Surface Mining Primary Loading Tool: Selection Guide
Surface Mining Primary Loading Tool: Selection Guide
Surface Mining Primary Loading Tool: Selection Guide
Selection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Product Descriptions. . . . . . . . . . . . . . . . . . . . . . . . .5-7
Site Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Mining Methods/Techniques. . . . . . . . . . . . . . . . 13-19
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Buckets and Dippers. . . . . . . . . . . . . . . . . . . . . . . 22-23
Selection Process
Surface mining-specific needs and working face attributes are primary selection considerations. The overall goal is to maximize profit
with a loading system that meets targeted hourly production at the lowest cost-per-unit of material moved.
4
Product Descriptions
5
Product Descriptions
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Surface Mining Primary Loading Tool Selection Guide
Wheel Loaders
Large wheel loaders have grown in size over time to match Favorable Conditions
increasing off-highway and mining truck payload capacities.
They increase productivity with consistent high bucket fill • Level, dry, smooth, firm floors
factors and are used effectively as primary loading tools where • Sufficient crossfall and drainage in wet areas to minimize
mobility is paramount. In conditions common to crushed-stone tire damage
applications, wheel loaders keep loading floors clean, work
• Well-fragmented materials that minimize crowding time,
between multiple faces, and transport oversize material away
particularly in the toe-area of the cut
from loading area. Productivity remains high even when the
machines encounter face conditions such as free-flowing • Lower face profile
material or material with low angles of repose. • Multiple faces and frequent traming
These reasons, plus traditionally low owning and operating
costs, have made wheel loaders very popular in mines Unfavorable Conditions
worldwide. • Poor underfoot conditions – wet, soft, jagged
Although wheel loaders articulate at a full 40 degrees, they still • Tight load areas
need ample maneuvering room. Caution should be noted with
• Poorly shot material
wheel loaders in tight box cuts. Due to the lack of room, the
loader may grind tires and decrease their life. This occurs by
not keeping the loader moving fore and aft while making tight
maneuvers and chewing the rubber from the tread.
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Site Conditions
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Surface Mining Primary Loading Tool Selection Guide
Loading Conditions
There is no single loading tool that will do all things on all jobs; each has a definite application range in which it is regularly used and is
suitable economically. This chart shows generally accepted guidelines for matching equipment to loading conditions.
Dark Yellow – Ideal *Bench height needs to be optimized for hydraulic backhoe.
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Surface Mining Primary Loading Tool Selection Guide
Floor Conditions
Solid, flat floors are ideal for all loading systems, but changing floor conditions require a careful choice of track shoes for hydraulic
shovels and electric rope shovels, and tires for wheel loaders, that are the best fit for the operation.
Tracks
In most surface mining applications, the narrowest single Electric rope shovels and the larger hydraulic shovels rely on
grouser shoes are generally the most durable choice. In soft, support equipment, like track-type tractors or wheel dozers, to
spongy conditions, a wider shoe provides better flotation. On adequately prepare ground conditions.
jagged or rolling ground, hydraulic shovels and electric rope Most loading systems can work on pitched slopes, or pitched
shovels will often “pad” a floor by adding fines to form a stable seams, but wheel loaders typically are less effective than
loading platform. This can prevent the shovel from rocking hydraulic shovels on steeper grades. Electric rope shovels are
on the undercarriage during the loading cycle, as rocking also not well suited to work on highly pitched slopes or seams. If
significantly reduces undercarriage life and operator efficiency. floor conditions are severe (wet) or change cannot be controlled,
Wheel loaders, which do not experience these undercarriage wheel loader production may decrease. Tracked machines are
constraints, also do an excellent job of adding fines and better suited for such conditions.
filling in low areas to construct a better working surface.
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Site Conditions
ground pressure
Nominal ground pressure and gross machine weight are In general, ground pressures increase as machine size
indicators of machine flotation in poor underfoot conditions. increases. Very large machines, like electric rope shovels and
Hydraulic shovels exert approximately one-third of the ground larger scale hydraulic shovels, must have a solid sub-base to
pressure compared to similar-sized wheel loaders. operate effectively. Also, wider tracks or tires will reduce
ground pressure.
Changing floor conditions, such as rainwater or the freeze/thaw
Ground Pressures Tire or Track
cycle, must also be taken into account. Good mobility, traction,
Electric Rope Shovels* and flotation must be considered during the entire range of
conditions. The operator has the ability to adapt the face and
7295-7495 220-374 kPa (32-54.1 psi)
floor conditions for the loading tool to ensure
Hydraulic Shovels continued productivity:
6015/6015 FS-6090 FS 167-251 kPa (24-37.4 psi) • Face height
Wheel Loaders • Floor padding (adding rock fines to the floor)
988-993 345-551 kPa (50-80 psi) • Additional support units
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Surface Mining Primary Loading Tool Selection Guide
Mining Methods/Techniques
the loading process
In many ways, loading is the central part of any earthmoving process. The entire system’s productivity is governed by the loading
tool’s productivity. There are strong links to the muckpile condition upstream and the truck fleet downstream of the loading tool.
If the loading process is productive and cost-effective, the entire material moving process will be as well.
Productivity
A good indicator of material ability is the average time it takes • Loading time should take less than 16 seconds, regardless of
to fill the bucket/dipper. A proper loading tool productivity study the loading tool.
measures the four-part loading cycle: • Loading times longer than 10-16 seconds may be an indication
1. Dump that the material/muckpile is not properly conditioned for the
2. Travel empty or swing empty loading tool. It could also be an indication of the operator’s
skill level.
3. Dig
Note: Load times are averaged and will vary cycle to cycle as the
4. Travel loaded or swing loaded loading face changes. Handling oversize pieces of material or
The total cycle time is the sum of segments 1 through 4. digging the toe of a highwall will increase individual dig times.
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Mining Methods/Techniques
digging ranges
Hydraulic Backhoe
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Surface Mining Primary Loading Tool Selection Guide
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Surface Mining Primary Loading Tool Selection Guide
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Mining Methods/Techniques
PASS MATCH
Caterpillar offers a world-class range of wheel loaders, hydraulic shovels, and electric rope shovels, as well as a full line of off-
highway and mining trucks designed to work together for maximum productivity. The loading tool must be matched to the truck, with
the correct bucket/dipper size, to optimize loading cycles.
795F
MT5500 AC
3 3 – – –
Passes Passes
MT5300 AC 3 3 4 – –
Passes Passes Passes
793F, 793D
MT4400D AC
– – 3 4 –
Passes Passes
789D
MT3700 AC
– – 3 4 –
Passes Passes
785D, 785C
MT3300 AC
– – – – 3
Passes
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Surface Mining Primary Loading Tool Selection Guide
795F AC
MT5500 AC
3-4 5-6 6-7 – – – –
Passes Passes Passes
MT5300D AC 3 5 6 – – – –
Passes Passes Passes
793F, 793D
MT4400D AC
3 4 5 6 – – –
Passes Passes Passes Passes
789D
MT3700 AC
– 3-4 4 5 6 – –
Passes Passes Passes Passes
785D, 785C
MT3300 AC
– – 3 4 4-5 7-8 –
Passes Passes Passes Passes
777G
777D
– – – – 3-4 5 8
Passes Passes Passes
793F, 793D
MT4400D AC
7 – – – – – – –
Passes
789D
MT3700 AC
– 6 5 – – – – –
Passes Passes
785D, 785C
MT3300 AC
– – 4 6 – 7 – –
Passes Passes Passes
777G
777D
– – – – 3-4 4-5 4 5-6
Passes Passes Passes Passes
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Applications
Working the Face
Excavating and loading operations account for a significant All the loading tools can work these types of faces, but each
portion of total material movement costs, so it is prudent to one has its best fit. For instance, a loading tool with high digging
search for the most cost-effective approach. forces applied at an easy loading face would be a waste of
There are several types of excavating faces: capability, raising the cost-per-unit. Or a wheel loader digging in
consolidated excavation might result in low productivity and high
•
Well Fragmented – The ideal conditions for all loading tools. component wear (GET), driving up unit cost.
•
Selective Digging – Both hydraulic front shovels and hydraulic Breakout forces and digging range play a part in each machine’s
backhoes are able to selectively dig. The narrow bucket and digging ability.
ability to load anywhere in the face makes it a good selective
loading tool for extracting specific material without disturbing •
Electric Rope Shovels provide breakout forces that can
or handling unwanted material. facilitate digging of the toughest materials. However, digging
well-blasted material is preferred, as it reduces wear and tear,
•
Consolidated/Poorly Shot – Hydraulic shovels may work in this limits downtime for maintenance, extends operating life, and
situation. Other site needs may drive the selection process. In provides high rates of productivity.
some cases hydraulic shovels can even work in free digging
rock applications, such as limestone. Pre-condition is a •
Hydraulic Shovels have the ability to dig tougher materials,
certain grade of natural fractures in the deposit, such as layer partly due to the higher breakout force per length of cutting
boundaries or fissures. edge. The bucket can penetrate at the weakest spot of the
working face, which is typically the border area of individual
•
Free Flowing – Favors the wheel loader, but a hydraulic layers, and can follow the direction of the layers. These higher
backhoe could be placed on top of the pile for high production cutting forces provide better loading, particularly for material
applications with proper support equipment. This type of that is fragmented and keyed together, or material that does
material produces high fill factors and fast cycle times, not flow well into a bucket.
resulting in high productivity.
•
Wheel Loaders have adequate breakout force for all but the
toughest materials.
Selective Digging
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Surface Mining Primary Loading Tool Selection Guide
21
Buckets and Dippers
Bucket and Dipper Options
Caterpillar offers a wide range of purpose-built, high Choosing the correct bucket or dipper can:
performance buckets and dippers, each designed to function • Reduce cycle and loading times
as an integral part of the wheel loader, hydraulic shovel, and
electric rope shovel. The combination of the correct bucket or • Lower operating costs by 10 to 20 percent or more
dipper with the correct machine will provide the best possible • Eliminate unnecessary stress and fatigue for the machine,
performance in a particular application. bucket, and operator
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Surface Mining Primary Loading Tool Selection Guide
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Caterpillar Loading Solutions
The success of your operation has a lot to do with selecting the
proper loading machine. The goal is to achieve the best results
at the lowest cost. First-hand knowledge and experience in
analyzing field data and site conditions can greatly increase
efficiency and improve production.
Deciding on one machine over another is a complicated process.
Cat wheel loaders, hydraulic shovels, and electric rope shovels
offer an established reputation in the industry for quality, with
exceptionally low owning and operating costs.
AEXQ0956
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