coal · 2013. 5. 15. · president, caterpillar global mining viewpoint is a publication of cat...

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

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© 2007 Caterpillar | All Rights Reserved | Printed in USA

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AEDQ0036

2007: issue 2

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Ravensworth to successSteady and straightforward approach drives

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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.


“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


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


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


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


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


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


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


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.


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


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

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westrac

p.t. traKindO

sOtreq

finninG chile

finninG canada

tOrOmOnt

c.i. walKer machinery carter machinery

ferreyrOs

finninG arGentina

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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


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


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.


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


“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


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

coal · 2013. 5. 15. · president, caterpillar global mining viewpoint is a publication of cat...

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