wildlife attractions, but it is less known to tourists than the ashanti, northern, central, or Greater accra regions. major attractions of the brong-ahafo region include Kintampo, with its beautiful falls and prayer park, and fiema, home of the boabeng monkey sanctuary.
newmont raises native plants in preparation for land reclamation and reforestation.
ghana brong-ahafo
region
6 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 7
rate of 1.6 percent—and to increase more than
one quarter between now and 2015. More than 70
percent of the increase in demand will come from
developing countries—with China alone accounting
for 30 percent of that growth.
Fossil fuels will continue to dominate energy
consumption and its growth—accounting for 85
percent of the increase in world primary energy
demand over the next 30 years. Renewable
energies are growing fast but from a small base—
and by 2030 are expected to meet 14 percent of
total energy demand, according to IEA, up from
13.1 percent in 2006.
As demand grows and countries become
increasingly dependent on imports, they become
vulnerable to disruptions in supply and resulting
price shock. “A small group of countries with large
oil reserves can increase market dominance and
their ability to impose higher prices,” says IEA.
Johnston says coal can address both the demand
and the rising prices. “There’s a lot of it—and it’s
relatively inexpensive.”
“World reserves of coal are enormous,” says IEA.
Coal makes up 60 percent of the world fossil fuel
reserves and is much more widely and evenly
dispersed than other fossil fuels. At current rates
of consumption, there is enough coal in the world
to last about 250 years.
Coal is mined in more than 50 countries and
extensive reserves are present in many countries—
particularly those that will see their own energy
demands substantially increase. IEA reports
proven reserves of coal worldwide are estimated to
exceed 1 trillion metric tonnes (1.1 short tons). In
comparison, current reserves of oil are projected
to last about 40 years and natural gas reserves are
projected to last about 65 years.
in addition to abundant supply, coal is one of the world’s least expensive energy sources. “it costs about a third of the cost of natural gas on a per-unit energy basis,” says Johnston. “Compared to petroleum, it’s about an eighth of the cost.”
Generating electricity from coal is also highly cost-
competitive compared to other sources, reports
the Center for Energy and Economic Development
(CEED), a U.S.-based organization that works with
regional and state policymakers to fashion public
policies that balance the need for a growing supply of
affordable, reliable electricity with the responsibility
to protect our environment.
Energy security concerns
As countries grow increasingly dependent on
imported fuel, they become more vulnerable to
disruptions in supply. Embargoes, permanent loss
of fuel sources, soaring prices, and events and
catastrophes that affect energy sources on a global
basis can threaten the energy security of countries
A variety of new energy and fuel sources are under
development—and in some cases being put to use
in limited applications at sites around the world.
Researchers are having success converting natural
gas and biomass to liquids. Photovoltaic (solar)
and wind energy are becoming viable for selected
markets. Nuclear energy may see a resurgence.
And new oil supplies are being uncovered around
the globe.
But to meet the energy needs of many areas of the
world, one source continues to make compelling
sense: Coal.
“Much of the world’s continued economic progress
depends on maintaining coal as a secure, reliable
and low-emissions source of energy,” says Chris
Curfman, president of Cat Global Mining. “Coal
often gets a bad rap in debates about climate
change, but we simply don’t have the option of
turning away from such an abundant energy
resource. Instead, we must continue to find ways
to process and use coal cleanly and efficiently. It’s
time to apply the same focus and intensity that
we did for the ‘space race’ in the 1960s—speeding
technology development and deployment to ensure
coal’s future viability.”
facing futuRe challenges
Like other energy solutions, coal faces some major
challenges, explains Darrin Johnston, a project
team leader in the Advanced Power Systems group
at Caterpillar Inc. He calls these three challenges
potential game-changers:
• Increasing demand for energy and associated higher prices
• National energy security concerns
• Regulations to reduce emissions of greenhouse gases
“Coal directly addresses the first two of these energy
challenges,” Johnston says. “And a number of new
technologies will help coal meet the third.”
Increasing demand for energy and associated higher prices
Rapid economic growth has resulted in a rising
demand for energy resources in countries like China
and India, and projections are that the growth will
continue as these countries’ economies expand. In
its World Energy Outlook 2006, the International
Energy Association (IEA) reports that global primary
energy demand is projected to increase by just over
half between today and 2030—an average annual
as economies boom and the quality of life improves in developing countries, the demand for energy grows at a staggering rate. at the same time, the world is searching for energy sources that are plentiful, secure and have minimal impact on the environment.
rest of the world
ukraineKazakhstanrussiasouth africa
indiachinaaustraliaeuus
35%
30%
25%
20%
15%
10%
5%
0%
% o
f w
orld
tot
al
tOtal primary enerGy supply (percent Of wOrld tOtal)
cOal reserve (percent Of wOrld tOtal)
cOmparisOn Of enerGy use and cOal reserves by cOuntry source: iea world energy Outlook and Key world energy statistics, 2006
1971
5000
4000
3000
2000
1000
01976 1981 1986 1991 1996 2001 2006
Oecd fOrmer ussr china asia latin america africa
wOrld cOal prOductiOn: evOlutiOn frOm 1971 tO 2006 source: iea Key world energy statistics, 2007
a Compelling ChoiCe to help meet the global energy demandSolution for an energy-DepenDent worlD
8 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 9
that lack indigenous energy supplies or have tenuous
relationships with supply countries.
Energy resources are essential to sustain the world
population, improve the quality of life and help
developing countries. “In today’s world, energy
means life,” says Phil Hansen, a Caterpillar
Inc. commercial mining manager. “If you take
away energy, you’re not just making people
uncomfortable; you are taking away a basic element
of survival. We can’t sustain this population without
efficient and effective energy.”
To achieve energy security, countries need a
source of energy that is stable in price and reliable
in supply.
“Widespread, indigenous sources of coal provide
energy security for many countries,” says Johnston.
“And some of the largest energy users in the
world—the United States, India and China—have
the largest reserves.”
In addition, coal is a flexible energy source. “Today,
it’s primarily used for electric power,” Johnston
says. “But it can be converted for other uses. New
technologies give coal the potential to reduce
or replace oil imports. Coal can be converted to
synthetic gasoline, diesel, hydrogen or other mobile
fuels.” In South Africa, for example, years of oil
embargoes forced the country to use the energy
source it had—coal—to produce the fuels it needed.
Coal conversion is expensive, Johnston says, but
can be competitive if oil prices stay above US$40 to
US$50 a barrel. “If someone made the investment
in a coal-to-liquids plant and it was profitable today,
it would still take years to recoup that investment,”
he explains. “And if oil prices dropped, that plant
could become unprofitable. If governments decide
that coal-to-liquids plants are an integral part of their
energy security strategies, they may need to enact
policies to protect investors from this possibility.”
Regulations to reduce emissions of greenhouse gases
Environmental impacts associated with energy
consumption must be addressed as society demands
cleaner energy and less pollution.
“This is a new political reality,” says Johnston. “It
appears highly likely that greenhouse gas legislation
will be increasingly adopted in developed nations,
and regulation could occur in developing nations as
well.” He estimates developed nations will aim to
reduce total greenhouse gas emissions 20 percent by
2020 and between 50 to 80 percent by 2050.
CEED says it is imperative that mining and power
generation companies move forward on researching
and deploying technologies that control emissions to
protect the viability of coal.
“ new investments in research, development, demonstration and deployment will make coal use possible in a carbon-constrained environment,” says Ceed. “a global focus on this issue is essential.”
A variety of regulatory compliance policies already
have been implemented or are being considered to
control carbon emissions.
For example, the Kyoto Protocol, ratified in 2005, now
covers 160 countries globally (more than 60 percent)
in reductions of carbon dioxide and other greenhouse
gas emissions. The protocol requires companies
to emit less carbon dioxide than their target or buy
carbon permits to make up any shortfall. The goal is a
5 percent reduction in carbon emissions before 2012
from their emissions base in 1990. Other countries
have instituted or are considering similar policies or
emissions regulations.
Market-based mechanisms like “cap and trade”
put limits on carbon emissions, which encourage
industrial companies and energy producers to
accelerate efficiency improvements and/or acquire
and trade credits to offset additional emissions. This
“carbon market” in the EU alone was estimated to be
US$30 billion in 2006.
“Although CO2 emissions from coal-fired power
plants are currently higher than other power sources
on a per-unit of electricity basis,” says Johnston,
“there are a number of solutions that will enable
dramatic reductions, enabling coal to meet emerging
regulations. We believe these developments
will ensure the environmental and economic
sustainability of coal as an energy source.”
cleaneR coal
New technologies address these emerging
environmental challenges—in particular greenhouse
gas emissions—as well as improve the performance
of coal as an energy source.
“ it can be done,” says hansen. “Coal can be clean, and much progress has been made to make it an environmentally friendly source of energy.”
Johnston points out two key ways to reduce carbon
emissions: Increasing the efficiency of coal-fired
power plants, and developing and implementing CO2
sequestration technologies.
Improving power plant efficiencies
Retrofitting and building new facilities in line with
state-of-the-art technologies that increase efficiency
will make a measurable difference in carbon
emissions, Johnston says.
For example, supercritical and ultra-supercritical
pulverized coal plants operate at temperatures
and pressures above the critical point—resulting
in significantly higher efficiencies and lower
In early 2007, Caterpillar Inc. joined some of
the world’s largest corporations to form the
U.S. Climate Action Partnership (USCAP)—an
alliance of 33 major business and leading non-
governmental organizations (NGOs) that have
come together to call on the federal government
to enact legislation requiring significant
reductions of greenhouse gas emissions. Some
of the 27 corporate members of USCAP include
DuPont, BP America, General Electric, Deere and
Company, General Motors and Rio Tinto.
Why would Caterpillar join an organization that
wants to drastically reduce greenhouse gas
emissions—much of which are the result of
large stationary power plants that burn coal?
“So we can be in the game while the rules are
being decided,” says Gerry Shaheen, Caterpillar
Group President.
“We know climate change legislation is coming,
which means we’re all going to have to operate in
a carbon-constrained world,” Shaheen said in a
speech given to the National Mining Association
(NMA). “And we believe we can help ensure that
legislation is good for the environment and
the economy.”
Caterpillar is 100 percent behind coal’s current
and future role, he said. “We know it’s critical to
our nation’s energy security and competitiveness.
We think the right pursuit of technology can
produce cleaner burning coal. And we believe
there are technology alternatives to explore.”
Shaheen urged the NMA to join Caterpillar in
encouraging government financing for clean coal
technologies and to take the lead in educating the
public about the benefits of coal.
USCAP shares common goals with others in
the mining industry, including energy security
and competitiveness, economic development,
environmental stewardship and the development
of clean coal technologies. Where they differ is the
enforcement of reductions in carbon emissions.
Some organizations support voluntary reductions
while USCAP promotes “cap and trade,” a system
whereby the federal government sets a “cap” on
the volume of select emissions that are permitted,
then distributes the rights to allowed emissions.
Importantly, from Caterpillar’s perspective, a
federal approach is preferable to a patchwork of
separate state climate regulations—something
that already is occurring around the country.
Shaheen calls cap and trade a financial incentive
to get businesses to develop their own solutions.
“That’s critical,” he said, “but it’s also slow.
I think we need to move more rapidly. We need
more government involvement, particularly
financial involvement in terms of research,
development and demonstration of carbon
sequestration systems.”
It’s time for all parties to accept the responsibility
to help find a sustainable and financially viable
solution to climate change, he said.
“By joining USCAP, we have put ourselves on the
line to support the coal industry. If we don’t come
together to support policies and technologies and
funding for clean coal now, we won’t be having
this argument in 15 or 20 years’ time. We won’t
have a coal industry to argue about.”
Caterpillar: worKing to enSure ViaBility of Coal
lOcatiOn Of the wOrld’s main fOssil fuel reserves (GiGatOnnes Of Oil equivalent) source: bp & world energy council
*values below 0.5 Gtoe have been rounded down to 0
north america
south america
africa
asia & Oceania
Oil coal Gas
indiamiddle east
central & eastern europe*
western & southern europe
china
former soviet union
8 178 7
2 8 5
14 14 7
15 36 13
3 63 10
1 65 1100 0 67
11 160 51
2 80 20 30 0
10 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 11
emissions than traditional coal-fired plants.
More than 240 high-efficiency supercritical
units are in operation worldwide, including 22
in China. Nearly 25 ultra-supercritical units are
operating worldwide.
These advancing technologies can reduce CO2
emissions up to 20 percent, thereby supporting the
continued view of coal as an important energy supply
for the future.
Adopting transformation and sequestration
Randy Richards, manager of business sustainability
within the Technology & Solutions Division of
Caterpillar, is well-versed in carbon emissions
reduction and is optimistic about the future of
clean coal.
“Coal can be the big winner in meeting the
growing energy needs for the future,” he says. “We
understand the emissions challenges of current coal
technology but applaud intensified industry efforts
to design and implement cleaner technology. This is
essential to the future viability of coal.”
Richards is a proponent of expansion of the use
of fuels based on the supply of coal for gasification
or liquefaction. “These technologies have very high
potential,” says Richards. “And in addition to power
generation, these fuels can be made available for
various types of mobile and stationary applications.”
Transformation of coal can produce hydrogen,
methane and synfuels—designer fuels that can be
customized based on the product and application
needs of the future.
“Even with improved power plant efficiencies,
we still must manage CO2,” Richards says. “And
sequestration is an increasingly viable option.
Sequestration means the storage of CO2 to prevent
its escape into the atmosphere.”
A study by the Massachusetts Institute of
Technology (MIT) identifies Carbon Capture
and Sequestration (CCS) as the critical enabling
technology that would reduce emissions
significantly while also allowing coal to meet
the world’s pressing energy needs.
CO2 capture can be done pre-combustion at
gasification/liquefaction plants, or post-combustion
at conventional power plants. Gasification and
liquefaction are generally considered the most
promising technologies because they reduce
emissions before coal is used for energy—
transforming coal to gas, in particular hydrogen,
and using this as the primary fuel source in power
stations instead of burning coal directly.
Investigations are under way for various storage
solutions. Underground storage options include
injecting the carbon underground to enhance the
recovery of coalbed methane, into depleted oil fields
to generate additional oil production, or into deep
saline aquifers.
These methods show promise, but significant
development is needed to overcome issues
that could slow their adoption. One key
issue may be the regulatory structure. To
date there is no definitive study on the long-
term stability and viability of these various
sequestration sites. Additionally, long-term site
monitoring, compliance, and liability/ownership
responsibilities are yet to be determined.
Richards says the ideal sequestration solution will
offer high CO2 storage capacity without the threat
of leakage and will render the stored CO2
permanently benign.
“Rock weathering sequestration is a fascinating
emerging concept targeted to meet these
expectations,” says Richards. “It is based on
mineral carbonation through a process called
Accelerated Rock Weathering (ARW).”
The key to ARW is magnesium silicate. This
mineral, commonly used for construction fill
and road gravel, naturally reacts with CO2 in the
atmosphere. As it absorbs the CO2, the mineral is
converted from a pebble form into powder.
“The earth has an abundance of this mineral,” says
Richards. “In fact, there’s nearly 60 times more of it
than there is coal in the world. Using it at a 1:1 ratio
to absorb CO2 from coal, there’s enough of it to be
feasible for all future use of coal.”
“The downside with ARW is that these carbon
capture and sequestration processes have not yet
been perfected and made financially viable,” he
says. “Some technologies need to be developed—
and talented people around the world are working
on them.”
“ to be successful, we must integrate broader systems-thinking that involves the transformation of coal into useful energy supplies and resolves the corresponding Co2 capture and sequestration,” richards says. “an integrated system can be the solution for the growing world hunger for energy.”
pRoJects in pRogRess
A number of advanced coal technologies for
electricity generation and CCS projects already are
being tested worldwide. Several government-backed
projects are in progress, including the FutureGen
Alliance, an innovative partnership developed by
leading international energy companies and the
U.S. Department of Energy to demonstrate and
move to market effective technologies to improve
the efficiency and reduce the emissions of electricity
generated from coal.
The US$1.5 billion project uses Integrated Gasified
Combined Cycle (IGCC) as the basis of its effort
to build a near emissions-free power plant. As
envisioned, the FutureGen project would produce
electricity and hydrogen from coal and capture
the carbon dioxide that would be generated in
the process.
The carbon dioxide would be injected thousands
of feet underground on site. The Energy
Department’s goal is to have an experimental
facility operational by 2012. Initially, the hydrogen
would be used to create electricity. Later on, the
same project would be used to create hydrogen to
fuel cars and other vehicles.
maKing it woRK
Johnston says international cooperation will
be a key driver of successful energy solutions,
encompassing:
• Multi-government joint research and
development programs
• Participation by developing nations due to rapidly
increasing coal consumption in those countries
• International harmonization of policies and
regulations to enable more standardization and
associated business efficiencies
• Regional, national and international trading
schemes for CO2 emissions reduction
“Companies up and down the coal-to-energy-to-
sequestration value chain should partner and
collaborate to develop optimized sequestration
systems,” says Johnston. “No one entity can tackle
this alone. This is an opportunity for businesses,
governments and scientific institutions to work
together to create a future with abundant, secure,
clean energy from coal.”
feed natural gas pipelines
produce synthetic gasoline and diesel to reduce oil imports
COALGASIFICATION
FUE
L P
RO
DU
CTS Methane
Synfuels
Syngas
CO2
Sulfur and Slag
SEQUESTRATION
BY
PR
OD
UC
TS
feed near emissions-free power plants
12 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 13
Combine a good Coal deposit, the right approaCh to mining it, and a skilled and stable work forCe—and you get a long-lived successful coal
mining operation. Xstrata Coal’s Ravensworth Mine in
the upper Hunter Valley of New South Wales, Australia,
makes the most of its resource by employing the low-
cost productivity of draglines aided by a more flexible
truck and shovel team and completed by a highly mobile
large wheel loader to load out coal.
“Ravensworth first started mining coal in 1972,” says
Terry Flynn, mine manager. “There is a very good
resource here, and it is a tribute to the people who
have worked here over the years that it remains a
strong and vibrant supplier of coal to the local power
stations. Many of the current employees have worked
here for more than 20 years. Four individuals have
more than 30 years’ service.”
photo/ ravensworth dragline pits are as deep as 42 meters (138 feet). the geology is good for mining.
RavenswoRth to success
steady and stRaightfoRwaRd appRoach dRives
14 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 15
1/ draglines remove 80 percent of the overburden at ravensworth.
2/ this dragline bucket will soon be filled with overburden from one of ravensworth’s two pits.
3/ an electric shovel pre-strips overburden to set the stage for dragline operations. the shovel works with the same trucks that haul coal.
4/ sitting on the spoil side of the pit, the dragline operator commands a 55-cubic-meter (72-cubic-yard) bucket.
1/ mine manager terry flynn is proud of ravensworth’s safety record—no lost time injuries since may 2006.
2/ ravensworth’s fleet of caterpillar® 789c trucks travel an average of 4.9 kilometers (3.0 miles) one way as they haul coal to the crusher.
3/ a 994f wheel loader works with 789c trucks to handle all coal loading and hauling.1 2 3
4
The relatively small work force of 121 racks up
high productivity marks and impressive safety
performance. The miners produced 4.3 million
metric tonnes (4.7 million short tons) of coal last
year as they mined seams ranging from 0.3 to 5.5
meters (1 to 18 feet) in thickness with a stripping
ratio that averaged 6:1. Including office staff and
maintenance technicians, the average amount of
material moved per employee in 2006 was about
213,000 bank cubic meters (280,000 bank cubic
yards). Equally impressive, the work force has
experienced no lost time injuries since May 2006.
“ We strive to make safety an integral way of how we do our work. It is not an add-on or a stand-alone issue,” Flynn explains. “Risk management principles are a consideration at all steps of our process including planning, completing and reviewing tasks.”
A team approach and a strong sense of
responsibility held by each miner and staff
member also contribute to good production and
safety. Tony Galvin, operations manager, points
out, “It’s a close-knit team. Maintenance and
production teams work together, and the WesTrac
(Caterpillar dealer) team works closely with us.
We work toward the same goals.”
“There is a strong sense of ownership of
performance in all aspects of the operation,”
Flynn says.
moving RocK and coal
Ravensworth operates two pits, each featuring a large
dragline for the majority of overburden removal. A
P&H 2300 electric shovel with a 20.6-cubic-meter
(27-cubic-yard) bucket teams with Caterpillar® 789C
trucks to pre-strip overburden before the draglines
take over. In the process, the truck-shovel team moves
about 17 percent of the 24 million cubic meters (31
million cubic yards) of overburden moved annually
by the entire fleet of machines.
1
2
3
16 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 17
The mobility of the wheel loader enables it to
handle all coal loading tasks. Both pits are served
by a single coal haulage ramp, which simplifies
truck assignment and scheduling. Last year
Ravensworth purchased the loader and a fleet
of five Cat 789C trucks with target payload of
177 metric tonnes (195 short tons) to do both
overburden and coal hauling. A single truck
from the previous fleet remains to comprise a
total of six.
A Caterpillar track-type tractor works in the pit with
the 994 to clean up the highwall, rip interburden
and maintain the pit floor. Currently the mine
operates three Cat D11N track-type tractors and two
Cat D10N track-type tractors, which are assigned to
a variety of tasks, including dragline bench work and
mined land reclamation. Ravensworth is reviewing
the replacement of the current dozer fleet.
The versatile truck-shovel operation levels areas
for optimum dragline productivity. But the geology
is predictable with the main types of rock being
sandstone, soapstone and carbonaceous mudstone.
“We have minor faulting and some dikes, but
nothing that has a big impact on mining,” says
Mark Williams, mining engineering and projects
superintendent.
The 2-kilometer-long (6,500-foot-long) Narama
pit hosts a Bucyrus 1570 dragline equipped with a
55-cubic-meter (72-cubic-yard) bucket. The single
dragline handles half of the total overburden
moved annually mine-wide. Some material is cast
during blasting, but that material is included in the
dragline production figures. The dragline makes
three passes from the spoil side and one pass from
the highwall side to dig the full 42-meter (138-foot)
depth and 55-meter (180-foot) width of the pit.
A Bucyrus 1370 dragline equipped with a
50-cubic-meter (65-cubic-yard) bucket is king
of the West pit and annually moves about 30
percent of all overburden. The 1.4-kilometer-
long (4,600-foot-long) pit is about 30 meters
(100 feet) deep. Currently the dragline is doing
spoil side stripping. The West pit has a public
road near one end; as a result, dust control and
blasting schedules get special attention. To avoid
any potential hazards that might be created by
dust emanating from blasting, the road is closed
temporarily when blasting in the West pit.
A Caterpillar 994F wheel loader, working with
Cat® 789C trucks, primarily loads out coal. But the
loader-truck team sometimes assists in stripping
overburden and removes interburden that averages
1.0 meters (3.3 feet) thick. The loader accounts for 3
percent of all overburden moved.
1/ westrac, the caterpillar dealer, maintains the fleet of cat trucks under a maintenance and repair contract (marc).
2/ the westrac team helps ravensworth meets its goal to integrate safety into every task.
3/ the stated aim of ravensworth mined land rehabilitation is “to produce long term and productive
landscapes compatible with the surrounding countryside and flora and fauna.” in practice, ravensworth backfills mined out areas, grades them to the original contour, and revegetates for a mix of pasture and forest. cattle grazing is the primary land use.
4/ ravensworth emphasizes solid haulage road construction and vigilant road maintenance.
5/ macquarie Generation transports the ravensworth coal to two power plants via an overland conveyor.
6/ caterpillar track-type tractors are used for a variety of tasks, including working in the pit and at the dragline bench, and for land reclamation.
1 4 5
6
3
2
18 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 19
photo/ ravensworth coal contains only 0.45 percent sulfur and has a high heating value—21.5 megajoules per kilogram (9,200 btu per pound).
1/ the expansive 10-bay shop has four bays plumbed with bulk fluids for fast scheduled maintenance.
2/ dave bull oversees a crew of six westrac service technicians at ravensworth.
3/ “Keep ’em clean, keep ’em running,” is a motto of the westrac maintenance crew responsible for the caterpillar trucks.
4/ ravensworth’s attention to tires is paying off with truck tire life of about 7,000 hours.
1
2
3
4
To keep truck productivity high, Ravensworth
managers pay particular attention to the long-life
haulage roads. Coal hauls average 4.9 kilometers
(3.0 miles) one way and pre-strip hauls are about 1.8
kilometers (1.1 miles) one way. Williams explains,
“Main coal haulage road segments that are relatively
permanent are built from mine spoil with effective
cambers for drainage, and they are sheeted with
imported crushed gravel. This ensures that coal
haulage can be done in all weather conditions.”
Cat 16H and 16G motor graders maintain the roads.
Each shift normally operates a water cart and a grader
for routine road maintenance. Generally only one
loading unit is operating each shift, so major road
repairs are scheduled for when the road is not in use.
The trucks carry coal to a crusher that reduces
coal size to less than 50 millimeters (2 inches).
The crushed coal feeds into a 5,000-metric-tonne
(5,510-short-ton) bin, which feeds an overland
conveyor operated by Macquarie Generation.
The conveyor takes the coal to two nearby power
stations—Liddell and Bayswater. The two plants total
4,400 megawatts of generating capacity and are the
sole customers for Ravensworth coal.
Keeping machines woRKing
The Ravensworth maintenance team of 28 people
focuses on the draglines, shovel and older mobile
equipment and coal handling facilities while the on-
site WesTrac team of seven maintains the new Cat
equipment—the five 789C trucks, 994F loader and
16H motor grader—under a maintenance and repair
contract (MARC).
“The MARC keeps our work force to a minimum in
these times of high demand for mechanics,” says
Galvin. “The MARC also allows us to more accurately
predict costs.” Galvin also is quick to point out that
the WesTrac project manager, Dave Bull, is on site and
attends the daily planning meeting at the mine. The
WesTrac maintenance functions are carried out as part
of the entire Ravensworth team.
“ The Ravensworth work force, management and WesTrac have good working relationships,” Bull says. “We are proud of the
contribution that the Caterpillar fleet and the MARC have had on helping the mine meet its KPIs (key performance indicators). The 789C fleet has met and exceeded the productivity requirements and has averaged more than 95 percent contract availability during the past 14 months.”
All of the maintenance crews work out of a large
10-bay shop featuring four bays set up for efficient
preventive maintenance work. A fully equipped tire
maintenance center and a fueling station are located
adjacent to one end of the shop. A field crew handles
refueling and in-field lubrication of some machines,
such as the pair of diesel-powered blasthole drills,
using two fully equipped field service trucks.
Maintenance staff members aim to identify problems
before they cause failures. “We make use of all
available technology,” Galvin says. All machines are
monitored with fluids analysis—the MARC machines
using Caterpillar SOS. The maintenance technicians
frequently use non-destructive testing techniques,
such as radiography and vibration analysis, especially
when assessing the condition of dragline structures
and components. And the maintenance department
has run noise testing on most machines for both
operator exposure and spectator exposure.
The maintenance and operations departments
coordinate their efforts to maximize tire life.
Weekly tire pressure checks, occasional tire
temperature checks, a monthly report on haulage
road conditions, and an investigation of any tire
events are all components of the program. The
attention to tires is paying off with truck tire life
of about 7,000 hours.
Despite apparent success, the maintenance
department is restructuring to better define
responsibilities and improve planning. The culture
of continuous improvement lives at Ravensworth.
Couple that approach with a good resource of low-
sulfur coal plus steady, low-cost production, and
you see continued success for Ravensworth.
20 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 21
RavenswoRth-FeatuRe stoRy
Caterpillar machines are designed so that components can be rebuilt several times over the life of the machine—allowing customers to benefit from maximum performance and reliability throughout the life of their equipment.
Component Rebuild Centers (CRCs) help
Caterpillar customers achieve optimum
component life and reliability through world-
class rebuild practices. Equipped to rebuild
and test all major components of the largest
equipment Caterpillar produces today, CRCs
meet the same safety, quality and contamination
standards as a Caterpillar factory.
“Customers have options when it comes to
repairing and rebuilding components,” says
Patrick Mohrman, a Caterpillar product support
manager. “But there isn’t another repair option
that can provide what a CRC does. It’s 100
percent Caterpillar.”
Dealers and Caterpillar work together at all
stages—sizing the facility, determining the
right equipment, providing all the necessary
specifications and tooling, and training the
technicians who work there.
“Dealers build CRCs to provide their customers
with the least cost to rebuild, a quick turnaround,
better quality through standardization, improved
contamination control and the latest updates for
Cat equipment,” says Mohrman. “And we believe
CRCs do all these things.”
using Quality tools
Certified Component Rebuild Centers are large
investments for Cat dealers. In addition to the
large square footage required for a facility, a
CRC also contains a number of high-tech tools
necessary to assess the condition and rebuild
all major equipment components. CRCs are
equipped for general machining as well as
outfitted with specific tools to rebuild and test
engines (including blocks, cranks, heads and
cylinder packs), powertrains, torque converters,
transmissions, differentials, wheel stations
and more.
following Quality pRocesses
Each rebuild follows a Cat-approved process—
beginning with a thorough cleaning of every
component and ending with rigorous testing to
ensure quality.
“Everything gets looked at,” says Caterpillar
product support manager Mike Staley. “For
example, engines are completely stripped to the
bare block and checked down to the bolts. Then
they’re re-assembled with whatever parts make
the most sense. They may be new, they may be
parts rebuilt from the same machine, or they may
be exchange parts from another rebuild. You use
all these components to do it in the fastest and
most economical way.”
Dealer CRCs are continually audited for
cleanliness and must meet stringent standards
set by Caterpillar. Many CRCs meet Cat’s Five
Star Contamination Control standards. Paying
attention to contamination control enhances
productivity, increases component longevity and
results in decreased downtime.
developing eXpeRt technicians
“CRC technicians are trained by Caterpillar experts
to rebuild Caterpillar components—and only
Caterpillar components,” says Mohrman. “And
they’re trained for their area of expertise. Whether
it’s a fuel system or a transmission, they become
experts in the rebuilding of that specific component.
They do it day in and day out.”
adding value in bRaZil
With customers in nearly every state in Brazil,
Cat dealer Sotreq knows the value of providing
major component rebuilds that offer quality
repair, fast turnaround and maximum value.
That’s why, in 2000, Sotreq decided to invest
in a 3,200-square-meter (34,000-square-foot)
Component Rebuild Center designed to restore
engine and drive-train components to factory
standards. An 820-square-meter (8,800-square-
foot) addition is in progress.
Sotreq’s newest CRC is centrally located in
Contagem, the third-largest city in the Brazilian
state of Minas Gerais. Rebuild activities at this
facility complement those of two smaller Sotreq
CRCs, one in Belem, Para, and the other in
Sumare, Sao Paulo.
“We know that having access to our CRCs helps
our clients to reduce downtime,” says Sinval
Colares Nassau, manager of the Sotreq CRC. “We
value our strong business partnerships with all
our clients and we work with all of them to satisfy
their expectations in terms of quality, reliability
and availability.”
“Our objective is to fully serve customer
machine, service and maintenance needs, so
that customers can concentrate on core
business needs.”
managing component life
Planned component rebuild intervals can
be based on a number of factors, including
past experience, condition monitoring, fuel
consumption, oil analysis or even arbitrary
target hours.
Mine site conditions can change over time and
impact component life. Deeper pits, longer
hauls, overloading, etc., can have a negative
impact on component life. Positive changes can
come from continuous improvement initiatives
like contamination control, fluid cleanliness,
application and payload management, and better
maintenance and monitoring.
CoMponentreBuilD CenterSTHE FLEXIBILITY OF A SERVICE SHOP WITH THE PROCESS CONSISTENCY OF A MANUFACTURER cRcs may be outfitted
with the following state-of-the-aRt tools:
- Dynamometers to test engines and powertrains
- paint booths
- Cylinder repair tools, including repair benches, hydraulic hones, parts washers and barrel cleaners
- lapping machines for pump and motor parts
- lathes and mills of various sizes
- Boring machines
- transmission test benches
- Hydraulic hose benches
- Hydraulic test bench
22 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 23
Component rebuilds completed so far for mining
machines have included 777, 785, 789 and 793
mining trucks; 990, 992 and 994 wheel loaders;
D9, D10 and D11 track-type tractors; and 16H
and 24H motor graders. Smaller machine
components—from 950 wheel loaders, 320
hydraulic excavators, 416 backhoe loaders and
D6 track-type tractors—are also repaired at the
CRC. Warranty repairs and partial rebuilds take
place there, too.
Sotreq’s largest CRC is designed to move
material systematically from receiving to initial,
external cleaning. Following that are disassembly,
component cleaning, inspection, component
reconditioning, re-assembly, testing, painting
and shipping.
“We have 20 work areas just to assemble
powertrain components,” says Sinval Colares.
“We also have six areas for disassembly and two
for testing. We have two dynamometers, one
that we use to test 3400 and smaller engines and
another larger one to test 3500 engines. We also
have two hydraulic/transmission tests that we use
to evaluate hydraulic pumps, hydraulic motors,
transmissions and torque converters.”
“Currently, we’re operating in two shifts, but
because of volume increases, we’re planning
to add a third,” he says. “With this new shift, we will be able to increase our annual production around 20 percent the first year and 30 percent the second year. We also plan to improve our hydraulic test and relocate the hydraulic area so that we can increase our capacity from 1,400 to 2,000 large components. all these improvements will allow us to offer customers even faster turnaround on rebuilds and repairs.” More than 120 technicians are responsible for
quality rebuilds within the CRC. Sotreq operates
its own mechanical training school and offers on-
the-job training by experienced technicians who
mentor less-experienced employees.
Sotreq insists on high standards for
contamination control as well and has received
Five Star Contamination Control certification
from Caterpillar. “We are pleased to have earned
this highest certification rating from Caterpillar,”
says Sinval Colares. “We set high standards
to maximize our competitive advantage in the
service capability area. In addition, we know
that reducing contamination has clear benefits
for our customers, including longer component
life, lower owning and operating costs, reduced
service rework and lower warranty costs.”
“ all this contributes to increased profitability for our customers.”
photos/ component rebuild centers are designed to provide caterpillar customers with the least cost to rebuild, a quick turnaround, and better quality through standardization. the centers are outfitted with state-of-the art tools to assess conditions, rebuild components and provide rigorous quality testing. technicians are trained specifically for their areas of expertise.
When a component is repaired or rebuilt in the
dealer CRC, dealers are able to assess the condition
of the component. Dealer documentation of the
component’s condition can be valuable information
for the customer.
Dealers can provide technical reports back to the
customer after every component rebuild or repair.
These reports may also offer recommendations and
information the customer can use to better manage
component life.
Repairs account for 25 to 30 percent of the costs
of owning and operating mining equipment. “It’s
important that customers know the status of every
component at all times so they can manage their
operations today and be better prepared,” says
Sinval Colares.
meeting the need
Sotreq built its newest CRC to meet the needs
of a booming mining industry as well as to meet
customer demand for improved contamination
control practices.
“Our decision to build this newest CRC was
motivated by the increasing number of mining
machines and volume of powertrain components
in our territories,” says Sinval Colares. “We
needed the additional capacity to better organize
our work flow—and offer our customers the full
advantages of contamination control and rebuild
certifications.”
Ten of Sotreq’s major mining customers and
more than 1,000 traditional dealer customers
have taken advantage of the new facility.
1
barlOwOrldhastinGs deerinG
westrac
p.t. traKindO
sOtreq
finninG chile
finninG canada
tOrOmOnt
c.i. walKer machinery carter machinery
ferreyrOs
finninG arGentina
GecOlsa
cashman equipment wheeler machinery empire machinery thOmpsOn tractOr
whayne supply
venequip mantrac (unatrac)
wyOminG machinery
1/ component rebuild centers are designed to move components systematically from receiving to shipping to provide the quickest possible turnaround for customers. parts are stocked and ready to help achieve optimum efficiency.
2/ caterpillar and cat dealers worldwide are committed to build and support world-class component rebuild centers (crcs) to support the demand of the mining industry with the best option for repair and rebuild of components.
2
westrac
venequip
matcO
24 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 25
The truck haul ramp at the Coleman McCreedy
East mine, on the northwest rim of the Sudbury
basin in Ontario, is a critical link in moving nickel
ore out of the mine. The truck haulage system is
effectively an extension of the hoisting shaft as the
ramp extends a distance of about 6 kilometers (3.7
miles) from the 1,000-meter to the 1,700-meter
level (3,370-foot to the 5,700-foot level). All
production below the 1,000-meter (3,370-foot) level
is hauled by truck. At the 1,000-meter (3,370-foot)
level, ore is delivered by conveyor to the shaft and
then skipped to the surface.
Since 1997 mining crews have stabilized the surface
of the ramp with asphalt emulsion in efforts to
provide a smooth, hard and dust-free surface. The
construction method created a quality roadway,
but the smoothness and durability did not live up
to expectations. As a result, the engineering staff
conducted a thorough review of the existing ramp
design and construction methods. Ultimately, the
staff determined that full depth reclamation (FDR)
with asphalt emulsion was the way to meet the
demands placed on the underground highway.
Roadway constRuction evolves
The design of the mine necessitates truck haulage.
Truck travel distances from the two ore bodies
to the hoisting shaft now range from about 2.5
kilometers (1.5 miles) to nearly 6 kilometers (3.7
miles) on ramps with a nominal grade of 14 percent.
Production averages 3,200 to 3,600 metric tonnes
(3,500 to 4,000 short tons) per day.
The initial road design used crushed waste rock
placed in a subbase and base layer. The layers were
25 centimeters (10 inches) and 20 centimeters (8
inches) thick and used minus 7.5-centimeter (minus
3-inch) and minus 3.2-centimeter (minus 1.25-inch)
material, respectively. The 46-centimeter (18-inch)
thick roadbed could be graded as required to provide
a smooth riding surface.
Dust rising from the roadbed quickly became a serious
problem. Road maintenance crews experimented
with a variety of dust suppression products including
calcium and magnesium chlorides and lignin. All
of the products provided some level of success in
controlling dust, but they tended to become slippery
and created safety concerns.
In 1996 the mine investigated asphalt as a
means to handle the dust problem. Asphalt is a
semisolid at ambient temperature and does not
readily mix with aggregate in this state; however,
it can be liquefied easily by heating, by adding a
petroleum solvent, or by emulsifying it in water.
Hot mix asphalt was not logistically viable in the
underground environment, and, similarly, the
underground environment precludes the use of
petroleum solvents in large quantities.
Liquefying the asphalt by creating an asphalt emulsion
was the choice for underground roadway paving. This
using cold mix asphalt paving technology more commonly used in highway construction, one of CVrd inco’s Canadian underground mines quickly created a smooth and durable roadway for its truck fleet. the innovative approach to building underground roads minimized production interruptions, solved potholing problems and created a smoother surface for enhanced truck productivity.
process involves milling asphalt into microscopic
particles, 1 to 10 microns in size, and dispersing them
in water. A small amount of chemical emulsifier also is
added to keep the asphalt droplets in stable suspension.
The resulting asphalt emulsion contains approximately
60 to 65 percent asphalt and 35 to 40 percent water.
The asphalt particles stay suspended in the
continuous water phase until the emulsion is mixed
with the aggregate on the roadway surface. After
mixing, the water and asphalt separate. The asphalt
bonds the aggregate particles together and the water
is brought to the surface by the use of compaction
equipment. Once the water completely evaporates,
the system is said to have cured. The result is a
stabilized hard surface that does not generate dust.
The initial methods used to apply asphalt emulsion
to the truck ramp achieved penetration and mixing
of the asphalt with the base aggregate to a depth
of about 38 millimeters (1.5 inches). But the thin
asphalt layer was susceptible to potholes created
when the trucks ran over spilled rock and ore and
pushed it through the surface layer. The puncture
holes were then prone to raveling into larger holes.
In addition to the pothole problem, the ramp was
not as smooth as needed. The construction process
required nearly perfect grading of the base, which
was very difficult to achieve.
Roadbed design
“The mine managers recognized that a smooth road
was necessary to help the mine reach production
targets,” says Andy Charsley, leader of the project
team. “So we reviewed different roadbed designs,
including developing methods for constructing new
sections of ramp as well as methods for improving
the existing ramp.”
Any proposed recommendations would be
constrained by available capital, and the method
selected must cause only minimal interruptions
to production haulage.
A detailed investigation of roadway layer design and
surface alternatives revealed opportunities to reduce
aggregate base thickness and to make changes in
material sizes.
“ the review team concluded that the asphalt-stabilized layer could be improved,” says Charsley, “by using the most up-to-date road construction techniques and asphalt pavement design methodology for both existing pavement and new construction.”
The initial design of the roadbed called for 46
centimeters (18 inches) of crushed material in
layers typical of designs for surface roads built on
soft subgrade. But in the case of underground hard
rock mines, the subgrade is bedrock, which does
not deflect significantly under load. As a result, the
purpose of using aggregate as a base in the mine
is for grading a smooth road and, if needed, for
handling drainage. At a minimum, the layer must
be thick enough to fill in the undulations in the
blasted rock surface and to form the thickness of the
pavement when mixed with asphalt emulsion.
Undulations in the rock are about 15 centimeters
(6 inches) above and below the desired grade. The
proposed pavement thickness is 10 centimeters
(4 inches). For practical purposes the design team
chose a granular layer thickness of 30 centimeters
(12 inches)—a 33 percent reduction in base
thickness compared to the previous design.
aSpHalt reClaMation paVeS way for
effiCient unDergrounD Haulage
26 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 27
constRuction
In situ asphalt recycling has grown in popularity as
the availability of cold planing equipment has grown.
Replaceable tungsten carbide milling tools make the
machines even more productive. A Caterpillar RM-
250C reclaimer was used for this project.
The reclaimer pulverizes and mixes in a single pass
to a depth of 100 millimeters (4 inches). Asphalt
emulsion is mixed in at the same time to provide
a homogeneous mixture of asphalt and aggregate.
The asphalt emulsion was added at a rate of 9 liters
per square meter, (2 gallons per 1.2 square yards),
which correlates to 3.8 percent addition by weight.
In the case of new construction, the process is the
same, but the asphalt emulsion addition rate is 14
to 15 liters per square meter (3.7 to 4 gallons per 1.2
square yards), correlating to an addition rate of 6
percent by weight.
Once mixing is complete, a single drum vibratory
roller does initial compaction. The roller used
had an operating weight of 6,550 kg (14,440
lbs). Following initial compaction, a modified
underground Caterpillar 120G motor grader
blades the material to provide the specified profile.
Recognizing that the life expectancy of pavement
surface is 5 to 10 years, smooth grading of the
recycled surface is essential.
Following grading, final compaction is completed
on the recycled layer. A Caterpillar CB-335D
combination steel drum and pneumatic tire roller
provided a smooth finished surface and compacted
the top layer of pavement. The roller has an
operating weight of 3,620 kg (7,980 lbs).
Finally, the recycled layer was swept and sealed to
prevent raveling. A spray application of CSS-1H
asphalt emulsion was applied at a rate of 0.45 to 0.70
liters per square meter (1 to 1½ pints per 1.2 square
yards) and diluted with water at 1:5. The sweeping
and fog sealing were done from one to three days
following the recycling operation.
The construction crews typically completed 200 to
305 meters (650 to 1000 feet) of ramp rehabilitation
daily in the 6-meter (20-feet) wide drift. The crew
completed a maximum of 535 meters (1,750 feet) in
one 10-hour day.
good Results
“Asphalt recycling provides an economical solution
by reusing all the existing roadbed aggregate
and asphalt,” says Charsley. “The total depth of
roadbed was reduced by a third for an additional
cost reduction. Another benefit is that in situ
construction keeps interruptions to traffic flow to a
minimum since the stabilized material can be driven
on immediately following grading.”
Superelevated corners, improvements in asphalt
smoothness, and greater roadway durability also
are paying off in reduced truck maintenance and
reduced roadway maintenance. The mine reduced the
roadway maintenance crew from five to four people.
“ now the mcCreedy east mine has a haulage ramp capable of meeting future production targets while achieving maximum truck utilization and availability,” says Charsley.
“ We agreed that a single, homogenous layer of aggregate would perform well,” says Charsley. “eliminating the two-layer system offers a further reduction in placement time, because finish grading is required only once.”
The design team also determined that aggregates
sizes should fit a tight size range so that the material
would offer good compaction characteristics and
would be highly stable when mixed with asphalt
emulsion. The gradation selected was granular A, an
Ontario provincial standard for roadways.
The base material was to be crushed from mine waste
rock on the surface at the mine. The waste rock makes
an ideal roadbed aggregate because it is very hard
and abrasion resistant. In addition, the rock is 100
percent fractured and is angular, which adds to the
high stability of the final product. Stability is defined as
resistance to lateral deformation due to imposed loads.
The design team also considered the layout of the
ramp. Despite many curves, the roadway did not
have superelevated curves, which are important
because they reduce lateral tire forces, reduce truck
frame stress and reduce the amount of spillage. At
a truck speed of 16 kph (10 mph) and a minimum
curve radius of slightly more than 30 meters (100
feet), 7 percent banking would result in zero
net lateral force on the tires. The design team
compromised and called for superelevated curves
with a minimum radius of 30 meters on a 4 percent
lateral slope.
asphalt stabiliZation and Recycling
The use of asphalt emulsion at the mine had evolved
into a spraying and raking process. The hydraulically
powered rake mixed the asphalt and aggregate
and provided about 38 millimeters (1.5 inches) of
stabilization. The design investigation revealed that
asphalt pavement thinner than 75 millimeters (3
inches) is more susceptible to pothole development.
That led the design team to choose a 100-millimeter
(4-inch) thickness, which would be durable and
practical to construct. The new depth of pavement
also would handle the expected surface punctures,
which penetrate as deep as 50 millimeters (2 inches).
The thicker layer would prevent the punctures from
going completely through the structure and would
allow repair with cold patch mix.
To assess road surface smoothness, the design
team conducted a full survey of the roadway
to collect data for calculating the International
Roughness Index (IRI). “We found that even
though the ramp was very good by underground
mine standards, the ride was poor compared to
accepted surface road roughness standards,” says
Charsley. “The ramp had an IRI average of 8 with
a range of 4 to 14.”
To meet the goal of creating a 100-millimeter-thick
(4-inch-thick) durable pavement that was very
smooth, the design team was charged with finding
a method or methods to rehabilitate the existing
roadway and to construct new roadway.
“ We identified full depth reclamation as such a construction method,” says Charlsey. “asphalt recycling and reclaiming reuses the existing asphalt and granular material, significantly reducing costs compared to other road improvement alternatives. in situ reconstruction also minimizes haulage interruptions.”
The process involves pulverizing the full depth
of the existing pavement and a portion of the
underlying material. That material is blended
and mixed with a stabilizing additive to provide a
uniform material. When the technique is used with
new granular material, the process is known as base
stabilization. The only difference is the amount of
asphalt emulsion added to the mix. For recycling, 1
to 4 percent asphalt emulsion by weight is typically
required, and 6 percent by weight is required for
new construction.
1
1/ a caterpillar vibratory compactor smooths and kneads the top asphalt layer for a dense, durable surface. the compactor, known as a “combi,” has a smooth steel drum on the front and side-by-side pneumatic tires across the entire width of the back.
2/ a caterpillar reclaimer recycled the underground asphalt roadway in place and in a single pass.
3/ the road reclaimer uses a rotary mill equipped with carbide-tipped bits to grind up existing asphalt and aggregate base and to mix it all with asphalt emulsion.
2 3 granular material
milling drum
OperatinG
directiOn
distressed pavement
emulsion injection
deep recycled layer
this article largely is based on a paper prepared for the 2005 canadian institute of mining (cim) conference held in sudbury, canada. the authors of the paper are andrew d. charsley, m.a.sc., p. eng., Garson mine, cvrd inco limited, copper cliff, Ontario; John J. emery, ph.d., p. eng., president, John emery Geotechnical engineering limited, toronto; and Gerry J. prevost, Operations foreman, Ontario Operations, cvrd inco limited.
asphalt miX design
once the design team identified asphalt recycling as the best alternative for ramp rehabilitation, an engineered asphalt mix design was required. an asphalt design laboratory used samples taken from the ramp and mixed portions of that material with five varying amounts of asphalt emulsion to determine the optimal mix.
- emulsion added was CSS-1H in increments of 0.5 percent from 2.5 to 4.5 percent by weight. all five mixtures exhibited high stability.
- the final recommendation was to use CSS-1H at 3.8 percent addition. the identifier denotes cationic slow set emulsion with hardener. the cationic charge on the asphalt creates an attraction to the aggregate, which has a natural anionic charge.
- the resulting stabilized layer will have residual asphalt content of 3.5 to 4 percent.
- a similar mix design was prepared for areas of new construction. an emulsion rate of 6 percent provides a residual asphalt content of 3.6 percent.
Compliance with the engineered mix designs is critical to the durability of the recycled layers. the main areas of quality control to monitor are percentage of asphalt addition, homogeneity of mixing, depth of stabilization and compaction.
28 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 29
Mining companies have long been aware of the
dangers of fatigue and have tried to manage the
situation through policies and procedures, and
through various education, training, scheduling,
diet and motivational efforts.
“These techniques all help deal with the root
causes of fatigue,” says David Edwards, Ph.D.,
an ergonomics research engineer who studied
operator fatigue in Caterpillar Inc.’s Technology
and Solutions Division before joining the new
Caterpillar Safety Services Division.
“ at the end of the day, there are still people falling asleep,” says edwards. “that’s why everyone in the industry is desperate for a new solution—a technology solution—to help better manage fatigue.”
the cost of fatigue
Sleep deprivation, fatigue and drowsiness
decrease awareness, diminish attention spans,
and increase reaction time—all significant factors
that contribute to accidents. The UK reports
over US$2 billion in fatigue-related accident
costs. Australia’s Transport Safety Bureau reports
that 30 percent of all fatal crashes are linked to
fatigue. Commercial on-highway truck collisions
due to fatigue are estimated to account for 1,200
deaths and 76,000 injuries a year in the United
States, at an estimated cost of US$12.4 billion
to the commercial trucking industry.
Fatigued drivers often are not aware of their
condition, frequently driving for up to 30
seconds with their eyes totally closed—a
situation known as micro-sleeps. Studies show
that driving drowsy is equivalent to being
under the influence of alcohol or drugs and
that drowsiness impairs the ability to make
decisions. Signs of fatigue include:
• Sleepiness/difficulty keeping eyes open
• Excessive yawning
• Blurred vision/loss of focus
• Irritability
• Becoming quiet and more withdrawn
• Inability to concentrate
• Inability to remember activities of the
last five minutes
• Lacking motivation to do the task well
Studies in the mining industry indicate that fatigue
affects even those with the best training and years
of experience. Human error due to fatigue is not
fundamentally a behavioral problem—it’s primarily
a problem of human physiology.
operator fatigue
around-the-clock operations are commonplace in the mining industry. the search is on to help those who experience the fatigue that goes along with shift-work. operator fatigue is proven to be one of the most prevalent causes of accidents within the mining industry. in the surface mining industry alone, some 60 to 65 percent of truck haulage accidents are directly related to operator fatigue.
finDing teCHnology SolutionS to CoMBat
managing the situation
Ergonomic improvements in the operator
environment have helped lessen fatigue. Education,
training and biocompatible scheduling have also
proven to be important tools.
“Miners can learn the importance of a good
diet—what foods to eat to keep them alert
and help them maintain energy levels,” says
Bill Sirois, senior vice president of Circadian
Technologies, Inc., a leading international
research and consulting firm that assists shift-
working companies. “Workers also can learn the right behaviors at work and at home that help minimize drowsiness.” A lot of sites have started educating the families of
employees about how to best support their family
members for shift-work. More and more companies
are also converting to user-friendly work schedules to
alleviate as much of the physical stress of shift-work
as possible, Sirois says.
In conjunction with Circadian Technologies Inc.,
Caterpillar will introduce a CD/DVD designed to
educate supervisors, operators and their families on
things they can do to lessen fatigue. “Caterpillar used
its resources to create an educational tool that we can
share with every mine site,” says Edwards.
While an educational video will be helpful,
Caterpillar customers have made it clear that they’re
looking for additional solutions—in particular
those that take advantage of technology to detect the
onset of fatigue and interface with the operator and
dispatcher to elicit a response.
“There has been a major effort to develop
technologies to monitor fatigue, but they have been
primarily for automotive use—particularly with
on-highway trucks,” says Edwards. “There isn’t one
technology that has come to the forefront for use in
the mining industry.”
Caterpillar and mining companies have tried to
leverage existing automotive technologies to adapt
them for mining, but have met with little success.
“We started thinking we would have more success if we
can get to the source and get them interested in mining,”
Edwards says. “Then we could develop a technology
that is focused on mining from the beginning.”
Caterpillar is providing funds and access to mining
equipment that allows research and development
groups to work on a fatigue management solution
for the industry.
“We want these researchers to see the differences
between on-highway trucks and large mining trucks
and their environments,” Edwards says.
“ We need to increase awareness in the scientific community that there is a need for them to provide solutions to help miners and mining companies mitigate the effects of fatigue.”
advancing eXisting technologies
Caterpillar recently partnered with customer
BHP Billiton to study existing technologies and
promote the advancement of the most promising
solutions. Results of that study will be published
and shared with the world to advance the cause,
says Edwards.
managing a mining lifestyle
one out of five people in the world currently works hours that fall outside the traditional workday. those who have long hours, work nights, or maintain irregular shifts face different challenges than day workers. Shift work affects sleep, alertness, health, and family and social lives.
Human alertness has a daily rhythm—measurably higher during the day and lower during the night. people also tend to get drowsy after lunch. it’s important to be aware of and manage these challenges.
Caterpillar is collaborating with Circadian technologies, inc., an international firm that helps companies manage shift-work and extended hours, to develop a DVD to help machine operators and their families better cope with the lifestyle required of those in the mining industry.
the video provides practical solutions for easing the adjustment and day-to-day challenges associated with mining lifestyles. the video serves as a powerful tool for improving the physical and psychological well-being of heavy equipment operators—increasing safety, morale and performance.
DVDs will be available in early 2008. ordering information will be included in the next issue of Viewpoint magazine.
fatal trucK accidents by time Of day
10 11 12 13 14 15 16 17 18 19 20 21 22 23
5
4
3
2
1
024 1 2 3 4 5 6 7 8 9relative risKbOdy temperature
30 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 31
“Along with Circadian Technologies, we evaluated
all known technologies that are commercially
available or will be emerging in the next three
years,” Edwards says.
The goal of the study was to:
• Identify the most promising technologies
• Develop an objective assessment tool
• Score each technology
• Examine the feasibility of incorporating the best
technologies into mining applications
“ We came up with a list of 35 technologies in all industries, and shortened that list to the 21 we felt were the most viable,” edwards says. “We then tested the leading technologies through driving simulation studies and field trials.”
Two main types of technology exist: “fitness for
duty” tests that check operator fatigue levels prior
to their shifts, and systems that measure operator
and machine behavior during operations. These
technologies measure:
• Machine behavior
- Lane deviation
- Steering wheel movement
- Pedal usage
- Machine movement
• Operator physiological conditions
- Eye behavior (blink and pupil response properties)
- Heart rate
- EEG
• Operator behavior
- Head nodding
- Mental and physical reaction times
Fitness-for-duty tests have been in use for some
time to check operators for drug and alcohol usage.
New technologies are being employed to test for
fatigue, including:
• Pupilometry—measures eye reflexes, pupil
constriction and the speed of eye movement.
Degradation of reaction times can indicate
impairment.
• Psychomotor Vigilance Tests—evaluate reaction
times and hand/eye coordination. Using a
computer mouse, trackball or joystick, operators
must follow a target and maintain their position.
“These units are not cost-prohibitive,” says Edwards.
“They range from US$5,000 to US$10,000 per unit
and they are rock solid for drugs and alcohol. We’re
still evaluating how well they work for fatigue, or
more precisely, impaired alertness.”
Systems that monitor operator activity in the
cab as well as vehicle activity also show promise.
These systems monitor the operators around
the clock, sometimes sending information to
dispatchers as well as accumulating long-term
data about the behavior of an operator or his or
her machine.
On-board technologies include:
• In-dash cameras or eyeglasses with sensors that
monitor eye movement and blink speeds—both
indicators of fatigue. In-dash systems can have
difficulty with vibration or motion in the cab,
making the glasses a more viable option, Edwards
says. The eyeglass system, called Optalert™ and
made by Sleep Diagnostics Pty Ltd., costs about
US$10,500 per truck. The price includes three
pairs of glasses and system hardware.
• Monitors that measure steering wheel and
machine movement. When operators are awake
and alert, they maintain consistent position
within their lane. When they get drowsy,
movements are more erratic and machines
swerve and sway. The leading system of this type
is ASTiD made by Pernix Ltd. and costs less than
US$10,000 per truck. Unlike the eyeglasses, this
system is passive to the operators.
managing infoRmation
One of the technology systems investigated helps
mine sites manage the information gained through
monitoring—a feature Edwards can see as the
future of fatigue management technologies. Data
goes to a dispatcher, who has a log of the operator’s
habits and can suggest a break or recommend the
operator end his shift.
Edwards says it’s important to make someone other
than the operator aware of any fatigue issues. “An
operator who is fatigued is the worst judge of how
tired he really is,” he says. “That’s like asking a
drunk person if they believe they are too intoxicated
to drive.”
Studies suggest that users strongly prefer systems
that require as little personal monitoring and
contact with the technology as possible. The
preference is for systems that monitor vehicles
instead of people.
“There are a lot of confidentiality issues, in
particular with the operator measurements,”
manage youR enviRonment
• Make the environment as dark as possible or wear eye shades because even low levels of light can keep people awake or disrupt sleep.
• Use a fan, air filter or other white noise machine to block outside noises, or wear earplugs.
• Keep the environment at a cool temperature and well ventilated.
manage youR diet
• Be aware that while alcohol may cause drowsiness, it can make sleep less restful and restorative.
• Avoid heavy caffeine use, which can cause less or poor quality sleep.
• Consult a doctor before using sleeping pills; they are not a long-term solution.
• Try warm milk, decaffeinated herbal teas or herbs like valerian and kava to induce sleep.
manage youR Routine
• Stick to the same routine whether you sleep at night or during the day.
manage youR health
• When eating late at night, avoid fatty and fried foods, pastries and dairy products to alleviate gastrointestinal problems.
• Eat small meals through the night shift, including pasta, breads, fruits, vegetables and low-fat dips and spreads.
• Eat lean protein and complex carbohydrates for your main meals to increase energy levels.
• Elevate your heart rate for 20 to 30 minutes several times a week.
manage stRess
• Try to identify and eliminate the causes of stress.
• Learn to control what you can and stop worrying about things that are beyond your control.
• Exercise.
• Take time for yourself.
• Spend time with family and friends.
• Slow down and eliminate extra activities if you can.
• Avoid excessive amounts of toxins and stimulants.
manage youR home life
• Identify and resolve family and social problems when they arise.
• Talk with your family regularly to discuss problems, resolve issues and plan activities.
• Keep a calendar and plan ahead as much as possible.
• Map out “recovery days” to allow you to catch up on sleep and get back into a regular daytime lifestyle.
How to get better sleep
cat launches safety web site
Customer Safety Services has launched SAFETY.CAT.COM™, a new Web site
dedicated to promoting the safety and health of everyone in, on or around Caterpillar
products. Visitors to the site will find information that reinforces safety messages
found in the company’s official Operation and Maintenance Manuals (OMM). The
site also covers the world of safety in motion. For the first time, Caterpillar videos on
walkaround inspections and operating tips are available on demand from one online
source. Other SAFETY.CAT.COM offerings include OMM excerpts, multimedia pieces,
and toolbox talks on a variety of safety topics.
1/ pupilometry measures eye reflexes, pupil reactions and the speed of eye movement to help determine fatigue levels.
2/ One out of five people in the world currently works hours that fall outside the traditional workday.
3/ a new dvd provided by caterpillar is designed to help workers manage a mining lifestyle. it includes tips to help shift workers get better sleep.
1 2 3
32 cat Global mining / viewpoint / 2007: issue 2 cat Global mining / viewpoint 33
cat bRaZil maKes fiRst undeRgRound machine
Recently Cat Brazil celebrated the first Brazilian-produced R1600G LHD machine—the first time an underground machine has been manufactured outside of Cat Underground Mining’s Australian manufacturing facility. This new source of loaders for underground hard rock mining will increase Caterpillar's production capacity and improve proximity to markets to better meet customer requirements.
cat RecogniZed foR sustainability
Caterpillar has been selected as a member of the Dow Jones Sustainability World Index (DJSI World) for the seventh consecutive year. The annual review of the DJSI is based on a thorough analysis of corporate economic, environmental and social performance, assessing issues such as corporate governance, risk management, branding, climate change, supply chain standards and labor practices. The subjective criteria for inclusion on the DJSI has become more stringent as the importance of sustainability issues continue to grow for investors. This year, Caterpillar saw a five-point gain in its total score and received the highest overall score reached by a company in the industrial engineering industry.
components to be built in china
As part of a long-term strategic plan to support manufacturing growth in China and at its operations around the world, executives with Caterpillar recently celebrated the grand opening of new manufacturing operations in Wuxi, China. Located in Jiangsu province in East China, the Wuxi campus includes nearly 19 hectares (47 acres) and will be home to Caterpillar (China) Machinery Components Co. Ltd. (CCMC), a wholly owned Caterpillar company. CCMC will manufacture a range of components to be used primarily in Caterpillar machines and to be sold to select original equipment manufacturers (OEMs). CCMC is part of Caterpillar’s Motion &
Power Control Division, which has facilities located around the world.
poweRtRain simulatoRs put new mining tRucKs to the test
Caterpillar recently put its next generation of large mining trucks to the test with rigorous powertrain simulator testing. Engineers at the Caterpillar Technology and Solutions Division have designed and constructed three full-scale powertrain simulators—two for mechanical drive and one for AC electric drive—to help integrate and validate the Cat C175 engine and the drive train components. Caterpillar relies on full-scale simulation to optimize component interaction for performance and durability.
cat logistics opens centeR in moscow
Caterpillar Logistics Services Inc. will open its first parts distribution center in the Commonwealth of Independent States (CIS) later this year. “The investment in this new facility demonstrates our support of our dealers’ mission to serve Caterpillar customers in Russia and our continued commitment to excellence in product support,” said Mary Bell, Caterpillar vice president and chairman and president of Caterpillar Logistics. A 10,250-square-meter (110,300-square-feet) logistics center located in the Northwest of Moscow will support five Caterpillar dealers in the CIS region. The facility will stock more than 23,000 Caterpillar parts and will provide an integrated logistics solution including inbound,
outbound, claims, returns and Caterpillar Remanufacturing core return services.
cat acQuiRes euRopean RemanufactuRing company
Caterpillar has completed the purchase of Eurenov S.A.S. (Eurenov), a remanufacturer of engines, transmissions and components for leading European automotive manufacturers. Caterpillar Remanufacturing Services (Cat Reman) recently concluded the two-phase purchase process. Eurenov operates its primary facility in Chaumont, France, and another facility in Radom, Poland. The acquisition will allow Cat Reman greater access to the European automotive and industrial engine and transmission remanufacturing market with expansion into eastern Europe.
cat and Rio tinto Reach agReement on dRill and dRagline systems
Caterpillar Inc. and Rio Tinto recently reached a three-year agreement for the Cat CAES and Aquila Drill and Dragline systems to be the preferred standard at the mining company’s open pit operations worldwide. The agreement covers nine Rio Tinto business units operating more than 30 mines in Australia, the United States, Canada and Namibia. The Caterpillar high-precision GPS mining technology products provide machine guidance and operator assistance as well as data collection of multiple production parameters. Rio Tinto is expected to order more than 200 Caterpillar high precision systems over the life of the agreement. In addition, the agreement includes a multi-year support contract.
newS CatfroM
» For more Caterpillar news, visit www.cat.com
cat Global mining / viewpoint 33
Gearing up for MINExpo—September 22-24, 2008 Once every four years, the entire mining world gathers in Las Vegas, Nevada, USA, for MINExpo. Sponsored by the National Mining Association (NMA), MINExpo is the industry’s premier showcase for companies specializing in every facet of mining. Caterpillar will be at MINExpo 2008 with a presence even more substantial than in 2004. Talk with your local Cat dealer about Caterpillar’s plans, or visit the National Mining Association’s Web site, MINExpo.com. says Edwards. “The operator could have a
perception that being personally monitored
is a bad thing—so they may choose not to use
a given technology.”
Recommendations
“Good technologies exist and we think they are
viable,” says Edwards. “The question is, ‘How
do you create a technology that deals with
the world, and works for all?’ The answer is,
‘You can’t.’ We know we must have multiple
solutions because all current technologies exhibit
shortcomings when the application range is too
broad. In other words, they don’t work everyone
in every situation.”
“There are some things you cannot change,” he
continues. “You will always have people falling
asleep no matter what you do. People are simply
not designed to be awake at night. No matter how
much you do, you can’t prevent it from happening.
The best thing you can hope for is to manage and
mitigate the risk.” His recommendation is to use a
combination of technologies.
“ the optalert glasses and astid steering system performed best in the lab testing. the ideal solution in the long term would be to fuse these types of technologies together. a system that combines information from both the machine and the operator is the best
hope for robustly detecting fatigue and drowsiness in the future. that’s what we’re recommending to the developers.”
Cat will continue to provide support for research and
development and allow access to Cat machines for
companies to test their products.
“They are the experts,” Edwards says. “We’re not
in a position to put this equipment on a machine
at the factory. The technology is too immature at
this point. But we can try to influence developers to
move quickly.”
The most important aspect of a successful fatigue
management program is taking responsibility.
“We must ensure that people recognize and take
responsibility for their own fitness for work,” says
Michael Farmer, global practice leader for fatigue
management at BHP Billiton. “Frontline supervisors
must understand and manage their workgroups, and
companies must develop a culture that encourages
workers to report and take action on drowsiness and
fatigue risks.”
Edwards says he is proud of Caterpillar’s focus on
this important topic. “We’re working to meet the
mining industry’s needs, the customer’s needs and
to energize the research community to care,” he says.
“We’ll share this with the world and hopefully all
companies can benefit. And we can make the world a
safer place to live and work.”
1/ eyeglasses with sensors that monitor eye movement and blink speeds are being considered as one possible technology to help indicate fatigue and keep operators safe on the job.
How to prepare for SHift worK
- prepare for night shifts by going to bed later at night and sleeping later in the morning on days off.
- wear dark sunglasses on the way home from work if it is daylight.
- go to bed as soon as possible after a night shift.
- eat a light breakfast before sleeping to prevent waking due to hunger.
- Sleep five hours after the shift, then take a nap just before going to work.
- avoid caffeinated beverages for the last three to four hours of your shift.
1