• Abstract and Figures
• Public Full-text

2007: issUE 1 A publication of Caterpillar Global Mining Seeing Clearly FOR SAfer MINE sites THE LAST MILE FROM EVERY TIRE CONTAMINAtiON CONtrOL PAYING Off FOR XSTRATA’S ALUMBRERA MINE Alternative Fuels: EXplOriNG BIODiesel Setting the pace for high production Copper Mining Phelps Dodge Morenci Technology keeping workers safe IN AUSTRALIAN UNDERGROUND MINE Welcome to Viewpoint, a magazine produced by Cat Global Mining to address the issues facing our mining customers today—and to share what we’ve learned from our industry partners around the world. This issue’s safety story focuses on operator hear from a mine owner who is demonstrating visibility—why it’s important, how you can improve best practices in tire life management. it, and the technologies that are either newly We also address the topic of energy. From price to available or under development to aid in visibility availability, energy concerns are at the forefront of many for operators of large equipment. mining managers’ minds. We’ll explore how biodiesel In addition, we profile the Phelps Dodge Morenci is being successfully used in off-highway engines. mine—one of the largest and most technologically We look forward to your feedback and to sharing advanced mines in the world. Morenci has been an more stories of this great industry in future editions early adopter of a number of technologies, including of Viewpoint. using GPS for ore and slope control and replacing smelting with solvent extraction/electrowinning. In the article “Last Mile from Every Tire,” Cat experts share some practical advice for extending tire life Chris Curfman through improved haul road maintenance. We’ll also PresiDENT, CAT GlOBAL MiNING Caterpillar Editorial Board Tami Nelson, Editor; Erik Elsmark, Viewpoint is a publication of Cat Global Mining, producer Wheel Dozers and Loaders; John Enderby, China and India; Greg of the mining industry’s broadest line of equipment and Gardner, Europe, Africa and Middle East; Chris Gehner, Underground technology. Caterpillar serves the worldwide mining Mining; Larry Gregory, Trucks; Dan Hellige, Safety; Kent Lynch, Tractors; community through its vast dealer network and a single Keith Malison, South and Central America; Patrick Mohrman, Field division called Caterpillar Global Mining, headquartered Support; Glenn Morrison, Australia, Indonesia, New Zealand; Shane in Peoria, U.S.A., with additional offices worldwide. O'Brien, North America; David Schricker, 6 Sigma. c Cat Global Mining / Viewpoint / 2007: issue 1 TABLE of CONTENTS Using biodiesel in off-highway engines AlterNAtive FUels:18 Contamination control paying off for XSTRATA’S ALUMBRERA MINE: 6 Technology keeping workers safe IN AUstrAliAN UNDerGROUND MINE: 9 Improved visibility means safer mine sites seeiNG cleArlY: 20 THE LAst Mile frOM everY tire: 2 Phelps Dodge Morenci SettiNG THE PAce FOR HIGH PRODUctiON COpper MiNING:10 NEWS FROM CAT: 25 Cat Global Mining / Viewpoint 1 THE LAST MILE FROM EVERY TIRE: HOW HAUL ROAD MAINTENANCE CAN EXTEND TIRE LIFE 2 Cat Global Mining / Viewpoint / 2007: issue 1 It used to be that tires were just a cost of doing business. Mine owners were accustomed to spending the initial purchase price of a large mining truck in tire-related costs over the lifetime of the machine. Today, with an unprecedented demand and production that can’t keep up, tires are no longer considered just a cost. They’re mission-critical to keeping your haulage fleet working. “This shortage isn’t going to end this year, or next Negotiating curves can generate high lateral tire MOTOR GRadER, WHEEL year, or even the year after that,” says Pete Holman, forces, which contribute to high tire wear and ply DOZER OR TRacK-TYPE senior consultant in Caterpillar Global Mining. “It’s separation. Superelevation—the difference in height TRacTOR? going to take a while for the manufacturers to catch between the inside and outside edges of the bed of a Motor graders, wheel dozers and track-type tractors are up. So mines have to do what they can to take care banked road—helps eliminate these forces. recommended for the following of the tires they have. And the only way to do that is haul road applications: When properly designed, superelevation keeps loads to change the site culture. Now tires are getting the Motor graders and wheel dozers level and square on the tires, decreasing side forces care they should’ve been getting all along.” - haul road construction and on the tire casing, and reducing scuffing and wear maintenance About 80 percent of all large tires fail before they on the treads. In addition, superelevation allows - blasting cleanup wear out. Cuts are responsible for about 45 percent trucks to operate at more consistent speeds, which - loading area cleanup of failures, with impacts causing nearly 30 percent. means less braking and less heat—another cause of - dust maintenance One of the most important things a mine can do to shortened tire and component life. - reclamation prevent these premature failures is to take care of its - snow removal The amount of superelevation depends on the curve’s haul roads. radius and the speed at which it is negotiated. Because Track-type tractors “Cuts and impacts are mostly caused by spillage superelevated turns can prevent a danger when slippery, - haul road construction on the haul road,” says Caterpillar application those over 10 percent should be used with caution. - production dozing at distances up to 500 feet consultant Kent Clifton. “When you’re driving a car, Another approach to superelevated curves is to determine - dedicated waste dump it’s easy to dodge a large rock. With a mining truck, operations the safe speed for negotiating a turn at a certain lateral tire by the time you see it, it’s too late.” - stockpile operations/steep force. In general a 20 percent lateral coefficient of traction slopes DESIGN IT RIGHT is safe for all but slippery conditions. - haul road construction - reclamation and ripping Clifton, who has visited sites all over the world Grade is also important because it affects where and witnessed best practices, says the first step is the load sits on the tires. The goal is for 33 percent designing roads properly. The best haul roads have of the load to be in the front of the truck and 66 crowned straight sections, superelevated curves, percent to be in the rear, Clifton says. The ideal safety berms and drainage ditches on both sides. grade is between 8 and 10 percent with low rolling resistance of 2 percent or less. 1/ A water truck wets down the 1 haul road at Pine Branch Coal 2 mine in Chavies, Ky., in the Eastern Coal area of the United States. Pine Branch is careful to use enough water to keep down dust without over-watering, which can cause slippage and make fallen rocks even more dangerous to tires. 2/ “Good haul roads improve production, extend tire life and reduce overall operating costs,” says Caterpillar senior product consultant Kent Clifton, shown here at a site in Arizona. Cat Global Mining / Viewpoint 3 DAILY MINE SITE It’s also important to remember that the haul road Making sure haul roads are free from rocks and CHECKLIST begins at the loading face and ends at the dump point. other debris should be a top priority on every mine Haul Road Proper design of bench and dump areas can increase site, Clifton says. And that dedication does make a - Road is free of puddles, tire life as well by reducing spillage that can become a difference. “Some mines will get just 4,000 to 5,000 potholes, ruts, gullies. hazard to tires. Trucks should be able to quickly come hours from a tire,” Clifton says. “But Pine Branch - Passing room is adequate. in, turn around, and then back up. “You don’t want to Coal, in the Eastern Coal area of the United States, is - Corner radius allows safe turn the steering wheel and move the tires while the averaging 11,400 hours from a tire. They operate in one operation at high speed. truck is not in motion because when tires twist on of the most severe environments for tires. If you can - Spillage is removed quickly. top of the rocks, it causes wear,” Clifton says. extend tire life at Eastern Coal, you can do it anywhere.” - No rubber deposits on tight, rocky turns. Road width is another concern. “Roads should be Pine Branch owner Dave Duff, who has been in the - High braking forces not necessary on corners. three times the width of the widest truck, so tires mining business for over 50 years, says proper haul - Expected road speeds are aren’t bumping into the safety berms or dropping road maintenance comes down to making it a priority. achieved. into ditches,” he says. “ It’s a lot of work, but you just have to Load Zone Using the proper material to prepare and maintain - Floor is smooth. keep after it,” he says. “We try to do it the road bed also is important. If the surface under - Water removal is adequate. the best it can be done. People have the haul road is soft or moist, rolling resistance is - Debris is cleared away. to care about it. And we do.” high and tires are allowed to sink—which means - Trucks don’t drive over rocks. contact with dirt along the sidewall. This can wear “The key is communication,” he continues. “We all - Trucks leave under full, continuous acceleration. away the rubber from the tires. have radios, and whenever anyone sees a rock, they tell someone and it gets picked up. It’s teamwork.” - Trucks return without making Usually in cases of high rolling resistance, the tight, high-speed turns.

Load more

  28

Copy Link