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New Cat mining shovels feature upgrades to drive efficiencies, lower cost per ton

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New Cat mining shovels feature upgrades to drive efficiencies, lower cost per ton

The 2021 Cat 7495 and 7495 HF electric rope shovels (ERS) combine multiple standard feature upgrades that increase operating efficiency up to 10 percent to improve machine productivity. Component enhancements, increased frame durability and improved serviceability help reduce cost per ton of material moved by as much as 15 percent.

“Consistently, our customers tell us machine availability and productivity are primary contributors to their operation’s success. From the full adaptive control system for HydraCrowd to more innovative technology and data security, the advances made to the 2021 electric rope shovels reflect our commitment to meeting their needs,” commented Dan Wyatt, ERS product value stream manager. “Many of these improvements are compatible with shovels in the field, so customers can realize these gains through upgrades to their existing fleets as well as new machine purchases.”

Drive updates

A new propel gear case for the 7495 and 7495 HF models nearly doubles the life of propel gear cases in some extreme operating conditions. Precise adjustments to gearing geometry and advancements in tooth hardening enhance gear case durability and productivity. The result is lower total cost of ownership as much as $8 per hour when the drive system is replaced at one scheduled time. Additionally, an ecology drain simplifies oil draining and enables kidney-loop flushing, which reduces abrasion-causing contaminants and oil change frequency.

Updates to the 7495 AC electric drive system deliver greater reliability, improved maintenance access, enhanced safety, and expanded high-altitude and temperature capabilities. A liquid-cooled motion regulator cabinet efficiently dissipates heat generated by electrical components and enables operation at -40 degrees C/F to 50 degrees C (122 degrees F) and altitudes as high as 5 250 m (17,220 ft) without derating. A faster propel transfer switch cuts lag time by 75 percent to improve productivity, while common motors in multiple applications means fewer parts to stock, improved parts availability and simplified maintenance.

Slashing maintenance time by days while enhancing safety, reconfiguration of the crawler carriage allows drive shaft and tumbler replacement from the outboard side without removing the propel transmission. With this design, thrust loads are evenly distributed on large, tapered roller bearings rather than bronze thrust plates, increasing durability to align with 25,000-hour planned rebuilds, even in harsh environments.

Cat 7495 electric rope shovel

Structural improvements boost longevity

Stress from every load passes through the swing rack. An enhanced design includes a single-piece rail casting that eliminates vertical segment cracks to increase durability. The rail provides a uniform path for roller movement, preventing rollers from coming loose and creating irregular wear patterns. The upgraded third rail improves access for inspection and retightening plus added support to the thrust rail during operation. New swing girder bushings and girder-to-chassis shim designs offer improved access, reducing service time.

All major rope shovel structures are built with high-strength steel and rugged castings, joined and thermally stress relieved to deliver reliable operation in harsh mining conditions. Full penetration, profiled and ground welds are made at critical junctures, and MT, UT and X-ray inspections ensure weld quality. Structures are stress-relieved to prevent cracking, and white painted interiors facilitate inspection.

Both the 7495 and 7495 HF ERS models now offer a full Cat bill of materials, streamlining the parts ordering process and improving parts availability.

Technology increases efficiency

Both the 7495 and 7495 HF come standard with Product Link Elite, which transmits critical machine operating data such as utilization, location and condition via cellular or site internet connection. Added router functionality helps to protect data security. Advanced productivity tools within Product Link Elite enable a cycle segmentation algorithm, and the combined data allows for advanced analysis of productivity.

When linked with the available Cat MineStar Fleet, real-time machine tracking produces a comprehensive overview of all equipment assets to assist with fleet management and productivity. Providing real-time feedback to improve loading efficiency, available MineStar Terrain uses guidance technology and an in-cab display to deliver precise dipper position guidance. Optional MineStar Health delivers critical event-based machine condition and operating data, while its advanced diagnostic and analytic tools improve service efficiency.

The standard Operator Assist – Enhanced Motion Control simplifies machine operation to promote high production while protecting the machine. This system is designed to yield more reliable crowd rope replacement schedules, full design life for hoist ropes, reduced wear on crowd brakes and longer life for hoist gear case components.

cat 7495 electric rope shovel

HydraCrowd full adaptive control

A final piece of a multiphase enhancement initiative for HydraCrowd, a new adaptive control system (ACS) delivers up to 25 percent cost savings on the ACS valve, resulting in up to 5 percent total cost of ownership savings for the entire system. Lower initial costs, rebuildable elements and improved accessibility combine to reduce the time required for replacements. The new design increases reliability without significantly changing the HydraCrowd maintenance schedule.

The new circulation filter employs two smaller, easily accessed filters that do not require roof panel removal for replacement. More affordable than the previous single-filter design, the new configuration also reduces replacement time.

A new filter placed at the pump drive transmission improves filtration of the lubrication fluid, helping to extend the life and reliability of the system by reducing contaminants and decreasing wear. The new pump drive transmission filter assists in reducing unplanned maintenance events to decrease downtime.

Gold price rally of 2020 crushes analyst forecasts

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Gold price rally of 2020 crushes analyst forecasts

Gold had a monumental 2020 as bullion soared to multiple record highs throughout the year amid the economic uncertainties brought by the covid-19 pandemic, which helped to cap off its best annual performance in a decade.

During the past calendar year, gold prices traded at an average of $1,769.59/oz, well exceeding what most analysts were forecasting in mid-January.

According to the London Bullion Market Association’s (LBMA) annual precious metals forecast competition, analysts were forecasting the gold price to be $1,558.8/oz on average, an increase of 12% from the average price in 2019, but still short of the actual average price by over $200/oz.

DURING THE PAST CALENDAR YEAR, GOLD PRICES TRADED AT AN AVERAGE OF $1,769.59/OZ, WELL EXCEEDING WHAT MOST ANALYSTS WERE FORECASTING

Therefore, only the most bullish analysts came close to the actual figures, with Sharps Pixley’s Ross Norman taking home the first place prize with his forecast of $1,755/oz, just $14 shy of the actual price.

Taking second place was Rene Hochreiter (Noah Capital Markets/Sieberana Research Pty Ltd) with his forecast of $1,670/oz, followed in third place by Frederic Panizzutti (MKS PAMP GROUP) with his forecast of $1,636/oz.

All three analysts secured first place finishes in the 2019 survey, which saw participants under-predict gold prices by about $80.

In other precious metals, Ross Norman also snatched first place in the silver category with his forecast of $19.25/oz, close to the actual price of $20.55/oz in 2020. This was Norman’s ninth first-place finish since the survey began.

Kieran Clancy of Capital Economics took first place in platinum with his forecast of $880, which was less than $3 from the actual average.

Lastly, Bank of China’s Zhenzing Wang won the first prize in palladium by virtue of his low/high ranges of $1,610-$2,500, which were closest to the actual low/high range of $1,557-$2,781.

The four winners would each receive a 1 oz gold bar donated by MKS PAMP.

Source: LBMA

Mining.com

Filter-less air filters for industrial applications

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Filter-less air filters for industrial applications

Air-Cleaning Blowers (ACBs) new filter-less air filters ventilate, pressurize, and clean particles from even exceedingly dusty air without using any filter elements. ACBs help reduce the costs and complications of providing ventilation in industrial, commercial and residential buildings, and are ideal for use in a wide range of industries, including at scrap yards and recycling facilities, and on construction and demolition sites.

This state-of-the-art technology makes it simpler to size and use than systems with ordinary air filters and air purifiers because they have no filter elements to clog. Without clogging, ACBs provide constant and predictable airflow, air pressure, air quality, and energy consumption.

For users, having no filter media provides numerous benefits, among them no filter media to buy or maintain, bring in dry fresh air from outside by removing mist and rain, and no deferred maintenance of filter media to cause surprise consequences.

On the company’s growing success, ACBs CEO Edward Roston said, “What we have developed here at Air Cleaning Blowers is a real innovative technology that can seriously help slow down the spread of pathogens and protect the health of many people.”

According to Air Cleaning Blowers,  while they originally developed ACBs for dusty, corrosive and other harsh industrial and military conditions, they are now used in applications as diverse and challenging as an African diamond mine, electrical controls in Nucor Steel plants, dust control in a Mitsubishi food-manufacturing plant, and US military satellite-tracking trailers in the Middle East. Currently, NIOSH (the National Institute of Occupational Safety and Health) is also using them to develop systems to produce clean air to surround and protect coal miners in underground mines.

Installation and operation of the Air-Cleaning Blower is simple. As ACBs pull the ambient air through their housings, they use the particles’ own momentums to separate them from the clean air in a multi-patented, novel way. They then eject the debris back into the atmosphere from where it came, usually outdoors. They remove large or small quantities of sand, dust and other particles, big and small—even mist and rain.

ACBs are available to fit applications with airflows from 50 to 3500 CFM (in other words, from the size of a computer to that of a good-sized store or factory). ACBs can also serve as prefilters for specialized downstream filters such as HEPA, activated carbon, and the media in swamp coolers, to increase their lives and to decrease their costs of operation, as well as to blow the air to the application.

15 rescued at Peace Mine in Silobela

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15 rescued at Peace Mine in Silobela

The Ministry’s efforts to rescue 15 miners that were trapped at Peace Mine in Silobela were successful, Ministry of Mines and Mining Development Engineer, Engineer Michael Munodawafa has said.

According to Engineer Munodawafa, the Ministry has assisted in the rescuing of all 15 miners who were trapped under the gold rich mine in the southern region.

The miners according to Munodawafa were rescued safely and no injuries or death recorded.

“All 15 trapped miners have been rescued safely without any fatalities or injuries.” He said.

Accidents in the mining sector have been on the rise which led the president to recently vow to shut down  all unsafe mines.

Many miners died last year due to mine accidents.

Last month a miner died at Jena Mines also in Silobela after the tunnel he was working in collapsed.

This comes as the Zimbabwe Miners Federation together with Environmental Management Agency issued statements warning miners to be cautious when carrying out their operations.

Late last month, the Meteorological Service Department (MSD) warned illegal miners against engaging in panning activities as their shafts could collapse as the ground was unstable due to the rains.

Several gold panners have died since the start of the 2020/21 rain season following collapse of shafts due to heavy rains.

Global natural graphite output to grow 7.6% in 2021 – report

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Global natural graphite output to grow 7.6% in 2021 – report

After increasing in 2018 and 2019, global natural graphite production has been adversely affected by covid-19 in 2020, with mines being placed either under care and maintenance or temporary suspension due to lockdowns and restrictions.

According to analytics firm GlobalData, while output has declined by 15.4% to 952.6kt in 2020, it is expected that natural graphite production will increase by 7.6% in 2021 to 1,025.5kt.

China, the world’s largest producer, is expected to produce 665kt of natural graphite over the year. This represents a decline of 5% versus 2019 due to covid-19 restrictions, mainly during the first quarter of 2020 when several mines and plants had to temporarily cease production activities.

Mozambique, the second-largest producer in 2019, is expected to see graphite output fall from 100kt to 20kt, placing the country sixth overall out of world production.

“The reduction is due to the Balama graphite project operated by Australia’s Syrah Resources being suspended due to restrictions and lower EV demand, with no production at all since April 2020,” said Vinneth Bajaj, senior mining analyst at GloblaData. “The project is well-positioned to commence operations once the market conditions improve.”

Similarly, production from Brazil is expected to decline by 4.1% due to lockdowns and restrictions, which became prevalent during the second and third quarters of 2020.

Looking ahead, natural graphite production is expected to reach 1,206.6kt by 2024 – a 5.6% CAGR. According to Bajaj, this will be supported by growing demand from the electric vehicle battery segment, where graphite is a key component.

Aside from the potential restart of Balama, projects that are most likely to commence operations during the forecast period include Madagascar’s Molo graphite project (2021), Mozambique’s Montepuez and Tanzania’s Jumbo (2022).

“These projects, together with the development of Syrah Resources’ Vidalia battery anode material project, which will make it the first vertically integrated producer of natural graphite active anode material outside China, will assist in reducing China’s dominance in the sector and providing alternative sources for battery makers across the globe,” Bajaj added.

Mining.com

 

Glencore in final talks over Mopani sale

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Glencore in final talks over Mopani sale

Glencore said on Friday it was in final-stage negotiations over a potential sale of its majority stake in Mopani Copper Mines to Zambia’s mining investment arm ZCCM-IH.

Zambian state radio ZNBC earlier reported the government had concluded talks with Glencore, citing President Edgar Lungu. According to the broadcaster, a deal was likely to be signed next week.

Zambia’s state mining investment arm has been in talks to buy Glencore’s 73.1% stake in Mopani since August. ZCCM-IH currently has 10% of Mopani, with Glencore holding 73.1% and First Quantum Minerals 16.9%.

GLENCORE HAS INVESTED MORE THAN $1 BILLION IN MOPANI SINCE 2014

Glencore shelved its plans to place the operations under care and maintenance for 90 days, after Zambia threatened to revoke its mining license in April. The government strategy is driven by a need to safeguard jobs at Mopani, rather than any desire to raise its shareholding, said Barnaby Mulenga, permanent secretary in the Ministry of Mines.

On a visit to Mopani Copper Mines on Friday, Lungu said the government would ensure the mine continued to operate and no jobs would be lost.

With Zambians heading to the polls in August, President Lungu has been working to win votes in the country’s northern copper belt. The government is also in a dispute over Vedanta’s Konkola Copper Mines, which is under the control of a liquidator since May 2019. Lusaka accused Vedanta of failing to honour licence conditions, including promised investment.

Glencore has invested more than $1 billion in Mopani since 2014 – extending its life by a further 25 to 30 years.

Mopani produced 119,000 tonnes of copper in 2018.

Reuters/Mining.com

Kuvimba seeks $1 billion for 2021 acquisitions, capex

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Kuvimba seeks $1 billion for 2021 acquisitions, capex

A mining company majority owned by the Zimbabwe government and whose profits will partly be used to compensate former white commercial farmers for land confiscated two decades ago intends to raise $1 billion for acquisitions and capital expenditure.

Kuvimba Mining House Ltd., in which the government holds a 65% stake, will invest a “significant amount” of the cash raised on the Darwendale platinum project, which belongs to its Great Dyke Investments unit, according to Chief Operating Officer David Brown. About $100 million will be set aside for acquisitions and capital expenditure over the next 12 months, he said in emailed responses to questions.

KUVIMBA HAS THREE WORKING GOLD MINES PRODUCING ABOUT 300 KG OF THE METAL EACH MONTH

“We require about $1 billion to build out mines and ensure that catch-up capital is made,” he said, referring to about three years during which little investment was made into the assets. “This will be done over time.

The group, whose portfolio includes gold, nickel and platinum, will raise part of the money internally through its operations, he said. It will also issue debt.

Kuvimba is held by government pension funds and Zimbabwe’s sovereign wealth fund, Finance Minister Mthuli Ncube said in a separate interview. He denied any ownership by Kudakwashe Tagwirei, an adviser to President Emmerson Mnangagwa, who’s under U.S. sanctions for alleged corruption.

Profits from Kuvimba will be used to compensate former white commercial farmers for land confiscated two decades ago and for pension payments that are in arrears, Ncube said.

Kuvimba has three working gold mines producing about 300 kg of the metal each month and owns a nickel mine with monthly output of 550 tonnes.

The company is finalizing negotiations to acquire Metallon Gold Zimbabwe Ltd.’s Mazwoe mine. It is looking at other assets such as lithium, nickel and copper and exploring opportunities in Africa too, Brown said.

Bloomberg News

Global cobalt production capacity expected to be cash positive in 2021 – report

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Global cobalt production capacity expected to be cash positive in 2021 – report

Market analyst Roskill forecasts that cobalt’s all-in sustaining cost of production will fall by around 2% y-o-y in 2021, from $23,085/t to $22,600t.

In a recent report, Roskill explains that, as a result of this prediction, it estimates that over 98% of cobalt production capacity will be cash positive on an AISC basis, based on cobalt price circa $39,700/t.

THE DEZIWA OPERATION IN THE DRC IS EXPECTED TO REDUCE THE INDUSTRY’S OVERALL SUSTAINING COSTS

“The DRC accounts for over 70% of mined cobalt supply and any movements in cost structures there, will have a significant impact on overall cobalt cost trends,” the document reads. “Since 2018, miners have renegotiated their intermediate transportation costs from the country to South Africa. The reduction in transportation costs has resulted in falling realization (transportation) costs, which will carry through into 2021.”

Roskill points out that, after heavy investments over the past few years, major operations in the DRC have experienced a decline in sustaining capital.

As an example, it presents the case of the Deziwa operation, a joint venture between state-owned Gécamines and China Nonferrous Metal Mining Company that is targeting production of 80,000 tonnes of copper and 8,000 tonnes of cobalt per annum. The project came online in 2020 with low sustaining costs on a unit cobalt basis, and now it is expected to also reduce the industry’s overall sustaining costs.

Similarly, Roskill’s experts believe that improved operational efficiencies at significant producers such as Katanga Mining’s Kamoto mine and China Molybdenum’s Tenke Fungurume operation in Congo, and Sherritt International and General Nickel Company’s Moa mine in Cuba will lower mining costs.

Despite this positive outlook, the analyst does predict higher plant costs – which would increase processing costs – at specific operations such as Tenke Funkurume, Vale’s Voisey’s Bay mine in Canada and Goro mine in New Caledonia.

“Increases will be due to a variety of mine specific reasons,” the report states.

Mining.com

Zambezi gas to double coal production next month

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Zambezi gas to double coal production next month

THE country’s second largest coal producer, Zambezi Gas is targeting to increase output to 200 000 tonnes next month on the back of a US$3 million investment in new opencast mining equipment.

Zambezi Gas, which is producing 100 000 tonnes per month from the existing opencast pit, commissioned the new mining equipment procured from China towards the end of last year.

The latest mining equipment comprises excavators, bull dozers, water bowsers, graders and dump trucks, among others.

Speaking by telephone yesterday, the colliery’s operations director Engineer Menard Makota said as part of the preparations to ramp up production to the projected output, they were in the process of removing overburden material from the northern pit (their second opencast pit).

“The equipment arrived and was commissioned in November last year. We are at the stage where we are now removing the overburden material at the site of the second opencast pit.

“We are hopeful that because of the latest equipment, our capacity has now improved by an additional 100 000 tonnes per month and in February we’ll be ramping up production to 200 000 tonnes per month,” he said.

“The second pit will also pave way for opening of underground mine planned later in the year.”

Zambezi Gas supplies coal locally to players in the agriculture sector like tobacco and sugarcane farmers, as well as hospitals and manufacturing companies in the food industry.

It supplies 60 percent of its output to the Zimbabwe Power Company’s four thermal power stations namely, Hwange, Bulawayo Munyati and Harare.

The Matabeleland North-based firm also has a strong footprint in the export market to the north supplying customers mainly in Zambia and the Democratic Republic of Congo (DRC).

The colliery, whose 10 percent of its existing production are exports, also has a market niche in Malawi and Mozambique.

Eng Makota said their operations had been affected by the Covid-19 pandemic as Zambezi Gas was to some extent failing to procure critical raw materials across the value chain.

“In light of the Covid-19 pandemic, you will find out that our operations have not been spared from the adverse effects of the contagion.

“For instance, although the mining industry has been classified as an essential service allowing it to remain operational during lockdown; some of our suppliers during lockdown are closed for business making it difficult for us to procure mining consumables.

“At the time when borders were closed, we couldn’t go outside the country for constant business meetings with our customers as well as to cultivate new customers in the export markets,” he said.

Zambezi Gas, which owns an 8 644 hectare concession in Entuba coalfields is a wholly-owned indigenous company with over 200 million tonnes of coal reserves.

The firm is also one of Zimbabwe’s fastest growing coal mining companies with potential for more beneficiation and exports_The Chronicle

Mimosa section head of systems & compliance succumbs to Covid-19

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Mimosa section head of systems & compliance succumbs to Covid-19

Zimbabwe’s second platinum producer, Mimosa’ section Head of Systems and compliance Mr. Tinashe Mutanda died yesterday from the Corona Virus Diseases of 2019 (Covid-19) the mine’s Managing Director Mr. Fungai Makoni confirmed.

Rudairo Dickson Mapuranga

According to Makoni, Mutanda tested positive for the pandemic during the Christmas break.

“It is true that we have one of our staff who succumbed to Covid-19, he tested positive during the Christmas break,” Makoni said.

The deceased was admitted at Mater Dei Hospital in Bulawayo where he sadly passed away. His death has sparked conversations on various WhatsApp groups.

Covid-19 cases and deaths have been spiking in Zimbabwe which has resulted in the Vice President and Health Minister Dr. Constantine Guvheya Chiwenga imposing a 30-day lockdown in order to curb the spread of the virus.

To prevent the spread of COVID-19:

  1. Clean your hands often. Use soap and water, or an alcohol-based hand rub.

2. Maintain a safe distance from anyone who is coughing or sneezing.

3. Wear a mask when physical distancing is not possible.
4. Don’t touch your eyes, nose or mouth.
5. Cover your nose and mouth with your bent elbow or a tissue when you cough or sneeze.
6. Stay home if you feel unwell.
7. If you have a fever, cough and difficulty breathing, seek medical attention.
Calling in advance allows your healthcare provider to quickly direct you to the right health facility. This protects you, and prevents the spread of viruses and other infections.

Masks

Masks can help prevent the spread of the virus from the person wearing the mask to others. Masks alone do not protect against COVID-19 and should be combined with physical distancing and hand hygiene. Follow the advice provided by your local health authority.
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