MC01

Mining System Efficiency
Getting more from your mining equipment
Caterpillar Bob Riggle

Hewitt Yves Lacquerre
September 2013
The Big Picture
Return
Dump Load
Haul
2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Mining Costs
Admin & Other

Functions Drilling
16% 4% Blasting
6%
Loading
Haulage 15%
Support
14%
Hauling
45%

Inefficient operations result in lost revenue
Estimated Lost Revenue Per Truck

TRUCK MODEL 797 793 789 785
Target payload ton 394 250 198 151
GOLD Revenue / Hr $21,500 $13,700 $10,800 $8,300
OIL SANDS Revenue / Hr $17,500 $10,900 $8,600 $6,600
COAL Revenue / Hr $3,450 $2,200 $1,750 $1,300
COPPER Revenue / Hr $1,280 $815 $645 $490

Cost Per Tonne Sensitivity
A 5% Change in Each of these Factors Results in the Following Reductions in Cost per Tonne…

Cost Per Ton Estimates
Electric Rope Shovel Hydraulic Front Shovel Hydraulic Backhoe

Reliable, low Breakout force Breakout force
cost-per-ton and selectivity and selectivity
Requires: Requires: Requires:

• Long mine life • Proper face • Proper bench
• Electric network height height
• Hard floor • Limited tramming • Limited tramming
• 15 m face height • Clean-up support • Clean-up support
• Well shot material
• Clean-up support

Hydraulic Front Shovel
Favorable conditions:
• Tight loading materials
• Selective digging
• Soft spongy floors (low PSI)
• Jagged, uneven floors
• Multi-loading targets
• Tight loading area
Unfavorable conditions:
• Excessive tramming
• Cleanup support
• Low face

Electric Rope Shovel
• Working a single face of the

correct height
• Solid, level floor
• Wide benches to facilitate
truck maneuverability
• Well-shot material
• Poor underfoot
• Low faces
• Poorly shot material
• Multiple faces

Hydraulic Backhoe
• Single-face loading
• Tight digging materials
• Face height to stick length
• Short swings (15 o )
• High production / job set-up
• Dig below and above grade
• Tight quarters
• Requires cleanup support
• High benches
• Low angle of repose

Caterpillar Production Systems
Cost Savings
994F & 789D

Production 2700 Tons (2410 mt) 2500 Tons (2270 mt)
CPT ($/ton) 7% -
CPT ($/ton) 17% -

CPT ($/ton) 22% -
Assumptions:
• 50 min hour Key Factors:
• 22.5 yd3 (17 m3) bucket More Productive
• 8760 Scheduled hours per year Cost spread out over more tons
• Overburden

Caterpillar Production Systems
Cost
Savings 994F:
BUCKET FILL 105% 80%

CPT ($/ton) 20% -
Assumptions:
• Poorly shot material ~2800 lb/lcy (1660 kg/lcm)
Percent Improvement
• 105% - 22.5 yd3 (17 m3) - Bucket
• Bucket width = 222 in (5650 mm)
• 80% - 23.5 yd3 (18m3) - Bucket Key Factors:

• Bucket width = 245 in (6300 mm) Production loss

Truck Exchange
Truck exchange time:
Elapsed time from when

loaded truck receives last
loading pass until next truck
receives first loading pass.
Exchange time:
• Good - 42 seconds or less
• Acceptable - 54 seconds
• Unacceptable – over 1 minute

Cat Cycle Timer
Results
Mine Site
Trucks Weighed 61
Passes Timed 278
Avg Dump Time (min) 0.0544

Avg Swing Empty Time (min) 0.1172
Avg Load Time (min) 0.2026
Avg Swing Loaded Time (min) 0.0940
Avg Loader Cycle Time (min) 0.4681
Avg Bucket Payload (Tons) 30.09
Avg Bucket Fill Factor 83.60
Avg Passes/Truck 6.20
AvgTruck Payload (Tons) 186.49
Truck Fill Factor 92.25
Avg Truck Load Time (min) 2.49 Equalized Exchange
Avg Truck Exchange (min) 1.09 0.70
Avg Trucks/Hour 16.77 18.83
Total BCY/60 min 2673.08 3000.85
Total Tons/60 min 3127.51 3511.00
Theoretical Loader Production (Tons/60 min) 3857.52
Efficiency 81.08

1 st Pass Full

What can 1 more pass COST $$$?
TARGET payload = 195 Tons (177 mt)

ONE MORE PASS 6 PASSES 7 PASSES
CPT ($/ton) 3.0% -
Percent Improvement

Hydraulic Front Shovel Applications

Hydraulic Face Shovels Applications
Optimal Bench Height Appr. 75 % of max. vertical reach
height
Cycle Times 23 - 30 seconds (depending on model)
Bucket fill factor in well- 90 - 100 %

shot rock
Most efficient pass 3 - 6 passes

match
Conditions favorable to Selective Digging

Hydraulic Face Shovels Multiple face heights
Single face loading
Multiple targets
Tight load areas
Tough digging
Poor floor conditions
Define dig pattern, R to L or L to R
Conditions unfavorable Excessive tramming
to Hydraulic Face Low benches
Shovels No cleanup support
Multiple faces

Hydraulic Face Shovels
Things to watch for:
• Whenever possible, dig the working

face from top to bottom
• Penetrating at the top area of the face

eliminates lifting effort
• Penetrating in the centre area of the

face reduces lifting effort
• Digging from the bottom requires

highest lifting effort and longer cycle
time

Hydraulic Face Shovels
• Take the first bucket during truck spotting from the bottom at a larger swing angle
• Once the truck is positioned, maintain smaller swing angles and dig as high as possible
to shorten cycle times

Hydraulic Backhoe Applications

Hydraulic Backhoe Applications
Optimal Bench Appr. equal to stick length

Height
Cycle Times 21 - 31 seconds (depending on
model)
Bucket fill factor in 90 - 100 %
well-shot rock
Most efficient pass 3 - 5passes
match
Conditions favorable • Low to moderate bench height

to Hydraulic Face • Truck spotted either on top or
Shovels bottom
• Tight load area
• Short swing -60deg
• Well shot material
Conditions • High benches
unfavorable to • Excessive tramming
Hydraulic Face • Multiple benches
Shovels • Unstable benches
• Low angle of repose material
• No clean up support

Hydraulic Backhoes

• Sufficient bench height essential for
efficient and safe operation
• Ideal height is in the range between

excavator stick lengths and truck body
edge
• A too low bench does not allow good

bucket fills and involves the risk to pull
material against the tracks
• Insufficient height also increases the

danger of collision between excavator
and truck under certain circumstances

Hydraulic Backhoes
Truck on the lower level - typical

application
• Lowest risk for collision with proper bench

height due to clear separation of loading and
hauling equipment
• Excellent operator view into the truck body
• Potential for short swing angles
• Shortest attachment lifting distance possible
• Various options for truck positioning with

loading through the body gate or over the side
wall

Hydraulic Backhoes

Can We Improve the Set-Up ?



Truck Applications

Truck Applications
Effects on Hauling Costs Operator, 14%
Maintenance, 3%
Tires, 16%
Wear, 2%
Repair, 25%
Fuel, 18%
(Prior July 2007)
Owning, 22%

Load Placement on Trucks

Load Placement on Trucks
Load placement:
• Lateral Incorrect loading
• Longitudinal Correct loading

• General
• Payload accuracy

Loading Tool Operators Responsibility




Caterpillar has identified optimal load size
Cat 10–10–20 Policy
Tested Limit
Durability
Productivity
Number of Loads
% of Target Payload
90% of loads should fall into this range, with no more than 50% of loads exceeding
100% of the target payload
No more than 10% of loads should exceed 110% of the target payload
No loads should be above 120% of the target payload


Truck Dump Applications

Truck Dumps

Truck Dumps

Truck Dump Efficiency
TRUCK DUMP Truck Dump - 1 Truck Dump - 2

CPT ($/ton) 3% -
Percent Improvement
Assumptions:
• 50 min hour
• 8760 Scheduled hours per year
• Overburden
• Truck Dump – 1: 30 second
cycle time improvement
• .25 minute on the haul cycle
Key Factors:
and .25 on the return cycle
Decreased cycle time
Productivity increase

Poor Dump Practices
Things to avoid
• Body bulldozing
• Pulling through berm after dumping
• Dumping into existing pile
• Not lowering body prior to moving forward

Poor Practice Results

• Poor dumping practices can result in

rear rib and tail area damage


Dump Over Without Body Contact



Tire Considerations
Over the life of the truck,

you will spend the initial
purchase price of the
truck in tire related cost.



Well Managed Dump

Short Lifts, Greater Compaction

Manage Floor, Maintain Proper Drainage

Back Fill Low Spots

Dump Zone Visual Inspection
• Floor is smooth.
• Trucks enter at high speed,
parallel to edge.
• Trucks brake in straight line,
then turn and stop to reverse
to dump.
• Safety berms are regulation
height.
• Is dump stable enough to
dump over safely or
should you dump short
and push off.

Haul Road Applications

Haul Road Applications

Haul Road Design and Maintenance
In both surface and underground mining, poorly designed and maintained haul roads
lead to dramatically increased costs
• Lost production
• Major equipment repair / replacement
• Tire life
• Fuel consumption
• Safety
Road Types:
• Permanent
• Semi-permanent
• Temporary

Design Parameters
• Cost
• Distances
• Grades
• Widths
• Traffic Layout / Intersections
• Curves / Superelevation
• Materials / Construction/ Surface
• Drainage
• Rolling resistance

Design Parameters – Road Cross Section

Rolling Resistance
• Tractive effort required to

overcome the retarding effect
between tire and ground
• Overcome by machine power
exerted to pull the tire up and out
of its own rut
• Expressed in terms of percent of
road grade Rolling Resistance

Rolling Resistance
Fact Check
4. A 785 Off-Highway Truck has 44% higher
compaction versus a 777 Off-Highway
Truck
5. A 789 Off-Highway Truck is 91% higher, a
793 Off-Highway Truck is 107%, and a
797 can be as much as 269% higher

Design /Maintenance - Rolling Resistance
For off-highway trucks on radial-ply tires, assume rolling resistance of
• Hard, well-maintained road . . . . . . . 1.5%

• Well-maintained road with flex . . . . . . 3%
• 25 mm/1 in tire penetration . . . . . . . . .4%
• 50 mm/2 in tire penetration . . . . . . . . .5%
• 100 mm/4 in tire penetration . . . . . . . .8%
• 200 mm/8 in tire penetration . . . . . . .14%
In practice, a 5% increase in RR%

can result in up to a 10% decrease in
production and 35% increase in
production costs .
Tire penetration

Fact Check
In practice, a 5% increase in RR%

can result in up to a 10% decrease
in production and 35% increase in
production costs

793C at Rated Payload
Assuming 3% Rolling Resistance (RR)
1st Gear 5th Gear

2nd Gear
Vertical Lift = 100m

1st Gear
3rd Gear 2nd Gear
1st Gear
5th Gear
Horizontal Run = 1250m
Constant Grade
Non-Constant Grade

793C at Rated Payload
Assuming 6% Rolling Resistance (RR)

1st Gear
TC 3rd Gear
1st Gear
Vertical Lift = 100m

1st Gear
TC
2nd Gear 1st Gear
1st Gear
3rd Gear
Horizontal Run = 1250m
Constant Grade
Non-Constant Grade

Worst Case vs. Best Case Comparison
Constant Grade at Non-Constant Grade at Potential Improvement

3% RR 6% RR
Haul Time 6.32 minutes 9.03 minutes 30.01%
Haul Fuel Burn 41.99 liters 56.22 liters 25.31%

Fact Check
A constant grade will decrease haul times by 8.2%,

decrease fuel burn by 3 - 4%
Engine life is a function of fuel burn.

Consistent Grade

Optimum Haul Road Grades
• Limit haul road grades to 8% - 10% with 2% rolling resistance
• Minimize haul road rolling resistance wherever possible
• Maintain payloads within the Cat 10-10-20 Truck Overload Policy

Horizontal and General Vertical Alignment
• Design corners and crests with clear visibility

at operating speeds
• Design for worst case scenarios

Sight Distance for Horizontal and Vertical Curves
“The extent of peripheral area visible to the vehicle operator”
Required Stopping Distance
Line of Sight
Sight Distance
Hazard
• Must be sufficient for a machine Vertical Curve
Case A
to stop before Required Stopping Distance
reaching a hazard or obstacle Sight Distance Line of Sight
Hazard
Vertical Curve
• Distance from the operator’s eye Case B
must equal
or exceed required stopping Required Stopping Distance
distances
Sight Distance Line of Sight
Vertical Face or Obstruction

Case C
Required Stopping Distance
Sight Distance
Line of Sight
Trees Removed and Slopes Laid Back
Case D

Design Parameters – Curves and Switchbacks
• Use maximum practical radius

• Considers widths and clearances
• Employ super elevation for higher
speed operations
• Use super elevation >10% with
caution
• Consistent truck speeds
• Consider both directions, empty and
loaded
Performance Handbook
Appendix Charts- -Curve
Speeds and Superelevation

Design Parameters – Bench Widths
• Truck must clear loader under full acceleration.
• Minimum width = machine swing diameter + truck width + width of safety berm.
Bench Width

Cross Fall
On flats
• Maintain minimum slope for
drainage
• Using 2% constant cross fall with
extreme caution and travel loaded
truck on the “uphill” side
• If constant cross fall is not
selected, crown haul roads with
minimum slope angle
On grades USE EXTREME CAUTION

• Minimal cross fall is required
unless rainfall is heavy
2% constant cross fall

Road Width
One-way straights and corners

• A minimum of 2 – 2.5 widths
is recommended
Two-way traffic
• In straights, a minimum of
3 – 3.5 truck widths
• In corners, a minimum of
3.5 – 4 truck widths
One-way (straights/corners)
Two-way (In straights)
Two-way (In corners)

Design Parameters – Drainage / Ditches
Adequate drainage must carry away

max. expected rainfall, with min.
pooling, potholing or water entry into
sub-base.
Ditches:
• All roads need to be ditched and maintained

• Rock linings in ditches steeper than 8%, to prevent erosion
• Ditches channel to diversions; diversions to settling ponds
• Staked bales of hay for temporary silt traps

Safety - Berms
Recommended height:
• Minimum half wheel height for conventional berms
Recommended placement:
• Along all haul road edges, with drainage gaps
• Along edges of dump areas
• Check local regulations
Other purposes: 1/2 wheel

height
• Marking devices for haul road edges
• Drainage channels
• Fixed reference points for operators

Points To Remember
Haul Road Support

Points To Remember
Haul Road Support

Remember – Good Haul Roads
• One indicator of good haul road conditions: Comfortable travel

on roads in light vehicle at 60 km/h
• Haul roads begin at the loading face and continue all the way to
the dump edge
_ Good floor conditions in load areas
_ Good floor conditions in dump areas
• Good roads require frequent attention: Once a road

deteriorates, it takes five times as long to repair
• “The haul road is either the mine’s greatest asset or its

greatest liability.”

Motor Grader Applications

Motor Grader Applications

Track-Type Tractor Applications

Track-Type Tractors
Favorable Applications:
• Production dozing ( CarryDozer )

• Dedicated waste dump operations Need new photo
• Stockpile operations / steep / slopes
• Haul road construction
• Reclamation
• Ripping

Sizing Track Type Tractors for Truck Dumps
Optimal Track Type Tractors – truck

match ups:
D9 777
D10 777 / 785 / 789
D11 789 / 793 / 797

Wheel Dozer Applications


Design Match-up
Wheel Loader - Wheel DozerTrack

992K 854K
990H 844H
988H 834H
980H 824H
966F 814F

Size Comparison
Wheel DozerTrack - Type Tractor
814H
D7R
824H
D8T
834H
D9T
844H
D10T
854K
D11T

Performance Comparisons Summary
854G 100% D10 > D11

844 70% D9 > D10
834G 55% D8 > D9

Wheel Dozer Powertrain
• Allows operator to vary rimpull from 100% to 20%

• Smooth ground speed control
• Reduced Tire Wear
• Allows use of throttle lock for faster cycle times and
maximum hydraulic efficiency
• Longer engine life and better fuel efficiency.
• Lockup Clutch allows for faster ground speeds in
direct drive

Wheel Dozer Blades
Straight Blade
• General mine clean-up
• 834
Semi-U Blades & Heavy Duty Semi-U Blades

• Good spreading characteristics
• 834/844/854
U-Blades
• Good load retention characteristics
• 834/844/854
Coal Blades
• Increased capacity for lighter materials
• 834/844/854

Sizing Wheel Dozers / Truck Dumps
Optimal wheel dozer – truck match ups:
834 773 / 777
844 777 / 785
854 785 / 789 / 793

Proper Application ?

Proper Application ?


Ground Pressure
• 55 psi • 20 psi
• Higher Compaction • Lower Compaction

IN GENERAL:
• If Compaction is Critical, Use the Wheel Dozer
• Always Use Track Dozers for Production Dozing
• Use Wheel Dozer if Roading Advantage Lowers Overall Cost

Analysis Tools
• Vital Information Management System (VIMS)

• Application Severity Analysis (ASA)
• Road Analysis Control (RAC)
• Fleet Production Optimization (FPO)
• Road Defect Management - Assessment Checklist
• Fleet Production and Cost Analysis (FPC)
• M.G Calculator
• MineEIA
• Cycle Timer

Reducing Your Costs Through Efficient Operating Procedures:
• To minimize cost, first look at the big picture,

then use a common sense approach
• Select proper type of equipment
• Properly equip for the specific job
• Properly match buckets and bodies
• Stress teamwork and communication
• Properly set-up load area

®
© 2013 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, their respective logos,
“Caterpillar Yellow,” 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.

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Mining System Efficiency

Getting more from your mining equipment

Caterpillar Bob Riggle

2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Admin & Other

3 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Estimated Lost Revenue Per Truck

Target payload ton 394 250 198 151

GOLD Revenue / Hr $21,500 $13,700 $10,800 $8,300

OIL SANDS Revenue / Hr $17,500 $10,900 $8,600 $6,600

COAL Revenue / Hr $3,450 $2,200 $1,750 $1,300

COPPER Revenue / Hr $1,280 $815 $645 $490

4 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

5 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Electric Rope Shovel Hydraulic Front Shovel Hydraulic Backhoe

Requires: Requires: Requires:

7 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

8 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Working a single face of the

9 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

10 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

994F & 789D

Production 3200 Tons (2900 mt) 2500 Tons (2270 mt)

11 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

BUCKET FILL 105% 80%

• 80% - 23.5 yd3 (18m3) - Bucket Key Factors:

12 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Truck exchange time:

Elapsed time from when

13 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Avg Dump Time (min) 0.0544

14 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

16 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

TARGET payload = 195 Tons (177 mt)

17 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

18 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Cycle Times 23 - 30 seconds (depending on model)

Bucket fill factor in well- 90 - 100 %

Most efficient pass 3 - 6 passes

Conditions favorable to Selective Digging

19 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Things to watch for:

• Whenever possible, dig the working

• Penetrating at the top area of the face

• Penetrating in the centre area of the

• Digging from the bottom requires

22 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Things to watch for:

24 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

27 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Optimal Bench Appr. equal to stick length

Conditions favorable • Low to moderate bench height

28 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Things to watch for:

• Ideal height is in the range between

• A too low bench does not allow good

• Insufficient height also increases the

31 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING