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Presentation Agenda
Introduction
Machine Descriptions
Selection Criteria
Machine Selection Process
Conclusion
Background
7
Hydraulic Mining Excavator (HMS)
Upper
Attachment
Lower
Typical HMS Deck Plan
Operator’s Cab
Engine Valves
Pump Drive
Pumps
Hydraulic Reservoir
Fuel Tank
Electric Mining Shovel (EMS)
Upper Attachment
Lower
Typical EMS Deck Plan
Hoist Gearcase
Swing Gearcase
Operator’s Cab
Electrical
Hoist Drum
Cabinets Transformers
The Work Cycle
Coasting
Decelerating
Dumping
Selection Categories
Technical
Machine Operation
Geology and Deposit Characterization
Digging and Loading
Productivity
Maintenance
Environmental Impact
Commercial Considerations
Technical
Digging Forces
Priority: High
HMS Attributes
Generates digging forces through
stick cylinder (crowd force) and
bucket tilt cylinders (breakout force)
Additional force generated from
boom cylinder (boom force)
EMS Attributes
Generates digging forces through
hoist machinery (rope or bail pull)
and crowd machinery (crowd/hoist
force)
Technical
EMS Attributes
Digging forces sustained
whether low or high in bank
Capable of maintaining dipper
penetration and material flow The electric mining shovel is
in all kinds of digging inherently more capable of
consistently generating higher
digging force.
Technical
EMS Attributes
Assembly typically takes 30-70
days
Larger and more skilled crew
required The hydraulic mining shovel has
an advantage when It comes to
erection time and crews.
Technical
Machine Weight
Priority: High
Mobility
Priority: Very High
HMS Attributes
Smaller and lighter
Relatively fast and mobile
Long propels may cause
overheating of components
EMS Attributes
Robust carbody, revolving
frame, boom and supporting
structures make it heavier
Relatively slow propel speeds The smaller size of the hydraulic
mining shovel yields a
maneuverability and mobility
advantage.
Technical
EMS Attributes
Long life and modular design
allow for retrofits
New technology upgrades are
offered in modular packages The EMS has a much longer life
expectancy, with a flexible design
that is adaptable to upgrades and
new technology.
Technical
Trail Cable
Priority: High
HMS Attributes
Most HMS are diesel powered
and do not have trail cables
The few electric powered HMS
do have trail cables
EMS Attributes
All EMS are equipped with trail
cables to provide electrical
power
Trail cables must be inspected All EMS are equipped with trail
and maintained cables, whereas most HMS are not.
Machine Operation
Cab Location
Priority: High
HMS Attributes
Typically located on the left side
of the machine
Located on the engine level
9.55 m
8.06 m
EMS Attributes
Typically located on the right
side of the machine
Located high above the mine The high position of the electric
floor, providing better visibility mining shovel cab provides greater
of haul trucks visibility and an added sense of
security for the operator.
Machine Operation
EMS Attributes 3
Four steps are typically 1 2
required to position and fill a
dipper
Operator joystick control The minimal control actions
actions are minimal required with the EMS minimize
operator fatigue, energy
consumption, and machine stress.
Machine Operation
Swing Swing
Left Right
Ergonomics HMS
Operator’s
Priority: High Cab
HMS Attributes Machinery
Typically mounted on an Deck
extension of the machinery
deck Machinery
Deck
Cab is located near sources of EMS
noise and vibration Elevated
Operator’s
Cab
EMS Attributes
Isolated above and in front of
the machinery deck and house
Spacious cab with floor to
ceiling glass for increased The elevated and isolated
visibility operator’s cab on the EMS provides
a quieter environment and
contributes to higher productivity.
Machine Operation
EMS Attributes
Has greater boom reach
Numerous digging cycles can
be executed before
repositioning is required, The HMS uses propel more often
resulting in minimized work during the digging cycle for
cycle time repositioning, increasing wear on
crawler system components.
Machine Operation
Visibility
Priority: High
HMS Attributes
Has floor-to-ceiling visibility
through the front window of the
operator’s cab
EMS Attributes
Operator is in a high location
with a clear view of the working
face in front and the mine floor
below Due to the higher location and
greater distance from the digging
face, the operator of the EMS has
a visibility advantage.
Geology and Deposit Characterization
Bench Height
Priority: High
HMS Attributes
Has a specified height reach
that is comparable to an EMS
Must work closer to the face
due to a much shorter digging
range
EMS Attributes
Has a higher boom point
sheave height and cutting
height of dipper teeth
Greater horizontal reach The size, attachment design, and
digging radius of the EMS make it
better suited for high benches.
Geology and Deposit Characterization
EMS Attributes
Begins its digging cycle at the
lowest toe point of the mining
face
The hydraulic mining shovel is
better suited for digging material
layer by layer, but this not typically
required in HPLC operations.
Geology and Deposit Characterization
EMS Attributes
Two motions are involved for
the operator to control the
cutting motion of the dipper up
a grade Both the HMS and EMS can follow
layers up a grade, but this in not
typically required in HPLC
operations.
Geology and Deposit Characterization
Material Abrasiveness
Priority: High
HMS Attributes
Lighter weight of the bucket
makes it more susceptible to
wear when working with
material classified as hard
and very hard digging
EMS Attributes
Features heavier dippers with
better wear protection for hard
and very hard digging
EMS dippers will perform better
in abrasive ground with less
downtime and lower maintenance
costs.
Geology and Deposit Characterization
Cycle Time
Priority: Very High
HMS Attributes
Theoretical cycle times are from
25 to 45 seconds per cycle
EMS Attributes
EMS cycle times are similar to
the HMS
Longer reach allows EMS to
maintain an optimal swing arc The greater reach of the EMS
while minimizing propelling provides optimal swing arcs,
resulting in reduced overall
cycle times.
Digging and Loading
Debris Removal
Priority: Low
HMS Attributes
Picking up debris from the
loading area is an easy task
EMS Attributes
Can clean the mine floor, but
not optimal use for the machine
Ancillary equipment is often
used for clean-up while the Clean-up equipment is necessary
EMS remains productive for both the HMS and EMS in HPLC
operations.
Digging and Loading
EMS Attributes
Crowd motion provides
capability to dig below ground
level and cut a downward The HMS has a slight advantage
ramp when digging downward ramps,
but it is typically not cost-effective
to use the primary loading tool in
this way.
Digging and Loading
Fill Factors
Priority: Very High
HMS Attributes Heaped
Quote bucket capacity in
“heaped” standard per Struck
SAE 2:1 or 1:1
Buckets are well-suited for
material described as easy
and medium digging
Fill factor is the ratio of actual Easy Digging 1.05 - 1.20 .95 - 1.05
1.00 - 1.15 .90 - 1.00
loose cubic yards or meters of a Medium Digging
Hard Digging .90 - 1.00 .85 - .95
material in the dipper or bucket Very Hard Digging .85 - .95 .80 - .90
compared to the dipper or
bucket’s rated volume Bucket or Dipper Fill Factor = Loose Volume Per Load
Bucket or Dipper Rated Volume
Floor Cleanup
Priority: Low
HMS Attributes
Front end maneuverability
provides excellent fills on low
faces or piles
EMS Attributes
Has a significant floor level
digging reach to remove
spillage
Both HMS and EMS have the
capability to remove spillage, yet
this ability is questionable for
HPLC mining operations.
Digging and Loading
EMS Attributes
Has a floor level digging reach
approximately the same as an
HMS of comparable capacity
Both HMS and EMS are capable
of floor level digging, but HMS
can control the tooth angle of the
bucket for a straighter cut.
Digging and Loading
Material Discharge
Priority: High
HMS Attributes
Measured discharge of bottom
dump buckets provides a
controlled flow to haul trucks
EMS Attributes
Material being off-loaded from
the dipper slides down the
sloped dipper bottom into the
haul truck load box Both HMS and EMS discharge
material in a comparable fashion,
yet control is greater with a
hydraulic shovel.
Digging and Loading
Proximity to Face
Priority: High
HMS Attributes
Low horizontal reach high in
the bank Bucket/Dipper Digging Radius
Capacity HMS EMS
More susceptible to hits from
falling bank sections and rocks 33.0 yd3 (25.2m3) 16.5m 21m
46.0 yd3 (35.2m3) 17.5m 24m
57.0 yd3 (43.6m3) 17.5m 24m
EMS Attributes
Works effectively at a greater
distance from the bank face
The safety and ease of operation
Working position provides a provided by an EMS digging farther
better view for the operator from the bank face is often cited by
operators as the reason they prefer
this machine.
Digging and Loading
Reach
Priority: Very High
EMS Attributes
Has the ability to rip upward
with the forward motion of the
hoist and the retract motion of
the crowd to remove floor Removal procedures for boulders
obstructions or toe sections are the same for
HMS and EMS (must be ripped or
pried upward).
Digging and Loading
Truck Compatibility
Priority: Very High
Truck Loading
Priority: Very High
Working Dimensions
Priority: High
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Operator Position
Tail Swing
Truck Truck
Spotting Spotting
Tolerance Tolerance
Productivity
Availability
Priority: Very High
Capacity
Priority: Very High
HMS Attributes
Continues to grow in physical
size and loading capacity as
technology advances Shovel Capacity Comparison
HMS EMS
Large machines can 5-pass Small 28.0 yd3 (21.4m3) 33.0yd3 (25.2m3)
load 290 metric ton (320 US Medium 33.0 yd3 (25.2m3) 46.0yd3 (35.2m3)
ton) trucks Large 46.0 yd3 (35.2m3) 73.0yd3 (55.8m3)
EMS Attributes
Can 3-pass load 290 metric ton
(320 US ton) truck
Large machines, such as the The EMS has much greater
P&H 4100XPB, produce capacity, and the trend in HPLC
approximately twice the output mines is to use larger and more
of large HMS efficient loading and hauling tools.
Productivity
Reliability
Priority: Very High
Ease of Maintenance
Priority: Very High
HMS Attributes
Components are located in
replaceable modules
Hoses and tubes for hydraulic
fluids complicate servicing
Cool-down period required prior
to servicing
EMS Attributes
Larger machine size and
modular component design
provide ample access space
Components conveniently Hydraulic shovels have hoses,
located to allow for rapid tubes, heat, fuel, oil discharge and
replacement safety issues that adversely affect
machine serviceability.
Maintenance
Fueling
Priority: Very High
HMS Attributes
May consume up to 10,000
liters of diesel fuel per day
Daily fueling requires 20 to 30
minutes of machine downtime
EMS Attributes
Requires no fueling downtime
since all power is supplied
through the trail cable
The 30 minutes or more of daily
downtime for fueling an HMS
equates to 2-4% downtime per year
(over 7 days) in an HPLC mine.
Maintenance
EMS Attributes
Static nature of power and
control systems minimizes
component replacement
The EMS has few components
Slower gear case speeds and requiring scheduled replacement,
reliable electric motors reduce resulting in significant long-term
the need for component savings in downtime and
replacement component costs.
Maintenance
Reliability Indicators
Priority: High
HMS Attributes
Hydraulic pressure and fluids
can indicate reliability
The complexity and number of
components result in a certain
percentage that will fail without
warning
EMS Attributes
Major components can be
precisely monitored using
predictive diagnostics
Technology includes vibration The use of predictive diagnostics
analysis, ultrasonic detection, and fewer moving parts provide the
infrared thermography, and electric mining shovel with a clear
electrical measurements advantage in reliability indicators.
Environmental Impact
Cleanliness
Priority: High
HMS Attributes
Large quantities of fluids
present an ongoing cleanliness
challenge
Maintenance and operations
personnel must continuously
watch for slippery surfaces
EMS Attributes
Low volume of fluids and
containment of gear oils help
maintain a high level of
cleanliness Electric mining shovels provide
Machinery house is pressurized a higher level of cleanliness and
with filtered air to ensure a reduced potential for
clean working environment contamination.
Environmental Impact
Fluid Disposal
Priority: High
EMS Attributes
Consumes less energy, and
introduces considerably less
carbon dioxide into the
environment Electric mining shovels generate
significantly lower levels of
undesirable emissions.
Environmental Impact
Spillage
Priority: High
HMS Attributes
Has thousands of liters of fuel
and hydraulic oil susceptible to
HMS Fluid Reservoir Capacity
spillage (typical)
High pressure tubes and hoses Hydraulic Fluid 6,500 - 13,000 liter
are susceptible to failure Diesel Fuel 9,500 - 16,000 liter
Coolant 500 - 900 liter
Engine Oil 520-760 liter
EMS Attributes
Uses sealed gear cases that
offer little danger of spillage
Large quantities of fluids, some
at high pressure, make hydraulic
shovels a high risk in
environmentally sensitive areas.
Commercial Considerations
Capital Cost
Priority: High
HMS Attributes 3rd HMS $7,000,000
Largest size machines may HMS
EMS Attributes
Largest size machines may Years
Fuel Cost
Priority: Very High
Insurance Liability
Priority: High
Machine Life
Priority: High
HMS Attributes
Typically approaches the end of
its useful service life after
approximately seven years
(50,000 hours) of operation in
HPLC mines
EMS Attributes
Renowned for its extremely
long life and typically operates
productively for 20 years or
more logging 100,000 plus The EMS has an overwhelming
hours advantage when it comes to
machine life, continuing to set
records for longevity.
Commercial Considerations
Manufacturers
Priority: Low
Project Life
Priority: High
HMS Attributes
Considered appropriate for
projects with lives of up to 7 or
8 years
Easier to transport to a new
project due to its smaller
physical size and lighter weight
EMS Attributes
Considered appropriate for
projects with a life as short as
8 to 10 years The EMS is the first choice for
Retains its value, resulting in long-term projects greater than
many good used machines 7 or 8 years, and the used electric
that can be applied to projects shovel market is a viable
of less than 8 years alternative for shorter projects.
Commercial Considerations
Project Risk
Priority: High
Relocation
Priority: High
HMS Attributes
Smaller class can be
transported with minimal
disassembly
As the size increases, some
expanded component
breakdown is required
EMS Attributes
Typically requires disassembly
prior to relocation
Some electric shovels have
been relocated intact up to A hydraulic mining shovel is easier
100km using a heavy-duty and less costly to relocate.
wheel or crawler loader
Commercial Considerations
Resale Value
Priority: High
HMS Attributes
Lower price makes it somewhat
attractive in the used equipment
market
Shorter life makes it impractical
for many projects
EMS Attributes
Robust design, high reliability,
high availability and
upgradability provide many
opportunities in the used A used electric mining shovel
equipment market provides the best value for an
HPLC mining operation.
Long life provides excellent
ROI on used EMS
Commercial Considerations
Support Infrastructure
Priority: Low
Technology Knowledge
Priority: High
HMS Attributes
Smaller machines have access
to labor pools with appropriate
skills (used for infrastructure
projects, such as buildings and
roads throughout the world)
EMS Attributes
Machines have been working
in remote regions supported by
individuals with limited
technical skills for many years There is no clear advantage with
Manufacturers provide either the HMS or EMS, as
customer technical training on specialized skills are required to
maintenance and repair operate and maintain both.
Key Selection Variables