The World’s Largest Mining Show Had Something for Everyone, Aggregates Producers Included.
By Mark S. Kuhar
More than 44,000 attendees converged on the Las Vegas Convention Center Sept. 26-28 for MINExpo International 2016, according to show officials. The event was sponsored by the National Mining Association.
MINExpo 2016 featured more than 840,000 sq. ft. of exhibit space, 12 indoor and outdoor halls, and more than 1,900 companies showcasing equipment and technology for the mining and aggregates industry.
Here are some of the product introductions seen by Rock Products staff at the event. Look for more in future issues.
ALLU showed its ALLU M Screener Crusher at the show. The equipment converts a base machine into a mobile processing plant while including the following features:
- Crushing and loading in one-step operation.
- Waste/oversize material can be separated simultaneously on site in one-step operation.
- High mobility of the processing plant on site.
- Reduced investment and operating costs.
- High production rate and cost efficiency.
- No need for site electrics.
- Lower carbon footprint.
- Lower transportation costs.
- Saves fuel and energy.
- Positive environmental effects.
Atlas Copco’s new ultra fuel-efficient drill rig, the SmartROC CL, was unveiled for the first time in public at MINExpo, ahead of its official world launch this month.
For the thousands of open pit miners around the world who use Down-The-Hole (DTH) drilling technology, the new rig will certainly be seen as a major step forward. Not only have the designers managed to slash fuel consumption by 45 percent, averaging 35 l/h using a 165-mm drill bit, they have also boosted the achievable penetration rate by 50 percent compared with conventional DTH rigs currently in use.
The engine power required to drive various functions and operations can now be controlled and optimized in a way that was previously not possible, thereby minimizing the amount of diesel fuel consumed overall.
The design of the COPROD drill string which, combined with a choice of robust, high-powered rock drills up to 50 KW, gives the kind of high penetration rates normally only achieved in top hammer drilling together with the superior hole quality that comes with DTH drilling.
In addition, this package includes a range of automated, time-saving features including automatic rod handling, hole navigation system and the ability to operate the rig by remote control using Atlas Copco’s BenchREMOTE system. Coupled with Surface Manager, Atlas Copco’s drill-management software, this rig will be unbeatable in mining applications.
Mattias Hjerpe, product manager, said: “Many of our customers in, for example, Australia, South Africa, Latin America and Scandinavia, who use the DTH drilling method, now have a great opportunity to slash their fuel bills and boost their productivity at the same time. It’s a winning combination.”
BKT USA Inc. (subsidiary of Balkrishna Industries Ltd.) released six new tires at the show as part of its Earthmax range.
The BKT Earthmax range is made up of 21 different patterns, each to meet a different need in the OTR sector.
- EARTHMAX SR 46 for rigid haul trucks is BKT’s innovative response to severe rocky, abrasive and harsh mining environments. This tire has been specifically designed to carry heavy loads offering superior resistance to cuts and chips as well as a long tire life-cycle. The all-steel casing and belts provide extraordinary protection against shocks, fatigue and flats to maximize uptime and enhance productivity. Earthmax SR 46 features a special lug block pattern with circumferential groove to optimize the cornering performance with minimum tread face damage.
- EARTHMAX SR 25 (G-2/L-2) is an all-steel radial tire, which has been specially designed for motor graders and loaders operating in the most severe road construction or mining applications. Its non-directional tread design offers excellent self-cleaning properties in addition to traction and stability off the road.
- EARTHMAX SR 49 (L-4) is an all-steel radial tire that has been engineered for loaders and dozers. EARTHMAX SR 49 provides optimum performance in severe mining operations requiring exceptional traction.
Bridgestone Americas introduced the next generation of its off-the-road (OTR) tire and rim management software, TreadStat. The performance-tracking solution has been enhanced to include several new features that support the evolving needs of the global OTR industry. The TreadStat system from Bridgestone uses industry-relevant analytics to help customers manage the lifecycle cost of their tires for increased efficiency and profitability.
The TreadStat tool features a new, innovative user interface that increases productivity through customizable dashboards that deliver rich analytics directly to users’ computers, tablets or smartphones anywhere in the world. Global efficiency is increased by technology improvements such as additional multilingual support, convenient application program interfaces, instantaneous data conversion and integration with the B-TAG tire pressure and temperature management system from Bridgestone. Advanced analytics also help operations of any size or location maximize tire usage, manage inventory, improve safety and minimize expenses.
“The next-generation TreadStat tool is an innovative tire performance management solution that uses integrated technology to serve global businesses of any size,” said Taylor Cole, president, commercial off-the-road, Bridgestone Americas Tire Operations. “Having a complete and real-time view of every tire’s status can reduce one of a fleet’s largest annual operating expenses, tire and rim management, to significantly increase the bottom line. With TreadStat, Bridgestone is setting the global standard for OTR tire tracking.”
Forecasting, work scheduling and budgeting also are improved by the data-driven analytics platform. Bridgestone has enhanced the TreadStat tool to be accessible on mobile devices and tablets through the TreadStat Mobile Inspection app. The app ensures vital details are accessible on any device across the globe, and allows users to quickly and easily:
- Conduct vehicle inspections online or offline, saving time, eliminating paper and improving productivity.
- Conveniently note critical exceptions requiring immediate action and share data via email to reduce operating costs.
- Manage a global operation via one system to unify data-driven tire and rim management decisions for increased efficiency.
Caterpillar announced an upgrade to Cat MineStar Terrain, one of the capability sets that makes up the company’s integrated mine operations and mobile equipment management system, during MINExpo.
Terrain combines GNSS guidance technologies that help operators work efficiently and accurately with integrated office software that enables remote monitoring and fact-based decision-making. Miners use Terrain to optimize production efficiency, enhance safety and reduce cost per ton. All Terrain products (for grading, drilling and loading) have been upgraded.
- Terrain for grading improves the efficiency and lowers the cost of grading in applications ranging from production dozing to reclamation.
- Terrain for drilling directs the execution of drill patterns and enables remote monitoring of drilling activities. With this upgrade, multiple drills on the same pattern can share the status of
- Terrain for loading assists operators with movement and placement of material, improving efficiency and accuracy.
Customers using Terrain as part of a fully integrated fleet-management system (Cat MineStar Fleet 4.4 or newer) will benefit from a new feature for large wheel loader applications that combines fully automatic ore control with improved production tracking capabilities. Whether working in-pit, at the stockpile or at the ROM pad, loader operators automatically receive 3-D grade block data from the mine plan, eliminating manual updates from the office and reducing the risk of human error. The system facilitates blending at the ROM pad as automatic material tracking capabilities enhance efficiency and accuracy. The system also automatically tracks material dumped to the crusher or loaded into trucks.
Continental Commercial Specialty Tires (CST) presented its ContiEarth portfolio consisting of two earthmoving tire lines at MINExpo: the Continental EM-Master and the Continental RDT-Master.
The new tires, Continental EM-Master and Continental RDT-Master, are the latest addition to Continental’s portfolio of specialty tires. “The tires were specifically designed for the extreme conditions our customers are facing in the earthmoving sector,” said Christian Luther, product line manager earthmover tires at Continental.
With the introduction of the new tire lines, Continental Commercial Specialty Tires (CST) follows the customized solution approach. This means, every tire line was developed for an individual vehicle type and therefore takes into consideration the requirements of each machine.
“The new tires perfectly fit our growth strategy for the future, as we will continue to expand and optimize our product and service portfolio for the earthmoving industry in the upcoming years,” said Luther. Continental underlines its strategy to be a solutions provider by demonstrating the ContiPressureCheck system as well as the upcoming technology around ContiFlexBox, which enhances efficiency in customer operations.
As a leading technology company, Continental combines its strength in the automotive and rubber sector and presents its iTire as essential part of the ContiEarth range. The iTire means that each tire of the ContiEarth range already comes with an integrated sensor. The sensor is able to constantly monitor inflation pressure as well as tire temperature and can transmit the information in real time to the ContiPressureChecksystem. With the help of additional components, the data can be visualized either via handheld tool or display in the driver cabin.
“With the iTire, we prepare the path to the next service level. We want to enhance the efficiency and safety of vehicle fleets with a comprehensive tire management system,” said Luther.
In future, the ContiFlexBox will be a major part, enabling the collection and provision of tire-related data from the sensor and transmitting it to a central server via Wi-Fi or GSM. This will enable the fleet operator to constantly monitor vehicle data on a dashboard and will even send alerts for quick maintenance reactions.
Haver & Boecker
Haver & Boecker introduced NIAflow plant simulation software. NIAflow helps producers optimize quarry and mine operations by diagramming plant flow, machine placement, product pre-calculations and more.
Developed by Haver & Boecker engineers, NIAflow instantly analyzes existing or proposed processes, records plant statuses, and recognizes potential for plant optimization. The software is available for download on Windows-based systems. NIAflow supports the user in every engineering phase, from drafting flow diagrams for product pre-calculation to plant start-up and simulating parameter changes. Its intuitive menu control makes it easy for all levels of experience, and Haver & Boecker provides several levels of training, if needed.
“As part of our ongoing efforts to optimize plant efficiency for our customers, we are constantly developing innovative machines, programs and software to help them be successful,” said Karen Thompson, president of Haver & Boecker Canada. “NIAflow will serve as a cornerstone in the development of process engineering projects. When paired with other Haver & Boecker technology, such as Pulse vibration analysis software, our customers will hold all of the tools they need to optimize process flow and increase productivity and profits.”
Komatsu unveiled an “Innovative Autonomous Haulage Vehicle” featuring a cabless structure at MINExpo.
Unlike the 930E and 830E autonomous models, Komatsu has developed this vehicle exclusively as an unmanned vehicle designed to maximize the advantages of unmanned operation. Komatsu plans a market introduction in the near future.
By distributing equal load to the four wheels when the vehicle is loaded and unloaded, and adopting four-wheel drive, retarder and steering, Komatsu is aiming for high-performance shuttling of this vehicle in both forward and reverse travel directions, thereby eliminating the need for K-turns at loading and unloading sites. In particular, Komatsu expects that this new vehicle will considerably improve the productivity at mines where existing unmanned haulage vehicles face challenging conditions, such as slippery ground due to frequent rain/snow fall as well as confined spaces for loading.
Komatsu AHS trucks have hauled more than 1 billion tons (cumulative) of overburden and minerals at large-scale mines mainly in Chile and Australia. By continuing its efforts to optimize the performance of mining equipment and aggressively promote remote-control and unmanned machine operation, Komatsu will help its mining customers significantly improve their productivity, thereby becoming their indispensable partner, the company said.
Johnson Crushers International showcased the Kodiak K500+, its 500-hp, remote-adjust cone crusher. The K500+ is part of the Kodiak Plus Cone Crusher family, which consists of three other models, the K200+, K300+ and K400+. The K500+ model fills the demand for larger secondary and tertiary cone crushers that are used by high production aggregate producers and mining companies, according to Ian Pendergrass, JCI product development manager.
“The Kodiak Plus product line includes a hybrid cast/fabricated base frame design, an automated control system, a patented liner retention system, patented thread locking ring, anti-spin cone brake, and other additional evolutionary refinements,” Pendergrass said. “The K500+ incorporates these innovations as well, and we are confident in its ability to fill a large need in the current aggregate and mining markets.”
Other features of the Kodiak Plus cone crusher product line include replaceable brass thread inserts, patented internal counterweights, a heavy-duty tramp iron system consisting of pressure relief valves in lieu of accumulators, brass v-seat liners, and other unique manufacturing and maintenance characteristics.
Liebherr introduced its new 100-ton mining truck, the T 236. This new mining truck demonstrates the company’s continued innovation in design, paired with the evolution of Liebherr’s own high-quality components and class-leading technology. This combination results in increased productivity, better efficiency, enhanced reliability and improved safety, while lowering the cost per ton.
Capitalizing on decades of proven experience, the T 236 takes advantage of Liebherr’s electric drive system innovations with the introduction of the vertically integrated Litronic Plus Generation 2 AC drive system.
This revolutionary machine provides the industry with a new benchmark in the 100-ton class for off highway haul trucks: focusing on top performance, maximum uptime and lowest possible operating costs. All components on our truck are designed and built to perform and last in the most extreme mining conditions. As a result, Liebherr trucks run much longer between component overhauls, saving time and money.
To ensure the safety of maintenance technicians and bystanders, the T 236 is equipped with double pole battery, starter motor and hoist system isolators as standard. In addition, the Liebherr truck provides an innovative drive system inhibit, electrically interlocked to grounding devices for each plug and drive power module. Operating on a voltage level of 690 VAC and 900 VDC enables regular site technicians to carry out system maintenance. An industry first, Liebherr’s Litronic Plus Isolation system ensures the safety of maintenance personnel through the elimination of hazards by design.
Litronic Plus Generation 2 features advanced Active Front End technology. Making efficient use of electrical energy during retarding events, the drive system is able to deliver controlled engine speed with almost no fuel consumption.
McLanahan Corp.’s Rotary Scrubbers are ideal for helping producers remove water-soluble clays, deleterious materials and coatings from a variety of hard rock and ores, but can be over 100-ft. long, 40-ft. wide and 25-ft. high and weigh more than 838 tons empty. To give mining producers the opportunity to see this equipment up-close-and-personal, McLanahan turned to the Gear Virtual reality (VR) system, powered by Oculus Technology.
Booth attendees received a complete experience with the rotary scrubber, as well as the jaw crusher. Visitors wearing the headset walked around and inside both these pieces of equipment for an experience like no other.
“It’s pretty incredible to look back over the four years since the last MINExpo and see changes that have happened both at McLanahan Corp. and in the mining industry,” said Sean McLanahan. “The changes in the commodities markets, which you all know have been tough, have caused us to look closely at how we serve our customers around the world – from the products we offer to the need for local service and support in emerging markets.
“In 2015 alone, we opened three new global offices, restructured internally to improve our focus on products, took our solutions into new industries, and delivered innovative new products to the market. Through it all, our main goal has been to make sure we are giving our customers the service and support they need – whether that means serving them from local offices or asking them what they need to improve their operations,” McLanahan said.
Philippi-Hagenbuch showcased its Material Spreader body. The Material Spreader was designed primarily for mining but with benefits in a variety of applications, including construction, aggregates, quarries and landfills. It provides a safe and efficient solution for mine haul road maintenance as well as improves the safety and traction of icy haul roads in winter by applying road grit. During spring thaw, the material spreader easily tackles deteriorating road areas by spreading repair material and building up areas.
“We receive multiple requests every year for a sanding body that can apply grit to haul roads,” said Josh Swank, Philippi-Hagenbuch vice president of sales. “When we started designing the material spreading system, we wanted to ensure that it met the same criteria as all of our products. This spreader, like all PHIL products, is robustly built to withstand the harshest worksite conditions, simple to operate, and designed to maximize efficiency and achieve the truck’s true hauling capacity.”
The heart of the system is a patented PHIL rear-eject body coupled with the new material spreader attachment. The Material Spreader easily spreads road grit, sand or other material ranging in size from very fine to more than 2 in. Operators can easily adjust the material spreading width from about 15 ft. to more than 60 ft. The haul truck operator controls the material spreading rate and width from the truck’s cab.
An optional top-loading Grizzly Screen controls the maximum size of the material being spread. The ejector blade on the proven PHIL Rear-Eject Body moves material to the rear of the body and into a Cross Auger Channel. The auger gathers material to the center of the spreader and then discharges it onto a set of Material Spinners for spreading.
Sandvik showed its Panterea DPi series drill rigs, which it said provide improved technical solutions for boosted productivity Sandvik has engineered notable productivity upgrades into the well-known DPi series surface top-hammer drill rigs. The latest release of the Pantera DPi series drill rigs introduces such features as a redesigned operating system combined with other substantial upgrades and a completely new rock drill.
The Pantera DPi drill rigs include a redesigned control system with an updated user interface and touch screen. Featuring the latest Sandvik user interface style, support for new drill rig options and enhanced troubleshooting functions, the new control system enables easier and even more accurate drilling.
To optimize drilling performance Pantera DP1500i is now available with a high frequency RD1635CF rock drill with Circulating Shank Lubrication (CSL) system that guarantees fast and efficient penetration. In CSL oil is circulated through filters and reused, rather than just collected. “The new CSL system reduces shank lubrication oil consumption by up to 70 percent compared to the old system, and significantly increases coupling sleeve life,” said Jarno Viitaniemi, product manager, surface boom drills, Sandvik Mining and Rock Technology. “The drill rig has really been redesigned with economy in mind. It has also been enhanced with a new compressor control system that provides even better fuel efficiency.”
Further Pantera DPi improvements include modifications to the exterior design, which improves accessibility thereby enabling easier maintenance. In addition, the drill rig comes with the latest high-tech options, such as Driller’s Notes. The latter is a completely new feature that allows the operator to add hole information, such as voids and cavities, to hole-quality reports during drilling.
Superior Industries Inc. showed its new Patriot Cone Crusher at MINExpo. The high-performance cone is the manufacturer’s first entry into crushing technologies for bulk processing applications.
Besides a strong commitment to service and convenient access to wear parts, the Patriot Cone Crusher will be recognized for rugged structural integrity and high-grade components to extend service life. Internally, bronze sleeve bearings are used for all moving components that are load bearing or perform load transmission (including countershaft bushings, thrust bearings, head and eccentric bushings and socket liners). In addition, these critical components are cast of high-grade steel, which typically exceeds standards for conventional cone crushers.
Superior said engineers uniquely designed high throw and high-pivot point crushing performance to achieve strong production rates at a low cost per ton. Mobile applications will appreciate a readily mounted design for transportation on a cone/screen chassis.
For protection from costly structural damage, each Patriot Cone Crusher is equipped with fail-safe hydraulics to defend the unit against damaging mechanical overload. Additionally, standard relief valves within the dual acting tramp release cylinders provide immediate, alternative protection should the accumulator fail. Engineers also developed overload sensing technology. In the event of force overload, a simple alarm can activate or optional advanced sensing technology will automatically take the necessary corrective action. This same automation can control the feed rate to optimize performance, adjust other settings and monitor critical lubrication and hydraulic parameters.
Terramac, a manufacturer of innovative rubber track crawler carriers, offered various models that deliver superior performance and versatility to tackle the toughest mining jobs. Terramac’s RT9, RT14 and RT14R crawler carriers are well-appointed to provide operators with maximum efficiency and easy maintenance, the company said.
The greatest feature that sets Terramac’s units apart from other vehicles is its rubber track technology. Terramac crawler carriers exert minimal ground pressure while fully loaded, making them ideal for loose and wet ground conditions where heavy, wheeled or steel track machines are likely to get stuck. Flotation from the units’ rubber tracks leave a minimal footprint and less disturbance on the soil while providing reduced slippage to conquer adverse conditions, climb faster on rugged terrain and reach remote areas.
The robust Terramac products feature powerful Cummins diesel engines and added torque, allowing operators to tackle a wide-range of mining applications with ease. Terramac crawler carriers also boast large carrying capacities to ensure quick cycle times and keep productivity levels on point – regardless of application.
Volvo debuted the A60H articulated hauler. The machine offers a 60-ton payload capacity. This new-to-industry hauler class opens increased production opportunities and cost savings potential not previously possible with smaller articulated haulers or rigid trucks in the 60-ton size class, Volvo said.
“The A60H is a perfect fit for contractors who typically run multiple articulated haulers on long-term earthmoving projects. In many cases, customers could expect reduced operating costs by replacing two smaller trucks with one A60H,” said Eric Fatyol, product manager, GPE products at Volvo Construction Equipment. “The A60H could also open up new areas of production for mine and aggregate sites by providing access to areas of the site that were previously inaccessible with rigid trucks. Similarly, the A60H could extend the production season in harsh-weather regions and also eliminate the need for hiring outside contractors to handle overburden work.”
Powered by a 673-hp Volvo D16J engine and built upon the Volvo platform, the A60H goes where others can’t, noted Volvo. The active hydraulic front suspension, hydro-mechanical steering and high ground clearance at the articulation joint enable the A60H to easily and comfortably navigate severe terrain, and the rotating hitch design makes the articulation joint virtually maintenance-free. Automatic traction control (ATC) and 100-percent differential locks continue to be a competitive advantage for Volvo.
The no-slip, no-wear differential locks work in 4×6 and 6×6 drive combinations. This industry-unique design employs the front two axles in full-time, and the back axle kicks in as necessary – allowing unmatched off-road performance while reducing fuel consumption and tire wear. With oil-cooled, wet, multiple disc brakes on all three axles, stopping distance is impressively short – even on steep, muddy gradients.