Caqital Equipment News October 2018

For informed decision-making OCTOBER 2018

RIGID HAULERS: Into new terrain

PROFILE HARNESSING THE POWER OF THE

MINING TIPPERS: Moving more payloads for less

NETWORK PAGE 32

EXCAVATORS: Driving increased efficiency and productivity

CAT ENGINES POWER FLAMEPROOF MINING SOLUTIONS

Transport & logistics news 34 Top-end Ctrack solution for Time Link Cargo fleet 34 Volvo Trucks presents its future transport solution electra mining news 36 WEG Motor Scan set to change industry 37 Global debut for Sandvik's Leopard DI650 38 Goscor Compressed Air's turnkey solutions construction NEWS 39 Next Gen Cat excavators deliver more choices 40 New app for paver operators 41 New Zim dealer for Wacker Neuson mining news 42 New Hyundai R850LC-9 excavators excel in southern Africa 43 New intelligent underground mining truck from Sandvik cover 4 Cat engines power flameproof mining solutions rigid haulers 8 Into new terrain mining tippers 12 Moving more payloads for less excavators 16 Driving increased efficiency and productivity transport 20 Towards fully-electric, autonomous trucks skid steer tyres 24 Skid steer tyres - solid or pneumatic? thought leadership 28 Hidden costs behind cheap tyres profile 32 Harnessing the power of the network CONTENTS Capital Equipment News is published monthly by Crown Publications Editor: Munesu Shoko capnews@crown.co.za Advertising manager: Elmarie Stonell elmaries@crown.co.za Design: Anoonashe Shumba Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Karen Smith PO Box 140 Bedfordview 2008 Tel: (011) 622-4770 Fax: (011) 615-6108 www.crown.co.za Printed by Tandym Print The views expressed in this publication are not necessarily those of the editor or the publisher. FEATURES REGULARS Total circulation Q2 2018: 4 271

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EDITOR'S COMMENT

IS ZIMBABWE OPEN FOR BUSINESS?

T hat there has been significant change in Zimbabwe since November 2017 – following the end of Robert Mugabe’s lengthy rule and Emmerson Mnangagwa’s subsequent ascendency to the top job – is no overstatement. However, the question remains: is Zimbabwe open for business? Although the recent disputed election left a damper on the averred reformation of the ruling party, the political change has somehow boosted business confidence. The change at the top, as well as the recent appointment of technocrats to the cabinet, has encouraged a unanimous sentiment that the country may be ready for business. It is the appointment of Professor Mthuli Ncube – an economist and vice-president

of the African Development Bank – to the Finance and Economic Development portfolio that has drawn plaudits. With his proven track record in the financial sector, he is expected to bring the much-needed fiscal discipline as the new dispensation seeks to resuscitate the economy. He has also made it clear that his immediate task is to provide a stable, competitive and optimal fiscal framework. One sector that is expected to play a major role in reviving the Zimbabwean economy is the mining industry. The development of a thriving mining sector hinges on three major components: prospective geology, human resources and capital. That Zimbabwe has abundance of the first two is no point of contention – a persistent shortage of capital and a hostile legislative regime have been some of the chief deterrents to the development of the sector over the past 10 years. However, it is encouraging to see that the government is prioritising the attraction of both domestic and international investment by implementing investor-friendly policies. For example, the repeal of a controversial indigenisation law passed under former president Robert Mugabe, which limited foreign ownership of local businesses to 49%, is definitely a step in the right direction. This is a key indicator that the new government is keen on reviving the mining sector after years of reticence by foreign investors. The mining ministry reports that, with a refocus on coal and coking coal, Zimbabwe has already attracted about US$300-million of investment this year. Elsewhere, the recent US$4,2-billion deal with Cyprus-based Karo Resources to develop a platinum mine and refinery – said to be the largest investment structure in the country’s mining industry – is testimony to the renewed investor confidence. Consequently, the Chamber of Mines of Zimbabwe (COMZ) expects the mining industry to grow by 10% in 2018. COMZ forecasts that the sector will generate

about US$3,7-billion from mineral exploits during this year. This follows a successful 2017, which recorded an overall growth of 8,5%. The industry is expected to reach US$11-billion by 2022, and US$18-billion by 2030. The mining body is encouraged by the recent rise in output volumes of 10 out of 14, or 71% of key minerals in the first three months of the year compared with the same period last year. Notable increases were recorded in gold, which went up 53%, coal 46%, cobalt 13% and nickel 18%. So what does this mean for the capital equipment industry? Zimbabwe seems to be the next interesting market for the supply chain. Unlike in construction, most of the mining projects are shovel-ready. As miners seek to boost volumes and return to profitability, they understand that fleet renewal is of utmost significance. Mining contractors and their clients have deferred their fleet replacement programmes over the past 10 years, and these assets are beyond their sustainable lifecycles. As you will see in this edition of Capital Equipment News , the renewed confidence in Zimbabwe is starting to manifest, with some capital equipment suppliers reporting improved business activity this year. A case in point is Scania South Africa’s recent sale of its eight mining tippers to mining contractor, R. Davis and Co. The contractor is looking at further boosting its fleet with four more Scania tippers later this year or in early 2019. Both Scania South Africa and Scanlink, its dealer in the country, report improving business conditions in Zimbabwe. Scania expects to exceed its annual targets for the country by this month. It is encouraging to see that Zimbabwe, once regarded as an economic force in southern Africa, is on a recovery path. However, it is worthwhile to note that the economic resuscitation programme will be a long-term initiative. In the short term, solving the liquidity crunch will be key, especially for capital equipment owners who are in need of immediate access to foreign currency to be able to purchase their mission critical assets.

Munesu Shoko – Editor

capnews@crown.co.za

@CapEquipNews

CAPITAL EQUIPMENT NEWS OCTOBER 2018 2

COVER STORY

The Cat C7.1 engine, with a power range from 112 kW to 186 kW, has become the engine of choice for flameproof OEMs looking to power a wide variety of machines, utilising components from respected flameproof equipment manufacturers. CAT ® ENGINES POWER FLAMEPROOF MINING SOLUTIONS

M ining machines that are cost-effective to maintain. The Cat C7.1 engine features a full mechanical fuel system and engine governing technology, making it ideal for the flameproof mining machine market. “Barloworld Power has supplied Cat engines to the South African flameproofing sector since local OEMs began to develop flameproof machines back in the mid-1970s,” explains Venash Raghunanan, industrial sales manager at Barloworld Power, the southern African dealer for Cat power systems. “The industry has matured tremendously in the past 40 years,” he adds. “For example, in 2012 Barloworld Power was part of a multidisciplinary project team that successfully flameproofed a Cat C7 electronic engine for an underground coal mine. The flameproof Cat C7 engine powered a 4x4 Bateleur underground stone duster built by White River-based OEM, Bird Machines. This was only the fourth Cat electronic engine to be flameproofed worldwide.” Mechanical engines “However the use of electronic engines for flameproof applications was fairly working in hazardous environments, both on and below surface, need reliable, robust engines

QUICK TAKE

The Cat C7.1, with a power range from 112 kW to 186 kW, is the engine of choice for flameproof OEMs looking to power a wide variety of machines

Barloworld Power has supplied Cat engines to the South African flameproofing sector since local OEMs began to develop flameproof machines back in the mid-1970s

70's

CURRENT

The use of electronic engines for flameproof applications was short-lived and in recent years mechanical engines have once again become the standard

The recent demand for mechanically driven engines, particularly in the underground coal mining industry, is driven by the lower initial cost and better fuel economy

CAPITAL EQUIPMENT NEWS OCTOBER 2018 4

The Cat C7.1 mechanical engine has become engine of choice for flameproofing applications.

solutions,” says Raghunanan. “Today’s flameproof machines look very different and are streets ahead of the early models. That’s how far we have come.” Bird Machines designs and manufactures trackless underground mining machines from multi-purpose vehicles, dump trucks and haulers, to personnel carriers, road compactors, graders and rock breakers. Aftersales support Alwyn van Biljon, MD of Bird Machines, explains that the company's flameproof machines are predominantly used in coal mines where there is a risk of methane gas explosions. “Flameproof machines operate at lower engine surface temperatures and special precautions are taken to prevent any spark or high temperatures that could ignite in the presence of methane gas,” he says. “Cat engines are built to be used in flameproof applications and OEMs also prefer to work with Barloworld Power due to its good aftersales support and comprehensive stockholding of engines and parts.” Elgin is a market leader in the flameproofing of diesel engine-powered OEM machines and diesel engine power packs for operation in underground mining, as well as in hazardous, explosive surface areas. Elgin’s flameproof tow tractors have evolved from modified agricultural tractors with diesel engine flameproof systems to the current in-house designed and manufactured six-cylinder 4x4 automatic flameproof tractors for low and high seam coal mining applications. “We have specialised in the flameproofing of diesel powered engines and equipment for both the mining and petrochemical industries for more than 30 years,” says Peet Hartman, MD of Elgin. “The flameproofing market prefers to work with local suppliers due to parts and technical service availability.”

Elgin’s newly-designed tractor for underground coal mines, fitted with a Cat C7.1 112 kW engine.

short-lived and in recent years mechanical engines have once again become the standard due to the high cost of repairing electronic engines,” says Raghunanan. In line with this shift, Barloworld Power today offers a range of Cat mechanical engines certified for flameproofing with outputs ranging from 38 kW to 186 kW, and more if needed. The range includes the C2.2, C4.4, 3054C and the C7.1. “The recent demand for mechanically- driven engines, particularly in the underground coal mining industry, is

largely due to the significantly lower initial cost and better fuel economy of Caterpillar’s mechanical system engines,” he points out. Barloworld Power shares long-term partnerships with both Bird Machines of White River, Mpumalanga, and Elgin Flameproofing of Johannesburg. “Over many years we have worked closely with these companies on several projects and we are proud to have been at the cutting edge of significant progress in the devel- opment of flameproof mining equipment

CAPITAL EQUIPMENT NEWS OCTOBER 2018 5

COVER STORY

Safety Raghunanan adds that there has been steadily rising demand for new and refurbished flameproof machines as the South African coal mining sector grows, with Caterpillar becoming the engine of choice. “Hazardous environments drive safety behaviour and we are privileged to be associated with companies that ensure the legislation is followed. Every new project follows a rigorous sign-off procedure by applications and installation engineers employed by Barloworld Power and our customers.” Bird Machines’ Van Biljon points out that certification is required before the equipment can be used on a mine. “Legislation dictates that the complete engine system, including each engine air inlet and exhaust component, has to be designed, tested and certified according to SABS standards,” he says. Elgin Flameproofing has held the SABS quality assurance mark for the flameproofing of diesel engines since 1983. According to Hartman, all flameproof systems and components manufactured and supplied by Elgin have been tested and certified for use by approved test and inspection authorities and the relevant government departments. b

Bird Machines’ flameproof multi-purpose vehicle is powered by the 83 kW Cat 4.4 engine.

Raghunanan says Barloworld Power shares a more recent partnership with DNS Hydraulics and Engineering in Kinross, Mpumalanga, which has manufactured and repaired hydraulic systems for the mining industry since 2006. DNS’s new hydraulic trammer, designed for use in underground coal mines, is fitted with a flameproofed Cat C7.1 (162 kW) engine. Nick van Huyssteen, MD of DNS Hydraulics, is confident that the design and performance of this machine, together with the tried and tested Cat engine supported by Barloworld

Power, will make it a great success. Barloworld Power has an extensive network of branches across southern Africa offering Cat power systems, parts and service to customers in various industries. “We also provide breakdown and field service support to OEMs,” says Raghunanan. “Working closely with Caterpillar, Barloworld Power offers sound technical support from project development to sign-off, support and maintenance for units in the field, and rebuild options that minimise cost and downtime.”

CAPITAL EQUIPMENT NEWS OCTOBER 2018 6

RIGID HAULERS

Following the completion of field operation trials in Austria, the first Liebherr T236 rigid hauler has arrived in South Africa.

Into new terrain With apparent growth of the 100 t rigid hauler market – mainly driven by demand from the contract mining fraternity – Liebherr Africa is excited to enter this market segment for the first time, following the arrival of its first T236 rigid hauler, the first diesel-electric truck in this size class, writes Munesu Shoko .

most,” says Munch. Munch adds that Liebherr also urgently needed a truck to complement its excavator range. Designed to carry up to 100 metric tonnes of payload, the T236 can be ideally paired with Liebherr’s R 9100, R 9150, R 9200 or R 9250 mining excavators. Munch reasons that the T236 is ideally suited for the contract mining market because it speaks directly to lower cost per ton, increased productivity and safety, three key parameters of sheer significance to mining contractors, especially in light of the current tight operating conditions. Mining companies have spent many years ruthlessly seeking ways to reduce their operating costs. One of the measures they have implemented is supply chain optimisation. In a bid to control their costs, many miners have tightened their contractor service level agreements. For example, many mines have put a fuel cap on each and every contractor’s machine. If a machine exceeds its fuel cap, the extra fuel consumption will be deducted off the mining contractor’s certificate. Donald Hewitt, national service manager – Mining at Liebherr Africa, says probably 60-70% of mining

F ollowing the completion of field operation trials at Austria’s largest iron ore mine, Erzberg, the first Liebherr T236 rigid hauler has arrived in South Africa. This is part of the pre-series units being rolled out to selected operations across the world to further validate the truck’s capabilities before its commercial launch. Liebherr Africa intends to deploy the truck to work at a leading Northern Cape mine. Tom Munch, Director Mining, says the new 100 t offering arrives at an opportune time for Liebherr Africa. “We are working in a contract mining market. If you look at the type of equipment this group of customers requires currently, it’s mainly 100 t excavators and 100 t dump trucks. This is due to the mobility they require, given that their contracts are limited to 3-5 years at

CAPITAL EQUIPMENT NEWS OCTOBER 2018 8

contracts awarded today have a fuel cap. Previously, “wet contracts” had no limit on fuel and contractors were not so concerned by the fuel efficiency of their machines. Today, mining contractors are being forced to rank fuel consumption high up on their buying checklists. With a range of fuel-saving innovations, the T236 will surely address these woes. Lower cost per ton Abie Kriel, technical manager – Mining at Liebherr Africa, says the T236 sets a new era by becoming the first truck in the 100 t segment to utilise a diesel-electric drive system. A major talking point is Liebherr’s Litronic Plus Generation 2 drive system, which introduces the advanced Active Front End technology. Making use of electrical energy during retarding events, the drive system is able to deliver controlled engine speed, controlled decent speeds via speed control and active braking. “The Active Front End control and electric drive work in harmony to use less fuel and cause less wear on components, translating into greater cost-savings,” says Kriel. “As the first diesel-electric truck in the 100 t class to incorporate an oil immersed braking system with four-corner braking control, the T236 is geared to deliver sound reliability and performance, even in tough operating conditions.” Christopher Vorster, national sales manager – Mining at Liebherr Africa, says with its high take-off torque and continuous power-to-ground capability, the T236 is less sensitive to grade and payload variations, resulting in greater productivity. Vertical integration of Liebherr designed and manufactured components ensures that the truck’s powertrain achieves optimal system efficiency and performance throughout the full range of applications. The truck’s innovative, variable hydraulic system lowers machine parasitic losses to provide maximum power, while lowering fuel consumption when power is not required. “Powered by a Cummins QST30-C engine, the T236 reduces fuel consumption due to its low parasitic powertrain losses. Optimised energy consumption during propulsion ensures the Liebherr T236 makes efficient use of constant engine power, providing the lowest possible fuel consumption,” explains Vorster. “Efficiency is a key ingredient for a successful mining operation. This truck enables customers to enjoy unrivalled performance while

Liebherr Africa intends to deploy the truck to work at a leading Northern Cape mine.

QUICK TAKE

The first Liebherr T236 rigid hauler has arrived in South Africa as part of the pre-series units being rolled out to selected operations across the world to further validate the truck’s capabilities before its commercial launch

100 metric tonne

Designed to carry up to 100 metric tonne payload, the T236 can be ideally paired with Liebherr’s R 9100, R 9150, R 92 00 or R 9250 mining excavators

The T 236 is said to be the first truck with a diesel electric configuration in this size class

The T236 is the first diesel-electric truck to incorporate an oil immersed braking system with four-corner retarding capabilities, thereby providing reliable braking capability

CAPITAL EQUIPMENT NEWS OCTOBER 2018 9

RIGID HAULERS

TALKING POINTS

competitive trucks in this category achieve about 92 t of payload, while the T236 loads a maximum 100 t, translating into 8% more payload. This improves productivity, while lowering cost per ton. This is achieved through the truck’s clever design. Its front suspension has the same width as the rear outside wheels’ suspension. This means that the truck has a more or less square track pattern, which makes it very stable, even when it has to turn or brake on a decline where, in most instances, tyres collapse. “We run a double-wishbone suspension, which reduces the ‘Ackerman error’, meaning you have got less tyre deformation during turns,” explains Vorster. “The intelligent design allows the T236 to move more tonnes per hour by maximising payload and reducing cycle times.” Munch says one of the most interesting aspects about the diesel-electric system is the elimination of mechanical components. These are subject to normal wear and tear and will require periodic maintenance and exchange. A considerable amount of time and money can be saved compared with a conventional mechanically-driven truck. That simultaneously drives down operational costs due to less maintenance. “Mechanically-driven trucks require more maintenance through oil changes, while service life of major components is shorter compared with electric drive systems,” reasons Munch. “The electric drive has fewer major components than the mechanical drive option, and this translates into less potential failures. Fewer components also mean less maintenance, which in turn translates into higher availability and ultimately higher productivity.” Liebherr has also incorporated an array of new technologies to provide customers with a high quality rigid hauler. The T236’s Advanced Traction Control System is said to have been developed exclusively for mining truck applications. With four-wheel speed sensing capability, torque is automatically adjusted to the rear wheels to maximise traction when cornering, accelerating from a standstill position, or travelling down wet or icy roads. An anti-rollback feature is standard on the T236. Meanwhile, the in-line electrical powertrain layout minimises cable lengths, while the maintenance-free IP- 68 rated plug-and-drive power modules ensure reliable operation in all weather conditions.

“The new 100-t Liebherr T236 arrives at an opportune time for Liebherr Africa as we are working in a contract mining market. If you look at the type of equipment this group of customers requires currently, it’s mainly 100 t excavators and 100 t dump trucks.”

Tom Munch, director Mining at Liebherr Africa

“As the first diesel electric truck in the 100 t class to incorporate an oil immersed braking system with four-corner braking control, the T 236 is geared to deliver sound reliability and performance, even in tough operating conditions.”

Abie Kriel, technical manager – Mining at Liebherr Africa

“Efficiency is a key ingredient for a successful mining operation. The Liebherr T236 rigid hauler enables customers to enjoy unrivalled performance while reducing cost per ton.”

Christopher Vorster, national sales manager – Mining at Liebherr Africa

“By effective use of electrical energy during retarding events, the drive system is able to deliver controlled engine speed with almost no fuel consumption. Engine over speed events are eliminated during retard events by actively using the four-corner braking and active speed control.”

Donald Hewitt, national service manager – Mining at Liebherr Africa

More benefits abound Apart from being the only mining truck with a diesel electric drive system in the 100-t class, Munch says the T236 also sets a new era in this class size with its 100 t payload. Many of the

reducing cost per ton.” “During retard, the power generated by the wheels is used to increase parasitic energy consumption and reduce truck speed by engine friction, while controlling the engine speed anytime,” says Hewitt.

CAPITAL EQUIPMENT NEWS OCTOBER 2018 10

for each plug and drive power module. For easy service access, the alternator is remote mounted and connected to the splitter box with a drive shaft. The electrical control cabinets of the drive are in maintenance-free segregated modules, ensuring protection in the tough mining environment. The power modules only control the drive, operating with 600 Volts AC and 900 Volts on the DC link to remain in a class of low tension, while all auxiliary systems are hydraulically driven – allowing regular site electricians to work on the system. An additional benefit of the external power module grounding system in the powertrain and positive drive isolation is that it allows work to be done on the machine while the engine is running. “Safety features in the truck’s cab, such as dual-side access and incorporation of ROPS comparable to a 150 t class truck, were engineered during the initial design process, while a recessed, full-size trainer seat allows for increased visibility,” concludes Kriel. b

The T236 is the first diesel-electric truck in the 100 t class to incorporate an oil immersed braking system with four-corner braking control.

Safety and serviceability To ensure maximum safety for

starter motor and hoist system isolators as standard. In addition, it comes with an innovative drive system inhibiter, electrically interlocked grounding devices

maintenance technicians, the T236 is equipped with a double pole battery,

CAPITAL EQUIPMENT NEWS OCTOBER 2018 11

MINING TIPPERS

R. Davis and Co. has deployed Scania tippers to haul run-of-mine material from the pit to the processing plants at the Cam and Motor Gold Mine in Eiffel Flats, near Kadoma, Zimbabwe.

Moving more payloads for less

A fleet of Scania mining tippers is proving its worth to a Zimbabwean mining contractor with its overall equipment effectiveness – high availability, utilisation, productivity, quick cycle times and lower fuel consumption – allowing the contractor to haul more volumes for less, writes Munesu Shok o.

G iven that transportation, on average, accounts for 30% of total mining costs, it’s imperative that mining contractors place efficiency of their hauling gear at the summit of their priorities. Conventional thinking has always been an obstacle to identifying the most cost-effective ways and means for improvement. While mining companies are start- ing to understand implicitly that productivity carries a value, many are still not armed with the right information to make informed choices on the rewards involved. A case in point is the migration from conventional yellow metal haulers to on-road type of haulers, such as Scania’s mining tippers. While this solution has gained popularity in developed markets, local miners still need a complete paradigm shift when it comes to their selection of hauling gear, which still favours yellow metal solutions,

mainly driven by the conventional “bigger is always better” mentality. However, it’s encouraging to see that as local mines start to look for ways to reduce the gap between earnings and operating costs, they are opening up to new and cost-effective solutions. It is for this reason that R. Davis and Co., a mining contractor operating in Zimbabwe, has chosen to deploy Scania mining tippers at its gold mining project at the Cam and Motor Gold Mine, operated by Rio Zim in Eiffel Flats, near Kadoma. Having always operated yellow metal haulers, R. Davis and Co first experienced the Scania mining tipper’s capabilities when it took two G380 8x4 first generation mining tippers on hire from another Zimbabwean contractor. Since then, the management team has never looked back. This prompted the decision to invest in its own first four G410 8x4 (single-cylinder) mining tippers in June 2017,

CAPITAL EQUIPMENT NEWS OCTOBER 2018 12

R. Davis and Co., a mining contractor operating in Zimbabwe, has deployed eight Scania mining tippers at its gold mining project at the Cam and Motor Gold Mine, operated by Rio Zim in Eiffel Flats, near Kadoma

One of the most noticeable improvements has been the fuel efficiency. Consumption varies from 7,75 to 8,27 ℓ /hour on the Scania tippers, compared with 18 ℓ /hour consumed by the articulated haulers working on site

The tippers are also deployed to haul waste material to the dump, at a haul distance of 1,4 km and a climb of 70 m.

R. Davis and Co. reports that operational costs are just over 50% of the costs of operating a comparable ADT

The first four Scania tippers, in operation since June 2017, have clocked between 3 500 and 4 000 hours

The new tippers with a dual cylinder achieve a 40-second tip and return cycle compared with 55 seconds on the first four single- cylinder tippers.

“We believe that investments in mining and infrastructure development will further drive

“We are more than pleased with the performance to date. We have experienced greater fuel economy, good cycle times and minimal downtime with our Scania vehicles.”

the market in Zimbabwe. The only setback at this stage is the liquidity issue, but the country has great potential for development in the short term.” Theuns Naude, Segment Manager, Construction/ Public and Special at Scania South Africa

Mike Davis, MD of R. Davis and Co.

“The new tippers with a dual cylinder achieve a 40-second tip and return cycle compared with 55 seconds on the first four single-cylinder tippers. They also offer 1,3 m³ more payload than the older tippers.”

Daniel Perlman, MD of Scanlink

TALKING POINTS

CAPITAL EQUIPMENT NEWS OCTOBER 2018 13

MINING TIPPERS

Construction/Public and Special at Scania South Africa, tells Capital Equipment News that the client struggled with cycle times in the first place. Experts from both Scania South Africa and Scanlink visited the site late last year to look at possible areas of improvement. “We managed to slightly improve the cycle times on the single-cylinder units by increasing the oil flow pump from 80 to 100 ℓ , as well as increasing the tipping speed,” explains Naude. To further better the cycle times, R. Davis and Co. was this year introduced to Scania’s twin-cylinder mining tipper and went on to purchase four units which were delivered in August this year. “The new tippers with a dual cylinder achieve a 30-second tip and return cycle compared with 55 seconds on the first four single- cylinder tippers,” says Perlman. “They also offer 1,3 m³ more payload than the older tippers. We have also fitted them with rock ejectors to protect the rear tyres.” performance of the Scania mining tippers to date. “The performance of the vehicles has been beyond our expectations. We are currently moving 32,4 m³ per hour of product on the older Scania trucks and 33,75 m³ per hour of product on the new tippers. The vehicles run two shifts per day,” explains Nhongonhema. One of the most noticeable improvements has been the fuel efficiency. Consumption varies from 7,75 to 8,27 ℓ /hour on the Scania tippers, compared with 18 ℓ /hour with the articulated haulers working on site. Uptime and equipment availability are some of the key operational gains. “The first four Scania tippers, in operation since June 2017, have lready clocked between 3 500 and 4 000 hours and the only breakdown we experienced was that of a leaking radiator hose on one of the trucks. This was a very simple repair which Scanlink attended to timeously and efficiently as part of the warranty,” says Davis. “In a nutshell, the Scania mining tippers are performing well for us; the productivity is excellent and operational costs are just over 50% of the costs of operating a comparable ADT – so we are moving more payloads at lower running costs and much lower downtime. We are looking at further boosting our fleet with four more Scania tippers later this year or in early 2019,” adds Davis. The contractor is also looking at five-year replacement Gains abound Nhongonhema is pleased with the

“We have had many enquiries from Zimbabwe this year. Demand has been great and we expect to exceed our annual targets by October already.”

Adriaan Serfontein, Export Sales Representative at Scania South Africa

Scania and Scanlink helped the customer improve the cycle times on the single-cylinder tippers by increasing the oil flow pump from 80 to 100 ℓ .

before boosting the fleet with another four G410 8x4 (dual-cylinder) tippers delivered at the start of August this year. “R. Davis and Co. is a strategic customer for us. We first supplied them with Scania mining tippers in 2017, although they were already operating two old first generation mining tippers on hire,” explains Daniel Perlman, MD of Scanlink, Scania’s authorised distributor in Zimbabwe. “The customer was very impressed with the two Scania 8x4 irst generation mining tippers on hire. We were then able to demonstrate that with extra payload (32 t) of the mining tipper range, their cost per tonne would be even better. To date, they are operating 8 x Scania G410 8x4 mining tippers of their own,” adds Perlman. According to Mike Davis, MD of R. Davis and Co., the Scania tippers are currently deployed to haul run of mine (ROM) material from the pit to the processing plants. “We are more

than pleased with their performance to date. We have experienced greater fuel economy, good cycle times and minimal downtime with our Scania vehicles,” explains Davis. Fleet in detail R. Davis and Co. owns 18 articulated dump trucks and eight Scania mining tippers. Currently, only the eight Scania tippers and two 35 t ADTs are operating at the Cam and Motor Gold Mine project. Claudius Nhongonhema, mine manager at R. Davis and Co., explains that the Scania tippers are hauling ROM from the pit, at a pit depth of 50 m, to the processing plant, over distances of 1,6 km. The tippers are also deployed to haul waste material to the dump, at a haul distance of 1,4 km and a climb of 70 m. The first four G410 8x4s delivered last year are single-cylinder mining tippers. Theuns Naude, Segment Manager,

CAPITAL EQUIPMENT NEWS OCTOBER 2018 14

Scanlink, together with bodybuilders from Pretoria, South Africa, came to site to look at possible areas of improvement,” explains Davis. “They advised that the hydraulic pumps were under specification for the work at hand and replaced them all at no cost to R. Davis and Co. An effective solution to resolve the tipping speed was implemented timeously.” Room for growth Both Naude and Perlman believe that there is room for the Scania mining tipper solution to grow significantly as both mines and contractors seek for cost-effective hauling solutions to boost their productivity at lower operational costs. There are currently few mining operations in Zimbabwe that employ mining tippers for haulage of heavy duty ROM from the face to the processing plants. Following the benefits reported by R. Davis and Co, Perlman believes that its just a matter of time before the market starts relooking its hauling equipment. “It is a slow process, but the market is definitely starting to understand the benefits of these tippers compared with

yellow metal haulers,” says Perlman. Following a new political dispensation in the country, which has its eyes on boosting mining productivity as part of the economic resuscitation programme, Adriaan Serfontein, export sales representative at Scania South Africa, says Zimbabwe is one of the interesting export markets this year. “We have had many enquiries from Zimbabwe. Demand has been great and we expect to exceed our annual targets by October already,” says Serfontein. Zimbabwe’s mining industry is expected to grow by 10% this year, according to the Chamber of Mines of Zimbabwe (COMZ), following a successful year in 2017, with an overall growth of 8,5%. The COMZ predicts that the sector will generate US$3,7-billion in 2018. The industry is expected to reach US$11-billion by 2022, and US$18-billion by 2030. “We believe that investments in mining and infrastructure development will further drive the market in Zimbabwe. The only etback at this stage is the liquidity issue, but the country has great potential for development in the short term,” concludes Naude. b

cycles for its current range. Apart from the product, Davis is also impressed by the aftersales service from both Scania and Scanlink. “When we had issues with slow tipping speeds on the first four trucks, Scania South Africa and Mike Davis, MD of R. Davis and Co. (left), with Daniel Perlman, MD of Scanlink, Scania’s authorised distributor in Zimbabwe.

CAPITAL EQUIPMENT NEWS OCTOBER 2018 15

EXCAVATORS

Using Volvo Co-Pilot, Dig Assist allows operators to easily input job specifications and track progress to ensure the job is done right the first time, every time.

Driving increased efficiency and productivity

In recent years, R&D efforts by leading OEMs have resulted in energy- efficient and more productive excavators. The technological advancements are positively impacting fuel efficiency and improving productivity, writes Munesu Shoko .

F uel expense in owning and operating excavators is a constant and accounts for a large chunk of total machine operating costs. With the unpredictable nature of fuel prices and its absolute necessity for fleet-driven operations, most equipment owners have simply looked at how much fuel they are burning and paid the bill. In recent years, technology has changed rapid- ly, and with the addition of production data, producers can now look at their fuel efficiency (how they are using it) and know its impact to the bottom line. At the heart of the efficiency drive in today’s excavators

is the introduction of energy-efficient engines by original equipment manufacturers (OEMs.) Martijn Donkersloot, product manager, Dig Assist EMEA at Volvo Construction Equipment, says fuel can account for as much as 95% of lifetime ownership costs. “Volvo boosts fuel efficiency through a highly optimised Volvo Group engine platform and efficient Tier 4 Final technology that includes SCR and light EGR. The combination allows engines to perform at optimum levels, burn less fuel and drive down costs,” says Donkersloot. According to Steven Faucher, excavation product application

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specialist for Africa, Middle East at Caterpillar, the OEM's Next Generation excavators come with a range of features that speak directly to lower fuel consumption and increased productivity. “Firstly, all engines use electronic injection to allow more precise control of the injection, and the use of various power modes to adapt machine performance and consumption to the needs of each specific situation,” says Faucher. Faucher adds that with Cat’s New Generation excavators, engine operating RPMs have been reduced significantly. For example, with the new Cat 320 and 323 models, RPMs come at 1 650, compared with 1 700 and 1 800 on the previous models. “The injection system has also improved. Our Cat engines use high pressure fuel systems and new injectors that work to achieve lower fuel consumption. In addition, the injection system has been designed to withstand challenges often encountered in Africa and the Middle East, such as a high sulphur fuel content, as well as water and debris mixed with fuel – this can drastically reduce the life of the injectors,” says Faucher. Faucher adds that power density has increased in the new Cat Next Generation range. Most of the machines either deliver the same power rating with lower displacement, or retain the same displacement with more power. With larger turbos and reinforced components there is no compromise to equipment durability. “The engine is clearly an important element in the reduction of fuel consumption, in addition, we have redesigned our hydraulic systems to help make the most of engine power,” adds Faucher. JCB has recently launched its JS305, a 31 700 kg excavator fitted with a mechanical 6-cylinder, 7,2 ℓ JCB DieselMAX 672 engine delivering 165 Kw/224 hp of power. “Peak torque comes at 960 Nm at a low RPM of 1 300, and consequently the fine-tuning of matching the engine to the hydraulics has resulted in a very fuel efficient excavator,” explains Andrew Boyers, business development manager – Africa at JCB.

Caterpillar has introduced a Smart mode operation on its new range of excavators. The mode constantly monitors how the operator is working.

The new JCB JS305 benefits from an innovative hydraulic regeneration system which recycles oil across the cylinders for faster cycle times and reduced fuel consumption.

With the new Cat 320 and 323 models, RPMs have been reduced to 1 650, compared with 1 700 and 1 800 on the previous models

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Modern Volvo excavators all have Volvo’s ECO mode, which delivers up to 5% improvement in fuel efficiency – without any loss of performance in most operating conditions

Sophisticated electronics The introduction of sophisticated

electronics has provided new tools to increase hydraulic system efficiency. Faucher says the addition of electronics allows for better management of engines and hydraulic systems, and so the whole system is more efficient. “Since

Fuel can account for as much as 95% of lifetime ownership costs of an excavator

95%

The engine is clearly an important element in the reduction of fuel consumption

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EXCAVATORS

response. They require the operator to make a choice between saving fuel and being slow, or working hard and burn more. “Caterpillar has introduced a Smart Mode operation on its new range of Cat excavators. The mode constantly monitors how the operator is working. If the operator is working slowly and not using maximum flow, engine speed will automatically reduce slightly to save fuel, and as soon as the operator resumes fast operations, engine speed will go back to normal. The system generates about 10% incremental savings without any impact on productivity,” explains Sarignac. Enhanced hydraulic systems In addition, manufacturers have found many ways to increase the efficiency of hydraulic systems through improved valve designs and optimised work modes. According to Boyers, the JS305 has two working modes, Eco and Power. “The Eco mode offers precise, efficient excavation, resulting in significant lower fuel consumption. The JCB JS305 also benefits from an innovative hydraulic regeneration system which recycles oil across the cylinders for faster cycle times and reduced fuel consumption,” says Boyers. Donkersloot says Volvo excavators offer the latest in operating sophistication. “For example, pump flow is controlled for combined digging and swinging operations to reduce the flow loss through the overload relief valves, while maintaining digging power and maximum swing torque,” he says. Faucher says Cat’s Next Generation of excavators is equipped with electro- hydraulic (EH) valves that provide several benefits over pilot-operated valves. These include reduced pressure losses, which help reduce fuel consumption; fewer hydraulic lines on the 320 and 323 Next Generation excavators, resulting in 20% less oil required, thereby lowering long- term operating costs; and positive flow control, which puts energy where needed precisely, when needed. “Pilot lines and associated filters are no longer required and so the associated maintenance costs are eliminated. Our EH valves are combined with larger pumps to allow productivity to be maintained while the engine RPMs are reduced. Finally, EH valves allow the integration of solutions to improve job site efficiency,

“With traditional engine control systems, engine speed is constantly monitored, and if an increase in hydraulic load causes a drop in engine speed, the engine control system will deliver more fuel to get back to desired engine speed. Because there is no anticipation, the engine speed fluctuates, and the fluctuations can be quite high. If the engine speed is low, the machine could stall.”

Laurent Sarignac, excavation product marketing specialist for Africa, Middle East

Hyundai Construction Equipment’s IPC controls power depending on work environments.

at Caterpillar we manufacture both machines and engines, we can go a step further and make sure the two systems communicate,” he says. “For example, with traditional engine control systems, the engine speed is constantly monitored, and if an increase in hydraulic load causes a drop in engine speed, the engine control system will deliver more fuel to get back to the desired engine speed,” says Laurent Sarignac, excavation product marketing specialist for Africa, Middle East. “Because there is no anticipation, the engine speed fluctuates, and the fluctuations can be quite high. If engine speed is low, the machine could stall,” adds Sarignac. With the latest Cat excavators, Sarignac says the engine and hydraulic systems work together. “The hydraulic system tells the engine ahead of time to inject more fuel and how much, and this reduces fluctuations in engine speed. The engine runs at a lower speed without the risk of

stalling under load and allows for greater fuel economy,” says Sarignac. According to Donkersloot, modern Volvo excavators all come with ECO mode, which delivers up to 5% improvement in fuel efficiency – without any loss of performance in most operating conditions. It also features a stop-start engine function to reduce fuel consumption after the machine is inactive for a pre-set period. Meanwhile, Hyundai Construction Equipment’s (HCE) Intelligent Power Control (IPC) controls power depending on work environments. The mode can be selected and released on the monitor. On the excavation mode, pump flow can be easily controlled by a lever, reducing fuel consumption significantly. When it comes to work modes, Sarignac reasons that in many instances the different machine working modes have an impact on engine speed (and therefore the maximum hydraulic flow) and engine

such as Grade Assist and Payload technologies, standard on the Cat

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time, every time. “Volvo CE is the only manufacturer that offers such an upgradable and flexible solution to assist excavating. In April 2018, during Intermat Paris, Volvo CE announced that the DigAssist system could now even be upgraded to a true 3D machine control system supplied by Topcon, which is running on the Co-Pilot system,” says Donkersloot. Digitalisation to the fore The global excavator market is also witnessing rapid digitalisation, which is helping the construction industry work efficiently. As the introduction of 3D CAD ignited the digitalisation of product data and lifecycle management, augmented reality/virtual reality (AR/ VR) technologies are now accelerating digitalisation of manufacturing (Smart Factory). Today, HCE reports that it has moved significantly on its journey towards digital transformation. The digital integrity of Hyundai’s excavator, better known as Digital Twin, enables virtual validations, where many performances and requirements are simulated and the excavator can even be manufactured in virtual world. New models’ styles can be reviewed with the aid of AR/VR technologies at the early stage of development and both fuel efficiency and productivity can be evaluated with the aid of site simulation. According to Donkersloot, automation, digitalisation and energy efficiency have been identified as important focus areas in the Volvo Group’s Technology Plan. An example of digitalisation within Volvo CE is CareTrack, its very own telematics system. “CareTrack is a system that gives extensive insight into Volvo machines. By monitoring key information, the system helps to reduce fuel costs, optimise machinery and operator performance, as well as proactively manage service and maintenance; all of which result in efficiency and higher profits,” says Donkersloot. Meanwhile, Cat Connect LINK technologies, such as Cat Product Link, transmit data wirelessly from Cat machines and turn it into essential insights about location, status and productivity of the equipment – from fuel burn and payload weights to cycle times and job progress. “LINK brings together all Cat Connect technologies to help customers make timely, fact- based decisions to boost productivity,” concludes Faucher. b

“CareTrack is a system that gives extensive insight into Volvo machines. By monitoring key information, the system helps to reduce fuel costs, optimise machinery and operator performance, as well as proactively manage service and maintenance; all of which result in efficiency and higher profits.”

Martijn Donkersloot, product manager, Dig Assist at Volvo CE EMEA

Performance Series excavators,” says Faucher. Machine control systems Machine control systems, such as digging operation assisting systems, are also taking centre stage. Faucher says over the past 20 years, productivity construction only increased by 25%. He is of the view that bridging such a gap can’t be done through traditional ways. “We believe control and guidance technologies are the breakthrough that will allow our customers to achieve unprecedented levels of productivity and operator efficiency gains,” says Faucher. For example, Sarignac notes that Cat’s Grade with 2D helps operators reach the desired grade quickly and accurately. When engaged, the monitor gives the operator a visual indication of the bucket depth, eliminating the need of a grade checker. The Assist Mode automates the bucket motion. When engaged, the bucket will follow the desired depth and slope, eliminating the guess work, undercutting, overcutting and reducing the need for surveyors. “Customers can easily upgrade from 2D to Cat GRADE with 3D to create and edit designs with ease and see the front linkage’s full range of motion on a second high-resolution 254 mm touchscreen monitor. The machine automatically compensates for excavator pitch and roll caused by sloping ground conditions,” says Sarignac. “The excavator’s exact position is known by using GPS and GLONASS systems. The operator can view the digitalised model of the result right in the cab to guide him/her to perform the job without any guess work. To assist per worked hour has doubled in manufacturing. Meanwhile, over the same period, productivity in

with planning and to monitor a job site progress accurately, the system can inform the back office of what has been done to update the ‘live’ project,” adds Sarignac. Another great technology introduced by Caterpillar is Payload, an on-board weighing system to achieve precise load targets and increase load efficiency with on-the-go weighing and real- time estimates of the payload without swinging. It enables customers to track daily productivity such as truck target weights and load/cycle counts. Calibration can be performed in a matter of minutes. By combining Payload with VisionLink, production targets can be remotely managed. When it comes to automation control systems for excavators, HCE has been conducting research and development (R&D) on its Machine Control (MC), a semi-auto levelling operation system, and Machine Guidance (MG), a surveying assistant system. The performance verification shows that overall productivity increases by 30%. The two systems are also effective in additional reduction of costs, such as overhead costs. In the case of the MG system, the commercialisation process is in progress and the MG-applied machines will be launched in European, North American and South Korean markets first. In future, Hyundai will expand to other regions depending on customer demand. Elsewhere, in 2016, Volvo CE launched its latest machine control technology, Dig Assist. Designed for crawler and wheeled excavators, Dig Assist provides real-time guidance for operators. Using Volvo Co-Pilot – the award-winning in-cab interface with a 10-inch high-resolution touch screen – allows operators to easily input job specifications and track progress to ensure the job is done right the first

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