Pala Hidraulica 6m416m
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Hydraulic Mining Shovel Agenda March, 2012
Agenda
2
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Agenda Details
3
•
Product Line Overview – Models – Specifications – Factories
•
Machine Overview – Features – Benefits – Productivity – Capacity
•
Application – Mines – Commodity – Combined with which other products
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
•
Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
•
Available Resources – Parts Identification (Where and How to look parts) – Service Information (Service Advisories, Dealer Web, etc) – Key s
•
Training (Factory)
Agenda
4
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Product Line Overview • Models • Factories • Specifications
5
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From O&K to Caterpillar Type 6 available with steam, diesel or electric drive
First hydraulic excavator RH 5
Largest hydraulic excavator worldwide RH 400
Caterpillar buys Bucyrus
1st excavator Type 16 Price: 32,500 Mark
1908 1876
1893
1930
Orenstein & Koppel AG
1976
1997
2011 2010
Hive down O&K Mining GmbH
Terex buys O&K Mining Dortmund Factory opening
6
1962
1993 1998
1930
Foundation April, 1st in Berlin
1943
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Bucyrus buys Terex Mining
Hydraulic Excavator Milestones RH 5 1 hydraulic excavator st
RH 75 Popular in quarries and mines
1962
1975 1970
RH 200 Launch at bauma fair
TriPower Launch
1981 1979
RH 400 Launch
1989
1983
1990
RH 340 No 75
1997 1999
2010 2004 RH 200 no. 100 RH 340 Launch at bauma fair
RH 60 st 1 twin-engine excavator
7
RH 300 largest hydraulic excavator worldwide: 475 tonnes
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RH 120-E Launch RH 120-C Most successful mining excavator: 217 units sold
New model names
8
Old name
New name
RH40E
6015 / 6015 FS
RH90C
6018 / 6018 FS
RH120E
6030 / 6030 FS
RH170B
6040 / 6040 FS
RH200
6050 / 6050 FS
RH340B
6060 / 6060 FS
RH400
6090 FS
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6xxx stands for hydraulic mining excavator The last three numbers indicate the payload of the HEX. For example: 6018 = 18 t payload
VERSATILITY CLASS
Product Line Overview 6015/6015 6015/6015 FS FS RH40E RH40E
RH90C RH90C
106 t / 105 t 477 / 522 kW 7.0 m³ / 7.0 m³
181 t / 177 t 858 kW 10.0 m³ / 10.0 m³
6030/6030 6030/6030 FS FS
6040/6040 6040/6040 FS FS
290 t / 287 t 1008 / 1140 kW 17.0 m³ / 16.5 m³
397 t / 397 t 1492 / 1516 kW 22.0 m³ / 22.0 m³
6050/6050 6050/6050 FS FS
6060/6060 6060/6060 FS FS
534 t / 525 t 1880 kW 28.0 m³ / 26.0 m³
565 t / 562 t 2240 kW 34.0 m³ / 34.0 m³
RH120E RH120E
PRODUCTIVITY CLASS
6018/6018 6018/6018 FS FS
RH200 RH200
RH170B RH170B
RH340B RH340B
ULTRA CLASS
6090 6090 FS FS
9
RH400 RH400
1000 t-class 3360 kW 52.0 m³
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Operating Weight Output Bucket Capacity
Payload Range 6015 / 6015 FS 12.6 tonnes (13.8 tons) 6018 / 6018 FS
Versatility Class 18 tonnes (20 tons) 30 tonnes (34 tons)
6030 / 6030 FS 6040 / 6040 FS
40 tonnes (44 tons)
Productivity Class
6050 / 6050 FS
50 tonnes (55 tons) 6060 / 6060 FS
61 tonnes (67 tons) 6090 FS
Ultra Class
10
93.6 tonnes (103 tons)
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Product Range Bucket and Drive Alternatives Model
6015
6018
6030
6040
6050
6060
6090
Weight FS Weight BH
105 t 106 t
177 t 181 t
287 t 290 t
397 t 397 t
525 t 534 t
562 t 567 t
980 t
28.0 m³ (1.65 t/m³) 7.0 m³ (1.8 t/m³)
10.0 m³ (1.8 t/m³) 16.5 m³ (1.8 t/m³) 22.0 m³ (1.8 t/m³) 26.0 m³ (1.8 t/m³) 15.0 m³ (2.0 t/m³)
Front Shovel
6.0 m³ (2.2 t/m³)
8.0 m³ (2.2 t/m³)
13.5 m³ (2.2 t/m³) 12.0 m³ (2.6 t/m³)
6.5 m³
10.0 m³ (3.0 t/m³)
20.0 m³ (2.0 t/m³) 18.0 m³ (2.4 t/m³) 15.0 m³ (2.8 t/m³)
23.0 m³ (2.0 t/m³) 21.0 m³ (2.2 t/m³) 18.0 m³ (2.6 t/m³)
34.0 m³ (1.8 t/m³)
52.0 m³ (1.8 t/m³)*
31.0 m³ (2.0 t/m³)
42.0 m³ (2.2 t/m³)*
28.0 m³ (2.2 t/m³)
45.0 m³ (2.0 t/m³)** 37.0 m³ (2.6 t/m³)*
23.0 m³ (2.6 t/m³) 21.0 m³ (3.0 t/m³) 7.0 m³ (1.4 t/m³) (on M.E. 1.8 t/m³)
Backhoe
6.0 m³ (1.8 t/m³) (on M.E. 2.2 t/m³) 4.6 m³ (2.4 t/m³) (on M.E. 3.0 t/m³)
Cummins
477 kW
Cat
522 kW
* = with CQMS or ESCO cast lip
Electric drive 11
10.0 m³ (1.8 t/m³) 17.0 m³ (1.8 t/m³) 22.0 m³ (1.8 t/m³) 28.0 m³ (1.8 t/m³) 8.5 m³ (2.2 t/m³)
15.0 m³ (2.0 t/m³)
20.0 m³ (2.0 t/m³)
12.0 m³ (2.6 t/m³)
18.0 m³ (2.2 t/m³)
28.0 m³ (2.2 t/m³)
6.5 m³
858 kW
25.0 m³ (2.4 t/m³)
1008 kW
1492 kW
1140 kW
1516 kW
** = only with ESCO cast lip
650 kW
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34.0 m³ (1.8 t/m³)
1000 kW
1880 kW
2240 kW
3360 kW
2240 kW
brightened buckets only on request (not yet designed)
1400 kW
1600 kW
1800 kW
3200 kW
Product Line Overview • Models • Factories • Specifications
12
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Manufacturing facilities around the world Caterpillar Global Mining Headquarters WISCONSIN, US
Truck Bodies
Draglines & Electric Rope Shovels
Articulated Trucks
South Milwaukee WISCONSIN, USA
RUSSIA
Mining Trucks RUSSIA
UNITED KINGDOM
Continuous Miners & Longwall PENNSYLVANIA, USA
Excavators, Wheel Loaders & Wheel Dozers
Longwall CZECH REPUBLIC
ILLINOIS, USA
Track-Type Tractors, Mining Trucks, Motor Graders & Scrapers
Highwall Miners
ILLINOIS, USA
VIRGINIA, USA
Mining Trucks MEXICO MEXICO
CHINA
Belt Systems, Idlers & Transportation
Drills TEXAS, USA
Truck Bodies
Longwall
Beckley WEST VIRGINIA, USA
Motor Graders ARKANSAS, USA
Longwall, Hard Rock Underground, & Hydraulic Shovels
Luenen / Dortmund
Hard Rock Underground THAILAND
Mining Trucks iNDIA
Truck Bodies iNDONESIA
Hard Rock Underground TASMANIA
Hard Rock Underground BRAZIL
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O&K - The Founders
Certificate of Incorporation
1876 Benno Orenstein & Arthur
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Koppel
The first products
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•
Tipping wagon
•
Narrow-gauge rails
•
Steam locomotive
•
Bucket dredger
•
Steam driven excavator
Pioneer in Excavator Design
Bucket dredger
Shovel with electric drive 16
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Steam driven shovel on rails
Excavator on a truck carriage
The 1st O&K Hydraulic Excavator
• 1962 - RH 5 – 0.5 m³ Bucket capacity – 18 t Operating weight – 60 HP Engine output
RH 5
“Raupe Hydraulik“ Eng. Crawler Hydraulic 17
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5 Bucket volume in m³ / 10
Dortmund Factory - Early Days
• •
•
Established in 1893 Built on the premises of an underground coal mine Former manufacturing of – Narrow gauge railways – Locomotives – Railway cars
18
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Dortmund Factory - 70ties and 80ties •
Manufacturing of – Railway cars – Graders – Hydraulic excavators
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Dortmund Factory - today •
Manufacturing of – Hydraulic excavators
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1997: The 1st and the largest Excavator
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ing Caterpillar
July 2011: Bucyrus International, Inc. s Caterpillar
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Manufacturing facilities Europe Dortmund, Hydraulic Shovels (6015 - 6060)
United States South Milwaukee, WI Hydraulic Shovels (6090 FS only)
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Bucyrus HEX GmbH Hydraulic mining shovel factory in Dortmund,
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Bucyrus HEX GmbH Hydraulic mining shovel factory in Dortmund, • Total area: • Under roof: • Employees Sept 2011:
25
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76,200 m² 33,500 m² approx. 700
Dortmund Factory All measurements in • Total area: 105,000 • Panopa parts logistic (outsourced): 30,000 • Caterpillar in total: 76,200 • Office 4,700 • Caterpillar under roof 33,500 • Subcontracted: 26
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
2,600
m²
Hydraulic Shovel Technology Areas Welding techn. Kinematics
Mechanics Sealing
Hydraulics
Mechatronics
Electrics
Tribology
Electronics
Fluid dynamics
Heat treatment Materials science Transmission techn. 27
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Simulation techn. Casting + Forging techn. Combustion engines
Core Competencies of Engineering • • • • •
28
Kinematics layout Structural design / FE Analysis Hydraulics Electronics System simulations
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Core Competences of Manufacturing • Heavy structural steelwork • Machining of all parts • Assembly • Testing • Commissioning
29
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Heavy Structural Steelwork •
Welding of steel plates from 25 mm up to 200 mm – Weld preparation: •
All bevels are free of corrosion, cutting slag and scale
– Heat treatment: • •
Preheating appr. 100° - 150° C Inter welding temperature < 250°C
– Welding sequence to avoid high shrinkage tension – Root welding procedure •
Gauging for full penetration welds
– Quality Control of all structural welds: • • • • •
Fusion defects Surface cracks Weld metal pore Weld undercut Surface quality
Welding workshop is certified as per DIN18800-7 – Class E (only mandatory for cranes and bridges) 30
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Outsourcing • Smaller structural steelwork of modules • Paint shop • Lubrication systems • Hose manufacturing • Parts logistics
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15 Mil. € Investment in 1999 – New manufacturing hall – New machining centre • Largest in Europe • Max. handling capacity: 100 t / 60 t
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Recent Investments •
2 CNC machining centers – Machining of track pads – Investment 800.000 € each
•
Heavy transport system – Capacity 75 t – Investment 350.000 €
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Recent Investments •
Gantry Crane – Capacity 2x 62 t – Investment 800.000 €
•
2nd Drilling and Milling Center – Capacity 65 t / 65 t – Investment 3.400.000 €
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Recent Investments •
Bevel cutting robot – High quality weld preparation – Investment 560.000 €
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Countries with Cat Hydraulic Mining Shovels
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/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Product Line Overview • Models • Factories • Specifications
37
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Specification Sheet (link)
38
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CAT 6015 & 6015 FS – Hydraulic Shovel Weight
6060 6060 FS: 6060 with LC undercarriage
106 t 105 t 113 t
Output
522 kW 477 kW
Caterpillar Cummins
Standard bucket Backhoe - short - standard Shovel:
7.0 m³ (SAE 1:1) 6.0 m³ (SAE 1:1) 7.0 m³ (SAE 2:1)
Ø-Production
900 - 1000 t/h
Granite, Ukraine
Manganese, Ghana 39
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299 Deliveries CAT 6015 & 6015 FS U.K. 13
22 (2)
Greece 2
Czech Republic 1 (1)
Sweden 1 Norway 1
Montenegro 2
Ukraine 7 (2)
Turkey 8
Israel 1
Russia 16 (2)
Kazakhstan 6 (2) Uzbekistan 12 (4) Kirghizstan 1 (1)
Spain 14 (1)
China 40 (17)
Canada 1
Algeria 1 (1)
USA 2
South Korea 3 India 3
Mexico 2 (1)
U.A.E. 8
Venezuela 3 Colombia 17 (15) Chile 9 (4)
Guine aBissau 1 Guinea 2
( ) = Deliveries in 2008-2011 Ghana 24. Oct. 402011 / Caterpillar Confidential: GREEN
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Zimbabwe 1 Tanzania 3 (3)
Dem. Rep. Nigeria Congo / WHEREVER 14 (6)THERE’S MINING 4 (2)
Zambia 1 (1)
South Africa 3 (1)
Laos 2
Jordan 14 (3)
Thailand 3 (2)
Saudi Arabia 1
Philippines 3
Yemen 2 Eritrea 3 (3)
New Caledonia 11 New Zealand 1
Egypt Singapore Indonesia 4 3 18 (1)
Papua NG 1 Australia 1
CAT 6018 & 6018 FS – Hydraulic Shovel Weight
6018
181 t 6018 FS:
Output:
Caterpillar 858 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
41
177 t
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10.0 m³ (SAE 10.0 m³ (SAE
1,400 t/h
Iron Ore, Brazil Armenia
166 Deliveries CAT 6018 & 6018FS [20 with electric drive] Canada 2 (1)
Spain 2
1
USA 6
Great Britain 19
Netherlands 1
6 (1)
Bosnia & Herzg. 1
Rep. Macedonia 1 Russia 19 (6) Bulgaria 4
Mexico 3
Kazakhstan 10 (1)
Guyana 2
S. Korea 1 Armenia 3 (2)
Mali 4
Peru 10(4)
Turkey 3
Brazil 7 (2)
Laos 2
Chile 7 (4) Argentina 1 Guinea 4
Thailand 3 (1)
Ghana 6 (6) Ivory Coast 2 (2)
Burkina Faso 1 (1)
( ) = Deliveries in 2008-11 42 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING Issue: 13. Oct. 2011
New Caledonia 1
Gabon 3(1) DR Kongo 1
New Zealand 1 South Africa 1
Tanzania 3
Libya 3
Egypt 7 (1)
India 15 (6)
CAT 6030 & 6030 FS – Hydraulic Shovel Weight
6060 6060 FS
Output:
Caterpillar 1140 kW Cummins
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
43
Gold, Canada
290 t
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287 t 1008 kW 17.0 m³ (SAE 16.5 m³ (SAE 2200 t/h
Gold, Tanzania
199 Deliveries CAT 6030 & 6030 FS [13 with electric drive] Spain Belgium Norway Bos. & Herzg. Bulgaria Russia 1 1 2 (2) 2 1 17 (15) Great Britain Finland Serbia & Kazakhstan Canada 18 (4) 1 1 Montenegro 7 (2) 8 (2) Mongolia 3 (2) 2 (2) USA 12 (2) Iran 8 (1) Mexico 3 (1)
Mali 3
Panama 8 (6)
Saudi Arabia 1 (1)
Sierra Leone 2 (2)
Venezuela 3 (1)
Jordan 2 (2)
Colombia 16 (5) Peru 2 Suriname 2 (2) Brazil 5 (5)
Niger 1 Ivory Coast 1 (1)
Egypt 4 (3) Tanzania 3 (3)
India 7 (3) Philippines 9 (2) Papua NG 2 Indonesia 12
( ) = Deliveries Burkina Faso Ghana Zambia Botswana South Africa Zimbabwe Australia in 2008-2011 3 (3) 3 (2) 1 (1) 6 (4) 1 (1) 2 13 issue 12. Okt. 2011 44 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
CAT 6040 & 6040 FS – Hydraulic Shovel Weight
6060
397 t 6060 FS
Output
Caterpillar 1516 kW Cummins
Standard bucket Backhoe (SAE 1:1) Shovel (SAE 2:1) Ø-Production
397 t
1492 kW
22.0 m³ 22.0 m³
Coal, Australia
3000 t/h
Iron ore, China 45
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95 Deliveries CAT 6040 & 6040 FS [2 with electric drive] Canada 3 (3)
Great Britain 1
Norway 1
Greece 2
Ukraine 3 (2)
Russia 3 Kazakhstan 2 (2) Mongolia 4 (4)
USA 6 (1)
Uzbekistan 2
Colombia 4 (4)
China 2 (2)
Brazil 2 (2) Chile 2
Indonesia 3 Mali 1
( ) = Deliveries in 2008 - 11; Issue 27. Sep. 2011 46
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Ghana 1
Tanzania 5 (4)
Australia 48 (15)
CAT 6050 & 6050 FS – Hydraulic Shovel Weight
6060 6060 FS
Output
Gold, Mexico
534 t
Cummins
525 t 1,880 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
28.0 m³ (SAE 26.0 m³ (SAE
3,500 t/h
Iron ore, Ukraine 47
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145 Deliveries CAT 6050 & 6050 FS [16 with electric drive] Spain 1
Great Britain 5
1
Ukraine 1 (1)
Russia 4 (2)
Canada 6 USA 15 (2)
Uzbekistan 2
Mexico 5 (3)
Indonesia 10 (2)
Venezuela 12 (1)
Papua New Guinea 18 (6)
Colombia 1 (1) Peru 1
Chile 4 (1)
Brazil 3 (1)
Mauritania 6 (6)
( ) = Deliveries in 2008-10; Issue 29. Sep. 2011 48
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Botswana 6
South Africa 16
Australia 28 (1)
CAT 6060 & 6060 FS – Hydraulic Shovel Weight
6060 6060 FS
Output
562 t
Caterpillar 2,240 kW Cummins 2,240 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
49
Coal, Australia
565 t
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34.0 m³ (SAE 34.0 m³ (SAE
4,200 t/h
Coal, Australia
111 Deliveries CAT 6060 & 6060 FS [21 with electric drive] Canada 9 (9)
Mauretania 3 (3)
Russia 1 (1)
Mongolia 2 (2)
India 5 (5)
USA 9 (1)
Indonesia 3
Colombia 3 (1)
Chile 7(4)
Australia 49 (29) Brazil 3
South Africa 12 (3)
( ) = Deliveries in 2008-2011; Issue 24. Oct. 2011 50
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D.R. Congo 4 (4)
Tanzania 1
CAT 6090 FS – Hydraulic Shovel Weight Output
1,000 t-class Cummins
Oilsand, Canada
3,280 kW
Standard bucket Shovel 2:1)
52 m³ (SAE
Ø-Production
6,000 t/h Platinum, South Africa
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11 Deliveries CAT 6090 FS [2 with electric drive] Canada 7
USA 1
South Africa 1 (1)
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Australia 2 (2)
( ) = Deliveries in 2008; Issue March 2010
Agenda
53
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
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Machine Overview – Features – Benefits – Productivity – Capacity
54
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Selection Criteria for Hydraulic Shovels
-
Cat
Cold weather packages
- Single/ Dual aircon -
Generator
- Service crane
Cummins
- Track pad width - Lighting - Access ladders Electric drive
- Oil extension - Grease container …
1. Base model - Production target - Truck size - Existing fleet
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2. Engine - Mobility - Energy cost -
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3. Attachment - FS/BH - Versatility - Flexibility - Application
4. Bucket - Density - Material - Abrasiveness
5. Options - Climate - Infrastructure - Environment
Technical Description Summary – Lay-out
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Twin Engine
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Technical Description Summary
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Technical Description Summary
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Technical Description Summary Track tensioning system
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Technical Description Summary - Rollers
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Technical Description Summary – Travel gearbox
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Technical Description Summary – Undercarriage
Rotor
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Technical Description Summary - Superstructure
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Technical Description Summary – Swing Bearing
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Technical Description Summary – Swing machinery
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Technical Description Summary – Swing circuit
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Technical Description Summary – Swing filters
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Technical Description Summary – Swing Pumps
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Technical Description Summary – PTO & Pumps Exemple on 6050 (RH200)
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Technical Description Summary – Engine mounting
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Technical Description Summary – Electric motor drive
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Technical Description Summary – PTO cooling line
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Technical Description Summary – Oil cooling
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Technical Description Summary – Fuel line
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Technical Description Summary – Air intake
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Technical Description Summary – Engine fan drive
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Technical Description Summary – Twin Diesel engines
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Technical Description Summary – Hyd oil tank
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Technical Description Summary – Shut off valves
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Technical Description Summary – CMS & PMS control
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Technical Description Summary – PMS system
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Technical Description Summary – Servo Lines
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Technical Description Summary – Servo Lines
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Technical Description Summary - Control
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Technical Description Summary - Control
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Technical Description Summary - Control
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Technical Advantages
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Technical Advantages
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Technical Advantages
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Technical Advantages
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Technical Advantages
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Technical Advantages
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Technical Advantages
94
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Technical Advantages
95
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Technical Advantages Control Blocks Position
96
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Technical Advantages Twin engine concept
97
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Technical Advantages Closed Loop Swing Circuit
98
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Machine Overview – Features – Benefits – Productivity – Capacity
99
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Features compared to the competition
100
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Machine Overview – Features – Benefits – Productivity – Capacity
101
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HEX Productivity Class
Calculation (li nk)
Twin engine design CAT, Cummins, E-drive TriPower (FS)
Twin engine design Highest engine output in class CAMP TriPower (FS) Claim: most productive HEX in class
CAT 6030 16.5 m³ 30 t
Komatsu
Hitachi
6040 22 m³ 40 t
PC 3000 15 m³ 27 t
6050 26 m³ 47 t
PC 4000 22 m³ 40 t
EX2500-6 15 m³ 27 t
6060 34 m³ 61 t
Most popular (>130 units) HEX in 500 tonne class TriPower (FS)
PC 5500 28 m³ 50 t
EX3600-6 21 m³ 38 t
By far most productive unit in 500 tonne class Decisive weight advantage vs. R996 TriPower (FS)
EX5500 27 m³ 49 t
Liebherr R 9250 15 m³ 27 t
102
Operating Weight (t)
250
R 9350 18 m³ 32 t
300
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350
R 9400 22 m³ 40 t
R 995 26.5 m³ 48 t
400
450
R 996 B 36 m³ (BH) 65 t
500
550
600
650
700
Productivity Calculation
Achievable during a production test over 4 h
103
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Productivity Calculation
• •
Long term average productivity depends on various factors: Application technique – Bench height – Truck size – Material
•
Mechanical availability – Breakdowns – Regular maintenance
•
Utilization – – – –
104
Share of travelling Share of auxiliary jobs Operator capability Truck spotting time
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Productivity Calculation
105
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Machine Overview – Features – Benefits – Productivity – Capacity
106
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Truck Loading Match
Model Tons
770 40
772 773 775 777 50
3-4
Model
6015
Cubic Meter 7.0 107
60
70
3-4
100
785
789
793
795
797
150
200
250
345
400
3-4 3-4
3-4
3-4
3-4
6018
6030
6040
6050
6060
6090
10.0
17.0
22.0
26.0
34.0
52.0
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Face Shovel Working Diagram Rock bucket SAE 2:1 16.5 m³ Boom 6.2 m Stick 4.4 m Crowd force maximum 1,370 kN max. at ground level 1,210 kN Max breakout force 920 kN
777G
Productivity: maximum 3,000 t/h average 2,200 t/h 108
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Backhoe Rock bucket SAE 1:1 17.0 m³ Boom 8.5 m Stick 4.0 m Max crowd force 880 kN Max breakout force 870 kN
109
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3,000 t/h 2,200
Surface extraction payload range Hydraulic Shovels
Electric Rope Shovels
Draglines
Payload tonnes
110
10
40
60
80
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100
120
140
160
180
200
220
240
CAT HEX and Rope Shovel Range 110
495HR 109 t
100 6090 94 t
90
Bucket / dipper capacity [t] (metric)
495HF 109 t
80
495HD 81.8 t
70 60 6060 62 t
50
395 63.5 t t
6050 47 t 40 6040 40 t
295HR 45 t
30
295HD 38 t
6030 30 t 20
Weight [t] (metric) 111
6018 18 t 0
182M 18 t 200
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400
600
800
1000
1200
1400
1600
Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
112
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Application – Mines – Commodity – Combined with which other products
113
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HEX selection criteria
- Cold weather packages
Cummins
- Single/ Dual aircon - Generator Cat
- Service crane - Track pad width - Lighting - Access ladders
Siemens / ABB
- Oil extension - Grease container …
1. Base model - Production target - Truck size - Existing fleet 114
2. Engine - Mobility - Energy cost -
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3. Attachment - Versatility - Flexibility - Application
4. Bucket - Density - Material - Abrasiveness
5. Options - Climate - Infrastructure - Environment
Bucket Capacity
•
•
•
115
Material – specific weight – abrasiveness (degree of hardfacing)
1
Different standards – SAE – CECE – PCSA – Struck capacity + heap Degree of fill – rock / grain size – humidity – “penetration resistance” – operator
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1
Backhoe = heap 1:1
2
1
Face shovel = heap 2:1
Bucket Fill Factor 100 %
RH30F BH Sand England
RH120E BH Overburden Scotland
RH30F BH Earthmoving
RH120E FS Platinum Ore Botswana
RH120E BH Iron Ore Brazil
RH120E FS Mudstone Scotland
116
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RH400 Oilsand Canada
RH200 FS Overburden South Africa
Bucket Fill Factor ≤ 100 %
RH120E BH Mudstone Scotland
RH120E BH Limestone
RH200 FS Platinum Ore South Africa
RH120E FS Platinum Zimbabwe
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RH170 BH Iron Ore Australia
RH120E FS Overburden Scotland
RH30F BH Limestone Spain
RH200 FS Sandstone England
Bucket Volume and Material Density RH120E FS 10.0 m³ Iron ore / India
RH120E FS - 15.0 m³ Overburden / UK
3.0 t/m³ x 10 m³ = 30.0 t payload
2.0 t/m³ x 15.0 m³ = 30.0 t payload
RH120E FS – 12.0 m³ Iron ore / Norway 2.5 t/m³ x 12 m³ = 30.0 t payload RH120E FS – 13.5 m³ Nickel / Botswana 2.2 t/m³ x 13.5 m³ = 28.35 t payload 118
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RH120E FS – 16.5 m³ Earthmoving / Panama 1.8 t/m³ x 16.5 m³ = 29.7 t payload
RH120E FS – 23.0 m³ Coal / Australia 1.2 t/m³ x 23 m³ = 27.6 t payload
Bucket Volume - Free Digging RH90C FS - 6.0 m³ Limestone, unblasted /
RH120E BH - 9.0 m³ Limestone, unblasted /
119
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Face Shovel or Backhoe?
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Face Shovel or Backhoe?
• •
Both configurations have their advantages and disadvantages The decision which type of attachment suits best depends on various factors – – – – –
•
Backhoe attachment is recommended for: – – –
•
Soft overburden Low bench heights Varying application conditions
Face Shovel attachment is recommended for: – – –
121
Type of material Quality of blast Bench height Mine plan Customers/Operators preference
Electric driven machines Tough digging (hard rock) High benches
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Face Shovel or Backhoe? Regional Preferences Backhoe: 7 Face Shovel: 16
Backhoe: 29 Face Shovel: 38
Backhoe: 19 Face Shovel: 43
Backhoe: 14 Face Shovel: 21 Backhoe: 1 Face Shovel: 32
Backhoe: 42 Face Shovel: 9
Backhoe: 1 Face Shovel: 16
Backhoe: 52 Face Shovel: 36
Bucyrus 100 t – 1000 t excavators Deliveries between 1990 and 2010
122
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Backhoe: 38 Face Shovel: 66
Backhoe: 1 Face Shovel: 17 Backhoe: 1 Face Shovel: 12
Backhoe: 77 Face Shovel: 32
Characteristics Loading Shovel
• • • • • • • •
123
Position in front of the face Excellent view on material to dig High bench heights Auxiliary jobs like ground cleaning High digging forces Tough digging conditions Tight loading areas Double side loading possible
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Face Shovel Operation
Hydraulic excavator • Three independent cylinder motions • All cylinder motions can be combined • Bucket can be adjusted to any position required
124
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Bench Height Loading Shovel
•
•
125
Hydraulic excavators can also work productive on low benches In some cases also working on higher benches is possible
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100% 75-80%
Rule of Thumb • Ideal bench height: 75 to 80 % of max. digging height
Face Shovel Operation
HEX working on high bench
HEX working on low bench
126
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Characteristics Backhoe • • • • • •
127
Position on top of the face Excellent view into bucket and truck body Low bench heights Auxiliary equipment necessary Double benching possible High bench heights Faster cycle time due to smaller swing angle
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Backhoe Operation
Hydraulic excavator • Three independent cylinder motions • All cylinder motions can be combined • Bucket can be adjusted to any position required
128
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Backhoe Operation
•
Backhoes are traditionally used in Overburden
•
2 different setups for using a backhoe – Backhoe on top of the bench and the truck below – Excavator and truck on the same level – Excavator and truck on different levels gains 15-20 % more production
129
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Backhoe Bench Height 20 19
Rule of thumb:
18 17 16 15
•
“Bench height = Stick (arm) length”
14 13 12 11 10 9
or
8 7 6
•
5
“Bench height = height of truck body floor” (depending on truck size)
4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10
130
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Backhoe Operation
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“Double Benching”
•
Increased bench height – appr. 1/3 below excavator level – appr. 2/3 above excavator level
• • •
132
Excavating of the higher portion first Digging of the lower portion on the way back Material needs to be lose / blasted for efficient productivity and to prevent overstressing of the attachment structure!!!
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“Double Benching”
2/3
1/3
133
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
134
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Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
135
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Hex Worldwide Fleet Distribution
136
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744 Delivered Units in excess of 200 t operating weight 6030 -
405
6040 -
89
6050 -
141
6060 -
98
6090 -
11
Issue May 2011
137
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6050 - Reported Working Hours > 65,000 Serial No 40034 40036 40037 40046 40055 40040 40061 40060 40042 40047 40057 40018 40051 40050 40035 40020
Deliv. date 02/94 10/94 02/95 03/96 07/97 05/95 09/98 08/98 09/95 04/96 11/97 10/91 09/96 09/96 12/94 12/91
40059
Working hours 103040 100775 85000 83271 79137 76822 75325 74458 74205 72848 72701 72450 70070 69591 69559 69000
Date W/h 06/10 12/09 01/09 06/10 06/10 01/09 10/09 10/09 06/10 10/09 06/10 08/06 01/09 08/08 10/09 09/05
Gold
67440
04/10
Coal
67254
12/08
Coal Platinum Coal
66389 66149 66000
02/09 01/09 01/09
Att.
Country
Customer
Site location
Kind of site
FS FS FS FS FS FS FS FS FS FS FS BH/E FS/E FS FS FS/E
Papua New Guinea Canada Canada USA Papua New Guinea Australia Papua New Guinea Papua New Guinea Australia Papua New Guinea Papua New Guinea South Africa South Africa Papua New Guinea Australia South Africa
Placer-Pacific Syncrude Fording / Coal Mountain Barrick Goldstrike Placer-Pacific Rio Tinto/Argyle Diamonds Curtain Bros. Curtain Bros. Leighton Thiess-Roche JV Thiess-Roche JV Amcoal Moolman Bros. Placer-Pacific Rio Tinto/Hamersley Iron Amcoal
Porgera t Venture Fort McMurray, AB Sparwood, BC AR Porgera t Venture Kununurra, WA Ok Tedi Mine Ok Tedi Mine Mt. Keith, WA Lihir Lihir Kleinkopje Potgietersrus Porgera t Venture Tom Price, WA Kromdraai
Gold Oil sand Coal Gold Gold Diamond Copper Copper Nickel Gold Gold Coal Platinum Gold Iron Coal
07/98
FS
Papua New Guinea
Thiess-Roche JV
Lihir
40012
07/90
FS
HBCM
40053 40063 40009
01/97 09/98 03/90
BH FS/E FS
Venezuela South Africa Canada
Carbones del Guasare Amplats Westar
138
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Mina Paso Diablo Potgietersrus Sparwood, BC
6050 - Reported Working Hours > 53,000 up to 65,000 Serial No
Deliv. date
Att.
Country
Customer
Site location
Kind of site
Working hours
Date W/h
40054
03/97
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
64769
02/09
40043
09/95
FS
Australia
Leighton
Mt. Keith, WA
Nickel
64154
06/10
40038
04/95
FS/E
South Africa
Moolman Bros.
Potgietersrus
Platinum
63290
05/04
40049
11/96
FS
USA
Hibbing Taconite
Minnesota
Iron
61710
02/09
40030
07/93
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
61131
10/06
40026
03/93
FS
Australia
Roche Bros.
KCGM Superpit, WA
Gold
60155
02/07
40031
09/93
FS
Australia
Roche / Eltin JV
Century Zinc, QLD
Zinc
59386
05/04
200072
06/00
FS
Papua New Guinea
Curtain Bros.
Ok Tedi Mine
Copper
59282
10/09
200073
06/00
FS
Papua New Guinea
Curtain Bros.
Ok Tedi Mine
Copper
59253
10/09
40015
05/91
FS
Canada
Syncrude
Fort McMurray, AB
Oil sand
59000
08/04
40002
04/89
FS
Australia
Callide Coal
Biloea, QLD
Coal
58415
07/04
200078
08/01
FS
Indonesia
PT Freeport
Grasberg , Irian Jaya
Copper
57500
06/09
200079
08/01
FS
USA
Rio Tinto / Kennecott
Bingham Canyon Mine
Copper
57500
03/10
40045
02/96
FS
Australia
BHP Billiton Iron Ore
Mt. Whaleback, WA
Iron
56437
03/07
40041
06/95
FS
Papua New Guinea
Placer-Pacific
Porgera t Venture
Gold
56319
05/04
40004
09/89
FS
Australia
Rio Tinto/Hamersley Iron
Paraburdoo, WA
Iron
56000
03/07
40033
10/93
FS
Australia
Rio Tinto/Hamersley Iron
Paraburdoo, WA
Iron
55568
10/08
40048
07/96
FS
USA
Fola Coal
Bickmore, WV
Coal
55534
03/05
40029
05/93
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
55000
12/04
40021
12/91
FS/E
South Africa
Amcoal
Kromdraai
Coal
54066
10/04
40065
08/99
FS
Australia
Argyle Diamonds
Kununurra, WA
Diamond
53223
02/09
139
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Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
140
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Company
141
Caterpillar
Joy Global
Komatsu
Hitachi
Liebherr
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Continuous Miners Diesel Transport
Truck s & Loaders
Drills
Shearers
Surface Mining Equipment Belt Systems Roof s Armored Face Conveyors
Surface Belt Systems
Surface Drills
Draglines
Rope Shovels
Highwall Miners
Hydraulic Shovels
Mining Trucks
Wheel Loaders
Dozers & Graders
Competition Underground Mining Equipment
Market Review 3Y Average Market Share, Hydraulic Mining Shovels > 100t
< 10% 10%-25% > 25% No Shipments Source: AEM Shipments from 2008 till 3Q2011, all excavators above 100t
142
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Market Review Shipments of Machines > 160t
Source: Parker Bay, Till 3Q 2011, machines above 160t
143
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Market Review Bookings and Reservations 2011/2012
Europe 20
North America 22
Asia 28
(inc. Mex & Can)
Units <5 5 -10 > 10
South America 18
Source: Bookings and Reservations 2011/2012 status December 2011
144
Russia CIS 55
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Africa 41
Australia Oceania 72
Cat Hydraulic Shovels Sold/Commodity ®
145
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Competition All values are based on the average of the machine sales in the last 3 years
6018
Liebherr
6030
R9250
Hitachi
R9350
EX1900 EX2500
Komatsu
PC2000
0
100
6040
200
300
R996
EX5500
PC4000
400
PC5500
500
146
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R9800
EX8000
PC8000
600
Operating weight (t) Source: Parker Bay, machine >160t
6090
6060
R995
EX3600
PC3000
6050
700
800
900
1000
HEX Product Vitality Comparison
147
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(#): All comments see file „Product Vitality Index“
Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
148
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CRM UPDATE
149
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NPI •
Several machine optimizations
– Reliability engineering – Mining standard compliance: MDG15 version of RH340 available, RH170, RH120 being finalized – CAMP (control and monitoring platform) + BCS III • •
•
Maintains benefits for all machines Available since 2011
New machine developments
– RH 400 ex SMIL (ongoing) – To fill gaps in product portfolio (no time frames yet) • • • • • • • •
150
6120 – new model 6080 – new model 6055 – new model 6025 – new model – introduction in late 2013/early 2014 6020 – new model – introduction in late 2013/early 2014 6018 – being phased out 6015B – replaces 6015, introduction in late 2013/early 2014 6015 – being phased out
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
151
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Available Resources • Parts Identification (Where and How to look parts) • Service Information (Service Advisories, Dealer Web Page, etc) • Key s
152
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Parts Identification and Service Information (link)
153
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WSS / PIR (link)
154
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Technical & Safety information
155
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Technical & Safety information
156
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Assembly Information (link)
157
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Available Resources • Parts Identification (Where and How to look parts) • Service Information (Service Advisories, BucyrusLink, etc) • Key s
158
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Current Resources: Mining.cat.com Surface Mining/Hydraulic Shovels Product Line Brochure (pdf) Specification Sheets (pdf) Technical Sales Presentations (ppt) Dealer Website: www.bucyrus-hex.com & www.bucyrus-hex.de “New” Dealer price Lists on: https://mining.cat.com (/Dealer Integration/Interim Pricing) “Old” Dealer Price lists on: www.bucyrus-hex.com & www.bucyrus-hex.de “OTO” Dealer price Lists on: https://mining.cat.com/sales/pricing (Access limited)
159
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Key s •
persons for: - Access to Hydraulic Shovels OTO Price Lists: Brad Sauder ([email protected])
•
Under development: – Feature/Benefits Presentation – ProMiner Training Materials
160
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s Latin America LATIN AMERICA REGION • Mario Caio Braga – Service Engineer • ([email protected]) • (+55 31 82124637)
161
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
162
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Training Factory (link)
163
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Agenda
2
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
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Agenda Details
3
•
Product Line Overview – Models – Specifications – Factories
•
Machine Overview – Features – Benefits – Productivity – Capacity
•
Application – Mines – Commodity – Combined with which other products
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•
Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
•
Available Resources – Parts Identification (Where and How to look parts) – Service Information (Service Advisories, Dealer Web, etc) – Key s
•
Training (Factory)
Agenda
4
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
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Product Line Overview • Models • Factories • Specifications
5
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From O&K to Caterpillar Type 6 available with steam, diesel or electric drive
First hydraulic excavator RH 5
Largest hydraulic excavator worldwide RH 400
Caterpillar buys Bucyrus
1st excavator Type 16 Price: 32,500 Mark
1908 1876
1893
1930
Orenstein & Koppel AG
1976
1997
2011 2010
Hive down O&K Mining GmbH
Terex buys O&K Mining Dortmund Factory opening
6
1962
1993 1998
1930
Foundation April, 1st in Berlin
1943
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Bucyrus buys Terex Mining
Hydraulic Excavator Milestones RH 5 1 hydraulic excavator st
RH 75 Popular in quarries and mines
1962
1975 1970
RH 200 Launch at bauma fair
TriPower Launch
1981 1979
RH 400 Launch
1989
1983
1990
RH 340 No 75
1997 1999
2010 2004 RH 200 no. 100 RH 340 Launch at bauma fair
RH 60 st 1 twin-engine excavator
7
RH 300 largest hydraulic excavator worldwide: 475 tonnes
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RH 120-E Launch RH 120-C Most successful mining excavator: 217 units sold
New model names
8
Old name
New name
RH40E
6015 / 6015 FS
RH90C
6018 / 6018 FS
RH120E
6030 / 6030 FS
RH170B
6040 / 6040 FS
RH200
6050 / 6050 FS
RH340B
6060 / 6060 FS
RH400
6090 FS
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6xxx stands for hydraulic mining excavator The last three numbers indicate the payload of the HEX. For example: 6018 = 18 t payload
VERSATILITY CLASS
Product Line Overview 6015/6015 6015/6015 FS FS RH40E RH40E
RH90C RH90C
106 t / 105 t 477 / 522 kW 7.0 m³ / 7.0 m³
181 t / 177 t 858 kW 10.0 m³ / 10.0 m³
6030/6030 6030/6030 FS FS
6040/6040 6040/6040 FS FS
290 t / 287 t 1008 / 1140 kW 17.0 m³ / 16.5 m³
397 t / 397 t 1492 / 1516 kW 22.0 m³ / 22.0 m³
6050/6050 6050/6050 FS FS
6060/6060 6060/6060 FS FS
534 t / 525 t 1880 kW 28.0 m³ / 26.0 m³
565 t / 562 t 2240 kW 34.0 m³ / 34.0 m³
RH120E RH120E
PRODUCTIVITY CLASS
6018/6018 6018/6018 FS FS
RH200 RH200
RH170B RH170B
RH340B RH340B
ULTRA CLASS
6090 6090 FS FS
9
RH400 RH400
1000 t-class 3360 kW 52.0 m³
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Operating Weight Output Bucket Capacity
Payload Range 6015 / 6015 FS 12.6 tonnes (13.8 tons) 6018 / 6018 FS
Versatility Class 18 tonnes (20 tons) 30 tonnes (34 tons)
6030 / 6030 FS 6040 / 6040 FS
40 tonnes (44 tons)
Productivity Class
6050 / 6050 FS
50 tonnes (55 tons) 6060 / 6060 FS
61 tonnes (67 tons) 6090 FS
Ultra Class
10
93.6 tonnes (103 tons)
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Product Range Bucket and Drive Alternatives Model
6015
6018
6030
6040
6050
6060
6090
Weight FS Weight BH
105 t 106 t
177 t 181 t
287 t 290 t
397 t 397 t
525 t 534 t
562 t 567 t
980 t
28.0 m³ (1.65 t/m³) 7.0 m³ (1.8 t/m³)
10.0 m³ (1.8 t/m³) 16.5 m³ (1.8 t/m³) 22.0 m³ (1.8 t/m³) 26.0 m³ (1.8 t/m³) 15.0 m³ (2.0 t/m³)
Front Shovel
6.0 m³ (2.2 t/m³)
8.0 m³ (2.2 t/m³)
13.5 m³ (2.2 t/m³) 12.0 m³ (2.6 t/m³)
6.5 m³
10.0 m³ (3.0 t/m³)
20.0 m³ (2.0 t/m³) 18.0 m³ (2.4 t/m³) 15.0 m³ (2.8 t/m³)
23.0 m³ (2.0 t/m³) 21.0 m³ (2.2 t/m³) 18.0 m³ (2.6 t/m³)
34.0 m³ (1.8 t/m³)
52.0 m³ (1.8 t/m³)*
31.0 m³ (2.0 t/m³)
42.0 m³ (2.2 t/m³)*
28.0 m³ (2.2 t/m³)
45.0 m³ (2.0 t/m³)** 37.0 m³ (2.6 t/m³)*
23.0 m³ (2.6 t/m³) 21.0 m³ (3.0 t/m³) 7.0 m³ (1.4 t/m³) (on M.E. 1.8 t/m³)
Backhoe
6.0 m³ (1.8 t/m³) (on M.E. 2.2 t/m³) 4.6 m³ (2.4 t/m³) (on M.E. 3.0 t/m³)
Cummins
477 kW
Cat
522 kW
* = with CQMS or ESCO cast lip
Electric drive 11
10.0 m³ (1.8 t/m³) 17.0 m³ (1.8 t/m³) 22.0 m³ (1.8 t/m³) 28.0 m³ (1.8 t/m³) 8.5 m³ (2.2 t/m³)
15.0 m³ (2.0 t/m³)
20.0 m³ (2.0 t/m³)
12.0 m³ (2.6 t/m³)
18.0 m³ (2.2 t/m³)
28.0 m³ (2.2 t/m³)
6.5 m³
858 kW
25.0 m³ (2.4 t/m³)
1008 kW
1492 kW
1140 kW
1516 kW
** = only with ESCO cast lip
650 kW
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34.0 m³ (1.8 t/m³)
1000 kW
1880 kW
2240 kW
3360 kW
2240 kW
brightened buckets only on request (not yet designed)
1400 kW
1600 kW
1800 kW
3200 kW
Product Line Overview • Models • Factories • Specifications
12
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Manufacturing facilities around the world Caterpillar Global Mining Headquarters WISCONSIN, US
Truck Bodies
Draglines & Electric Rope Shovels
Articulated Trucks
South Milwaukee WISCONSIN, USA
RUSSIA
Mining Trucks RUSSIA
UNITED KINGDOM
Continuous Miners & Longwall PENNSYLVANIA, USA
Excavators, Wheel Loaders & Wheel Dozers
Longwall CZECH REPUBLIC
ILLINOIS, USA
Track-Type Tractors, Mining Trucks, Motor Graders & Scrapers
Highwall Miners
ILLINOIS, USA
VIRGINIA, USA
Mining Trucks MEXICO MEXICO
CHINA
Belt Systems, Idlers & Transportation
Drills TEXAS, USA
Truck Bodies
Longwall
Beckley WEST VIRGINIA, USA
Motor Graders ARKANSAS, USA
Longwall, Hard Rock Underground, & Hydraulic Shovels
Luenen / Dortmund
Hard Rock Underground THAILAND
Mining Trucks iNDIA
Truck Bodies iNDONESIA
Hard Rock Underground TASMANIA
Hard Rock Underground BRAZIL
13
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O&K - The Founders
Certificate of Incorporation
1876 Benno Orenstein & Arthur
14
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Koppel
The first products
15
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•
Tipping wagon
•
Narrow-gauge rails
•
Steam locomotive
•
Bucket dredger
•
Steam driven excavator
Pioneer in Excavator Design
Bucket dredger
Shovel with electric drive 16
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Steam driven shovel on rails
Excavator on a truck carriage
The 1st O&K Hydraulic Excavator
• 1962 - RH 5 – 0.5 m³ Bucket capacity – 18 t Operating weight – 60 HP Engine output
RH 5
“Raupe Hydraulik“ Eng. Crawler Hydraulic 17
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5 Bucket volume in m³ / 10
Dortmund Factory - Early Days
• •
•
Established in 1893 Built on the premises of an underground coal mine Former manufacturing of – Narrow gauge railways – Locomotives – Railway cars
18
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Dortmund Factory - 70ties and 80ties •
Manufacturing of – Railway cars – Graders – Hydraulic excavators
19
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Dortmund Factory - today •
Manufacturing of – Hydraulic excavators
20
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1997: The 1st and the largest Excavator
21
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ing Caterpillar
July 2011: Bucyrus International, Inc. s Caterpillar
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Manufacturing facilities Europe Dortmund, Hydraulic Shovels (6015 - 6060)
United States South Milwaukee, WI Hydraulic Shovels (6090 FS only)
23
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Bucyrus HEX GmbH Hydraulic mining shovel factory in Dortmund,
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Bucyrus HEX GmbH Hydraulic mining shovel factory in Dortmund, • Total area: • Under roof: • Employees Sept 2011:
25
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76,200 m² 33,500 m² approx. 700
Dortmund Factory All measurements in • Total area: 105,000 • Panopa parts logistic (outsourced): 30,000 • Caterpillar in total: 76,200 • Office 4,700 • Caterpillar under roof 33,500 • Subcontracted: 26
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2,600
m²
Hydraulic Shovel Technology Areas Welding techn. Kinematics
Mechanics Sealing
Hydraulics
Mechatronics
Electrics
Tribology
Electronics
Fluid dynamics
Heat treatment Materials science Transmission techn. 27
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Simulation techn. Casting + Forging techn. Combustion engines
Core Competencies of Engineering • • • • •
28
Kinematics layout Structural design / FE Analysis Hydraulics Electronics System simulations
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Core Competences of Manufacturing • Heavy structural steelwork • Machining of all parts • Assembly • Testing • Commissioning
29
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Heavy Structural Steelwork •
Welding of steel plates from 25 mm up to 200 mm – Weld preparation: •
All bevels are free of corrosion, cutting slag and scale
– Heat treatment: • •
Preheating appr. 100° - 150° C Inter welding temperature < 250°C
– Welding sequence to avoid high shrinkage tension – Root welding procedure •
Gauging for full penetration welds
– Quality Control of all structural welds: • • • • •
Fusion defects Surface cracks Weld metal pore Weld undercut Surface quality
Welding workshop is certified as per DIN18800-7 – Class E (only mandatory for cranes and bridges) 30
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Outsourcing • Smaller structural steelwork of modules • Paint shop • Lubrication systems • Hose manufacturing • Parts logistics
31
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15 Mil. € Investment in 1999 – New manufacturing hall – New machining centre • Largest in Europe • Max. handling capacity: 100 t / 60 t
32
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Recent Investments •
2 CNC machining centers – Machining of track pads – Investment 800.000 € each
•
Heavy transport system – Capacity 75 t – Investment 350.000 €
33
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Recent Investments •
Gantry Crane – Capacity 2x 62 t – Investment 800.000 €
•
2nd Drilling and Milling Center – Capacity 65 t / 65 t – Investment 3.400.000 €
34
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Recent Investments •
Bevel cutting robot – High quality weld preparation – Investment 560.000 €
35
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Countries with Cat Hydraulic Mining Shovels
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Product Line Overview • Models • Factories • Specifications
37
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Specification Sheet (link)
38
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CAT 6015 & 6015 FS – Hydraulic Shovel Weight
6060 6060 FS: 6060 with LC undercarriage
106 t 105 t 113 t
Output
522 kW 477 kW
Caterpillar Cummins
Standard bucket Backhoe - short - standard Shovel:
7.0 m³ (SAE 1:1) 6.0 m³ (SAE 1:1) 7.0 m³ (SAE 2:1)
Ø-Production
900 - 1000 t/h
Granite, Ukraine
Manganese, Ghana 39
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299 Deliveries CAT 6015 & 6015 FS U.K. 13
22 (2)
Greece 2
Czech Republic 1 (1)
Sweden 1 Norway 1
Montenegro 2
Ukraine 7 (2)
Turkey 8
Israel 1
Russia 16 (2)
Kazakhstan 6 (2) Uzbekistan 12 (4) Kirghizstan 1 (1)
Spain 14 (1)
China 40 (17)
Canada 1
Algeria 1 (1)
USA 2
South Korea 3 India 3
Mexico 2 (1)
U.A.E. 8
Venezuela 3 Colombia 17 (15) Chile 9 (4)
Guine aBissau 1 Guinea 2
( ) = Deliveries in 2008-2011 Ghana 24. Oct. 402011 / Caterpillar Confidential: GREEN
8
Zimbabwe 1 Tanzania 3 (3)
Dem. Rep. Nigeria Congo / WHEREVER 14 (6)THERE’S MINING 4 (2)
Zambia 1 (1)
South Africa 3 (1)
Laos 2
Jordan 14 (3)
Thailand 3 (2)
Saudi Arabia 1
Philippines 3
Yemen 2 Eritrea 3 (3)
New Caledonia 11 New Zealand 1
Egypt Singapore Indonesia 4 3 18 (1)
Papua NG 1 Australia 1
CAT 6018 & 6018 FS – Hydraulic Shovel Weight
6018
181 t 6018 FS:
Output:
Caterpillar 858 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
41
177 t
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10.0 m³ (SAE 10.0 m³ (SAE
1,400 t/h
Iron Ore, Brazil Armenia
166 Deliveries CAT 6018 & 6018FS [20 with electric drive] Canada 2 (1)
Spain 2
1
USA 6
Great Britain 19
Netherlands 1
6 (1)
Bosnia & Herzg. 1
Rep. Macedonia 1 Russia 19 (6) Bulgaria 4
Mexico 3
Kazakhstan 10 (1)
Guyana 2
S. Korea 1 Armenia 3 (2)
Mali 4
Peru 10(4)
Turkey 3
Brazil 7 (2)
Laos 2
Chile 7 (4) Argentina 1 Guinea 4
Thailand 3 (1)
Ghana 6 (6) Ivory Coast 2 (2)
Burkina Faso 1 (1)
( ) = Deliveries in 2008-11 42 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING Issue: 13. Oct. 2011
New Caledonia 1
Gabon 3(1) DR Kongo 1
New Zealand 1 South Africa 1
Tanzania 3
Libya 3
Egypt 7 (1)
India 15 (6)
CAT 6030 & 6030 FS – Hydraulic Shovel Weight
6060 6060 FS
Output:
Caterpillar 1140 kW Cummins
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
43
Gold, Canada
290 t
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287 t 1008 kW 17.0 m³ (SAE 16.5 m³ (SAE 2200 t/h
Gold, Tanzania
199 Deliveries CAT 6030 & 6030 FS [13 with electric drive] Spain Belgium Norway Bos. & Herzg. Bulgaria Russia 1 1 2 (2) 2 1 17 (15) Great Britain Finland Serbia & Kazakhstan Canada 18 (4) 1 1 Montenegro 7 (2) 8 (2) Mongolia 3 (2) 2 (2) USA 12 (2) Iran 8 (1) Mexico 3 (1)
Mali 3
Panama 8 (6)
Saudi Arabia 1 (1)
Sierra Leone 2 (2)
Venezuela 3 (1)
Jordan 2 (2)
Colombia 16 (5) Peru 2 Suriname 2 (2) Brazil 5 (5)
Niger 1 Ivory Coast 1 (1)
Egypt 4 (3) Tanzania 3 (3)
India 7 (3) Philippines 9 (2) Papua NG 2 Indonesia 12
( ) = Deliveries Burkina Faso Ghana Zambia Botswana South Africa Zimbabwe Australia in 2008-2011 3 (3) 3 (2) 1 (1) 6 (4) 1 (1) 2 13 issue 12. Okt. 2011 44 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
CAT 6040 & 6040 FS – Hydraulic Shovel Weight
6060
397 t 6060 FS
Output
Caterpillar 1516 kW Cummins
Standard bucket Backhoe (SAE 1:1) Shovel (SAE 2:1) Ø-Production
397 t
1492 kW
22.0 m³ 22.0 m³
Coal, Australia
3000 t/h
Iron ore, China 45
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95 Deliveries CAT 6040 & 6040 FS [2 with electric drive] Canada 3 (3)
Great Britain 1
Norway 1
Greece 2
Ukraine 3 (2)
Russia 3 Kazakhstan 2 (2) Mongolia 4 (4)
USA 6 (1)
Uzbekistan 2
Colombia 4 (4)
China 2 (2)
Brazil 2 (2) Chile 2
Indonesia 3 Mali 1
( ) = Deliveries in 2008 - 11; Issue 27. Sep. 2011 46
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Ghana 1
Tanzania 5 (4)
Australia 48 (15)
CAT 6050 & 6050 FS – Hydraulic Shovel Weight
6060 6060 FS
Output
Gold, Mexico
534 t
Cummins
525 t 1,880 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
28.0 m³ (SAE 26.0 m³ (SAE
3,500 t/h
Iron ore, Ukraine 47
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145 Deliveries CAT 6050 & 6050 FS [16 with electric drive] Spain 1
Great Britain 5
1
Ukraine 1 (1)
Russia 4 (2)
Canada 6 USA 15 (2)
Uzbekistan 2
Mexico 5 (3)
Indonesia 10 (2)
Venezuela 12 (1)
Papua New Guinea 18 (6)
Colombia 1 (1) Peru 1
Chile 4 (1)
Brazil 3 (1)
Mauritania 6 (6)
( ) = Deliveries in 2008-10; Issue 29. Sep. 2011 48
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Botswana 6
South Africa 16
Australia 28 (1)
CAT 6060 & 6060 FS – Hydraulic Shovel Weight
6060 6060 FS
Output
562 t
Caterpillar 2,240 kW Cummins 2,240 kW
Standard bucket Backhoe 1:1) Shovel 2:1) Ø-Production
49
Coal, Australia
565 t
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34.0 m³ (SAE 34.0 m³ (SAE
4,200 t/h
Coal, Australia
111 Deliveries CAT 6060 & 6060 FS [21 with electric drive] Canada 9 (9)
Mauretania 3 (3)
Russia 1 (1)
Mongolia 2 (2)
India 5 (5)
USA 9 (1)
Indonesia 3
Colombia 3 (1)
Chile 7(4)
Australia 49 (29) Brazil 3
South Africa 12 (3)
( ) = Deliveries in 2008-2011; Issue 24. Oct. 2011 50
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D.R. Congo 4 (4)
Tanzania 1
CAT 6090 FS – Hydraulic Shovel Weight Output
1,000 t-class Cummins
Oilsand, Canada
3,280 kW
Standard bucket Shovel 2:1)
52 m³ (SAE
Ø-Production
6,000 t/h Platinum, South Africa
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11 Deliveries CAT 6090 FS [2 with electric drive] Canada 7
USA 1
South Africa 1 (1)
52
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Australia 2 (2)
( ) = Deliveries in 2008; Issue March 2010
Agenda
53
Product Line Overview
Machine Overview
Application
•
Market Review
•
Available Resources
•
Training (Factory)
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Machine Overview – Features – Benefits – Productivity – Capacity
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Selection Criteria for Hydraulic Shovels
-
Cat
Cold weather packages
- Single/ Dual aircon -
Generator
- Service crane
Cummins
- Track pad width - Lighting - Access ladders Electric drive
- Oil extension - Grease container …
1. Base model - Production target - Truck size - Existing fleet
55
2. Engine - Mobility - Energy cost -
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3. Attachment - FS/BH - Versatility - Flexibility - Application
4. Bucket - Density - Material - Abrasiveness
5. Options - Climate - Infrastructure - Environment
Technical Description Summary – Lay-out
56
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Twin Engine
57
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Technical Description Summary
58
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Technical Description Summary
59
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Technical Description Summary Track tensioning system
60
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Technical Description Summary - Rollers
61
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Technical Description Summary – Travel gearbox
62
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Technical Description Summary – Undercarriage
Rotor
63
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Technical Description Summary - Superstructure
64
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Technical Description Summary – Swing Bearing
65
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Technical Description Summary – Swing machinery
66
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Technical Description Summary – Swing circuit
67
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Technical Description Summary – Swing filters
68
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Technical Description Summary – Swing Pumps
69
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Technical Description Summary – PTO & Pumps Exemple on 6050 (RH200)
70
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Technical Description Summary – Engine mounting
71
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Technical Description Summary – Electric motor drive
72
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Technical Description Summary – PTO cooling line
73
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Technical Description Summary – Oil cooling
74
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Technical Description Summary – Fuel line
75
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Technical Description Summary – Air intake
76
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Technical Description Summary – Engine fan drive
77
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Technical Description Summary – Twin Diesel engines
78
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Technical Description Summary – Hyd oil tank
79
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Technical Description Summary – Shut off valves
80
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Technical Description Summary – CMS & PMS control
81
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Technical Description Summary – PMS system
82
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Technical Description Summary – Servo Lines
83
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Technical Description Summary – Servo Lines
84
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Technical Description Summary - Control
85
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Technical Description Summary - Control
86
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Technical Description Summary - Control
87
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Technical Advantages
88
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Technical Advantages
89
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Technical Advantages
90
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Technical Advantages
91
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Technical Advantages
92
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Technical Advantages
93
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Technical Advantages
94
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Technical Advantages
95
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Technical Advantages Control Blocks Position
96
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Technical Advantages Twin engine concept
97
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Technical Advantages Closed Loop Swing Circuit
98
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Machine Overview – Features – Benefits – Productivity – Capacity
99
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Features compared to the competition
100
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Machine Overview – Features – Benefits – Productivity – Capacity
101
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HEX Productivity Class
Calculation (li nk)
Twin engine design CAT, Cummins, E-drive TriPower (FS)
Twin engine design Highest engine output in class CAMP TriPower (FS) Claim: most productive HEX in class
CAT 6030 16.5 m³ 30 t
Komatsu
Hitachi
6040 22 m³ 40 t
PC 3000 15 m³ 27 t
6050 26 m³ 47 t
PC 4000 22 m³ 40 t
EX2500-6 15 m³ 27 t
6060 34 m³ 61 t
Most popular (>130 units) HEX in 500 tonne class TriPower (FS)
PC 5500 28 m³ 50 t
EX3600-6 21 m³ 38 t
By far most productive unit in 500 tonne class Decisive weight advantage vs. R996 TriPower (FS)
EX5500 27 m³ 49 t
Liebherr R 9250 15 m³ 27 t
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Operating Weight (t)
250
R 9350 18 m³ 32 t
300
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350
R 9400 22 m³ 40 t
R 995 26.5 m³ 48 t
400
450
R 996 B 36 m³ (BH) 65 t
500
550
600
650
700
Productivity Calculation
Achievable during a production test over 4 h
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Productivity Calculation
• •
Long term average productivity depends on various factors: Application technique – Bench height – Truck size – Material
•
Mechanical availability – Breakdowns – Regular maintenance
•
Utilization – – – –
104
Share of travelling Share of auxiliary jobs Operator capability Truck spotting time
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Productivity Calculation
105
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Machine Overview – Features – Benefits – Productivity – Capacity
106
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Truck Loading Match
Model Tons
770 40
772 773 775 777 50
3-4
Model
6015
Cubic Meter 7.0 107
60
70
3-4
100
785
789
793
795
797
150
200
250
345
400
3-4 3-4
3-4
3-4
3-4
6018
6030
6040
6050
6060
6090
10.0
17.0
22.0
26.0
34.0
52.0
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Face Shovel Working Diagram Rock bucket SAE 2:1 16.5 m³ Boom 6.2 m Stick 4.4 m Crowd force maximum 1,370 kN max. at ground level 1,210 kN Max breakout force 920 kN
777G
Productivity: maximum 3,000 t/h average 2,200 t/h 108
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Backhoe Rock bucket SAE 1:1 17.0 m³ Boom 8.5 m Stick 4.0 m Max crowd force 880 kN Max breakout force 870 kN
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3,000 t/h 2,200
Surface extraction payload range Hydraulic Shovels
Electric Rope Shovels
Draglines
Payload tonnes
110
10
40
60
80
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100
120
140
160
180
200
220
240
CAT HEX and Rope Shovel Range 110
495HR 109 t
100 6090 94 t
90
Bucket / dipper capacity [t] (metric)
495HF 109 t
80
495HD 81.8 t
70 60 6060 62 t
50
395 63.5 t t
6050 47 t 40 6040 40 t
295HR 45 t
30
295HD 38 t
6030 30 t 20
Weight [t] (metric) 111
6018 18 t 0
182M 18 t 200
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400
600
800
1000
1200
1400
1600
Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
112
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Application – Mines – Commodity – Combined with which other products
113
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HEX selection criteria
- Cold weather packages
Cummins
- Single/ Dual aircon - Generator Cat
- Service crane - Track pad width - Lighting - Access ladders
Siemens / ABB
- Oil extension - Grease container …
1. Base model - Production target - Truck size - Existing fleet 114
2. Engine - Mobility - Energy cost -
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3. Attachment - Versatility - Flexibility - Application
4. Bucket - Density - Material - Abrasiveness
5. Options - Climate - Infrastructure - Environment
Bucket Capacity
•
•
•
115
Material – specific weight – abrasiveness (degree of hardfacing)
1
Different standards – SAE – CECE – PCSA – Struck capacity + heap Degree of fill – rock / grain size – humidity – “penetration resistance” – operator
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1
Backhoe = heap 1:1
2
1
Face shovel = heap 2:1
Bucket Fill Factor 100 %
RH30F BH Sand England
RH120E BH Overburden Scotland
RH30F BH Earthmoving
RH120E FS Platinum Ore Botswana
RH120E BH Iron Ore Brazil
RH120E FS Mudstone Scotland
116
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RH400 Oilsand Canada
RH200 FS Overburden South Africa
Bucket Fill Factor ≤ 100 %
RH120E BH Mudstone Scotland
RH120E BH Limestone
RH200 FS Platinum Ore South Africa
RH120E FS Platinum Zimbabwe
117
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RH170 BH Iron Ore Australia
RH120E FS Overburden Scotland
RH30F BH Limestone Spain
RH200 FS Sandstone England
Bucket Volume and Material Density RH120E FS 10.0 m³ Iron ore / India
RH120E FS - 15.0 m³ Overburden / UK
3.0 t/m³ x 10 m³ = 30.0 t payload
2.0 t/m³ x 15.0 m³ = 30.0 t payload
RH120E FS – 12.0 m³ Iron ore / Norway 2.5 t/m³ x 12 m³ = 30.0 t payload RH120E FS – 13.5 m³ Nickel / Botswana 2.2 t/m³ x 13.5 m³ = 28.35 t payload 118
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RH120E FS – 16.5 m³ Earthmoving / Panama 1.8 t/m³ x 16.5 m³ = 29.7 t payload
RH120E FS – 23.0 m³ Coal / Australia 1.2 t/m³ x 23 m³ = 27.6 t payload
Bucket Volume - Free Digging RH90C FS - 6.0 m³ Limestone, unblasted /
RH120E BH - 9.0 m³ Limestone, unblasted /
119
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Face Shovel or Backhoe?
120
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Face Shovel or Backhoe?
• •
Both configurations have their advantages and disadvantages The decision which type of attachment suits best depends on various factors – – – – –
•
Backhoe attachment is recommended for: – – –
•
Soft overburden Low bench heights Varying application conditions
Face Shovel attachment is recommended for: – – –
121
Type of material Quality of blast Bench height Mine plan Customers/Operators preference
Electric driven machines Tough digging (hard rock) High benches
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Face Shovel or Backhoe? Regional Preferences Backhoe: 7 Face Shovel: 16
Backhoe: 29 Face Shovel: 38
Backhoe: 19 Face Shovel: 43
Backhoe: 14 Face Shovel: 21 Backhoe: 1 Face Shovel: 32
Backhoe: 42 Face Shovel: 9
Backhoe: 1 Face Shovel: 16
Backhoe: 52 Face Shovel: 36
Bucyrus 100 t – 1000 t excavators Deliveries between 1990 and 2010
122
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Backhoe: 38 Face Shovel: 66
Backhoe: 1 Face Shovel: 17 Backhoe: 1 Face Shovel: 12
Backhoe: 77 Face Shovel: 32
Characteristics Loading Shovel
• • • • • • • •
123
Position in front of the face Excellent view on material to dig High bench heights Auxiliary jobs like ground cleaning High digging forces Tough digging conditions Tight loading areas Double side loading possible
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Face Shovel Operation
Hydraulic excavator • Three independent cylinder motions • All cylinder motions can be combined • Bucket can be adjusted to any position required
124
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Bench Height Loading Shovel
•
•
125
Hydraulic excavators can also work productive on low benches In some cases also working on higher benches is possible
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100% 75-80%
Rule of Thumb • Ideal bench height: 75 to 80 % of max. digging height
Face Shovel Operation
HEX working on high bench
HEX working on low bench
126
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Characteristics Backhoe • • • • • •
127
Position on top of the face Excellent view into bucket and truck body Low bench heights Auxiliary equipment necessary Double benching possible High bench heights Faster cycle time due to smaller swing angle
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Backhoe Operation
Hydraulic excavator • Three independent cylinder motions • All cylinder motions can be combined • Bucket can be adjusted to any position required
128
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Backhoe Operation
•
Backhoes are traditionally used in Overburden
•
2 different setups for using a backhoe – Backhoe on top of the bench and the truck below – Excavator and truck on the same level – Excavator and truck on different levels gains 15-20 % more production
129
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Backhoe Bench Height 20 19
Rule of thumb:
18 17 16 15
•
“Bench height = Stick (arm) length”
14 13 12 11 10 9
or
8 7 6
•
5
“Bench height = height of truck body floor” (depending on truck size)
4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10
130
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Backhoe Operation
131
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“Double Benching”
•
Increased bench height – appr. 1/3 below excavator level – appr. 2/3 above excavator level
• • •
132
Excavating of the higher portion first Digging of the lower portion on the way back Material needs to be lose / blasted for efficient productivity and to prevent overstressing of the attachment structure!!!
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“Double Benching”
2/3
1/3
133
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
134
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Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
135
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Hex Worldwide Fleet Distribution
136
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744 Delivered Units in excess of 200 t operating weight 6030 -
405
6040 -
89
6050 -
141
6060 -
98
6090 -
11
Issue May 2011
137
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6050 - Reported Working Hours > 65,000 Serial No 40034 40036 40037 40046 40055 40040 40061 40060 40042 40047 40057 40018 40051 40050 40035 40020
Deliv. date 02/94 10/94 02/95 03/96 07/97 05/95 09/98 08/98 09/95 04/96 11/97 10/91 09/96 09/96 12/94 12/91
40059
Working hours 103040 100775 85000 83271 79137 76822 75325 74458 74205 72848 72701 72450 70070 69591 69559 69000
Date W/h 06/10 12/09 01/09 06/10 06/10 01/09 10/09 10/09 06/10 10/09 06/10 08/06 01/09 08/08 10/09 09/05
Gold
67440
04/10
Coal
67254
12/08
Coal Platinum Coal
66389 66149 66000
02/09 01/09 01/09
Att.
Country
Customer
Site location
Kind of site
FS FS FS FS FS FS FS FS FS FS FS BH/E FS/E FS FS FS/E
Papua New Guinea Canada Canada USA Papua New Guinea Australia Papua New Guinea Papua New Guinea Australia Papua New Guinea Papua New Guinea South Africa South Africa Papua New Guinea Australia South Africa
Placer-Pacific Syncrude Fording / Coal Mountain Barrick Goldstrike Placer-Pacific Rio Tinto/Argyle Diamonds Curtain Bros. Curtain Bros. Leighton Thiess-Roche JV Thiess-Roche JV Amcoal Moolman Bros. Placer-Pacific Rio Tinto/Hamersley Iron Amcoal
Porgera t Venture Fort McMurray, AB Sparwood, BC AR Porgera t Venture Kununurra, WA Ok Tedi Mine Ok Tedi Mine Mt. Keith, WA Lihir Lihir Kleinkopje Potgietersrus Porgera t Venture Tom Price, WA Kromdraai
Gold Oil sand Coal Gold Gold Diamond Copper Copper Nickel Gold Gold Coal Platinum Gold Iron Coal
07/98
FS
Papua New Guinea
Thiess-Roche JV
Lihir
40012
07/90
FS
HBCM
40053 40063 40009
01/97 09/98 03/90
BH FS/E FS
Venezuela South Africa Canada
Carbones del Guasare Amplats Westar
138
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Mina Paso Diablo Potgietersrus Sparwood, BC
6050 - Reported Working Hours > 53,000 up to 65,000 Serial No
Deliv. date
Att.
Country
Customer
Site location
Kind of site
Working hours
Date W/h
40054
03/97
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
64769
02/09
40043
09/95
FS
Australia
Leighton
Mt. Keith, WA
Nickel
64154
06/10
40038
04/95
FS/E
South Africa
Moolman Bros.
Potgietersrus
Platinum
63290
05/04
40049
11/96
FS
USA
Hibbing Taconite
Minnesota
Iron
61710
02/09
40030
07/93
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
61131
10/06
40026
03/93
FS
Australia
Roche Bros.
KCGM Superpit, WA
Gold
60155
02/07
40031
09/93
FS
Australia
Roche / Eltin JV
Century Zinc, QLD
Zinc
59386
05/04
200072
06/00
FS
Papua New Guinea
Curtain Bros.
Ok Tedi Mine
Copper
59282
10/09
200073
06/00
FS
Papua New Guinea
Curtain Bros.
Ok Tedi Mine
Copper
59253
10/09
40015
05/91
FS
Canada
Syncrude
Fort McMurray, AB
Oil sand
59000
08/04
40002
04/89
FS
Australia
Callide Coal
Biloea, QLD
Coal
58415
07/04
200078
08/01
FS
Indonesia
PT Freeport
Grasberg , Irian Jaya
Copper
57500
06/09
200079
08/01
FS
USA
Rio Tinto / Kennecott
Bingham Canyon Mine
Copper
57500
03/10
40045
02/96
FS
Australia
BHP Billiton Iron Ore
Mt. Whaleback, WA
Iron
56437
03/07
40041
06/95
FS
Papua New Guinea
Placer-Pacific
Porgera t Venture
Gold
56319
05/04
40004
09/89
FS
Australia
Rio Tinto/Hamersley Iron
Paraburdoo, WA
Iron
56000
03/07
40033
10/93
FS
Australia
Rio Tinto/Hamersley Iron
Paraburdoo, WA
Iron
55568
10/08
40048
07/96
FS
USA
Fola Coal
Bickmore, WV
Coal
55534
03/05
40029
05/93
FS
Venezuela
Carbones del Guasare
Mina Paso Diablo
Coal
55000
12/04
40021
12/91
FS/E
South Africa
Amcoal
Kromdraai
Coal
54066
10/04
40065
08/99
FS
Australia
Argyle Diamonds
Kununurra, WA
Diamond
53223
02/09
139
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Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
140
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Company
141
Caterpillar
Joy Global
Komatsu
Hitachi
Liebherr
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Continuous Miners Diesel Transport
Truck s & Loaders
Drills
Shearers
Surface Mining Equipment Belt Systems Roof s Armored Face Conveyors
Surface Belt Systems
Surface Drills
Draglines
Rope Shovels
Highwall Miners
Hydraulic Shovels
Mining Trucks
Wheel Loaders
Dozers & Graders
Competition Underground Mining Equipment
Market Review 3Y Average Market Share, Hydraulic Mining Shovels > 100t
< 10% 10%-25% > 25% No Shipments Source: AEM Shipments from 2008 till 3Q2011, all excavators above 100t
142
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Market Review Shipments of Machines > 160t
Source: Parker Bay, Till 3Q 2011, machines above 160t
143
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Market Review Bookings and Reservations 2011/2012
Europe 20
North America 22
Asia 28
(inc. Mex & Can)
Units <5 5 -10 > 10
South America 18
Source: Bookings and Reservations 2011/2012 status December 2011
144
Russia CIS 55
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Africa 41
Australia Oceania 72
Cat Hydraulic Shovels Sold/Commodity ®
145
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Competition All values are based on the average of the machine sales in the last 3 years
6018
Liebherr
6030
R9250
Hitachi
R9350
EX1900 EX2500
Komatsu
PC2000
0
100
6040
200
300
R996
EX5500
PC4000
400
PC5500
500
146
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R9800
EX8000
PC8000
600
Operating weight (t) Source: Parker Bay, machine >160t
6090
6060
R995
EX3600
PC3000
6050
700
800
900
1000
HEX Product Vitality Comparison
147
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(#): All comments see file „Product Vitality Index“
Market Review – Installed Base (Global and Local) – Competitors (Global and Local) – Opportunities (Global and Local)
148
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CRM UPDATE
149
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NPI •
Several machine optimizations
– Reliability engineering – Mining standard compliance: MDG15 version of RH340 available, RH170, RH120 being finalized – CAMP (control and monitoring platform) + BCS III • •
•
Maintains benefits for all machines Available since 2011
New machine developments
– RH 400 ex SMIL (ongoing) – To fill gaps in product portfolio (no time frames yet) • • • • • • • •
150
6120 – new model 6080 – new model 6055 – new model 6025 – new model – introduction in late 2013/early 2014 6020 – new model – introduction in late 2013/early 2014 6018 – being phased out 6015B – replaces 6015, introduction in late 2013/early 2014 6015 – being phased out
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
151
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Available Resources • Parts Identification (Where and How to look parts) • Service Information (Service Advisories, Dealer Web Page, etc) • Key s
152
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Parts Identification and Service Information (link)
153
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WSS / PIR (link)
154
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Technical & Safety information
155
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Technical & Safety information
156
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Assembly Information (link)
157
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Available Resources • Parts Identification (Where and How to look parts) • Service Information (Service Advisories, BucyrusLink, etc) • Key s
158
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Current Resources: Mining.cat.com Surface Mining/Hydraulic Shovels Product Line Brochure (pdf) Specification Sheets (pdf) Technical Sales Presentations (ppt) Dealer Website: www.bucyrus-hex.com & www.bucyrus-hex.de “New” Dealer price Lists on: https://mining.cat.com (/Dealer Integration/Interim Pricing) “Old” Dealer Price lists on: www.bucyrus-hex.com & www.bucyrus-hex.de “OTO” Dealer price Lists on: https://mining.cat.com/sales/pricing (Access limited)
159
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Key s •
persons for: - Access to Hydraulic Shovels OTO Price Lists: Brad Sauder ([email protected])
•
Under development: – Feature/Benefits Presentation – ProMiner Training Materials
160
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s Latin America LATIN AMERICA REGION • Mario Caio Braga – Service Engineer • ([email protected]) • (+55 31 82124637)
161
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Agenda Product Line Overview Machine Overview Application • Market Review • Available Resources • Training (Factory)
162
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Training Factory (link)
163
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