 2003 Harnischfeger Corporation

Conteúdo

Introdução
Descrição do Equipamento
Critério de Seleção
Processo de Seleção do
Equipamento
Conclusão
 Revisão

 Seleção do equipamento de excavação é um processo

complexo
 Minas precisam considerar técnicas de desmonte,
manutenção no local, recuperação de capital
 Escavadeiras Hidráulica e Elétrica necessitam de
adequada consideração
 Background (cont)

 Foco em alta produção e baixo

custo de operação (HPLC)

 Minas com alta produção e

baixo custo no mundo.
Exemplos:
 Minas de cobre na América do Sul e
Indonésia
 Minas de Ferro do Quadrilátero Ferrífero e
Carajás
 Minas de carvão na Austrália, Australia,
China, Ìndia, Canadá, e EUA
 Minas de Metais preciosos em vários locais
Typical HPLC Digging Face
 Representação Conceitual de uma Mina
1. Remoção de solo
2. Remoção subsolo
3. Perfuração & desmonte
3
2 4. Excavação
1
4 5. Dragline
4
3 6 6. Carregamento de
carvão
5 7 7. Reabilitação

7
 Escavadeira Hidráluca (HMS)

 Projetada para escavar e

carregar material em minas a
céu aberto
 Disponível na configuração
shovel ou retro
 Motores diesel ou elétrico
 Capacidade típica 28 j3 (21 m3) a
46 j3 (35m3)
 Typical HMS Assemblies

Upper
Attachment

Lower
 Typical HMS Deck Plan
Operator’s Cab

Engine Valves

Pump Drive

Pumps
Hydraulic Reservoir
Fuel Tank
 Electric Mining Shovel (EMS)

 Designed specifically to dig and

load material in surface mines
 Uses electric motors, gear
reducers, drums and wire rope
to actuate motions
 Typical capacity is 33 yds3 (25
m3) to 82yds3 (63m3) for standard
rock applications
 Typical EMS Assemblies

Upper Attachment

Lower
 Typical EMS Deck Plan

Hoist Gearcase

Swing Gearcase

Operator’s Cab

Electrical
Hoist Drum
Cabinets Transformers
 Ciclo de Trabalho

 O ciclo de trabalho para

ambas Esc. Hidráulica e
a Cabo consiste de
quatro fases:
 Escavação
 Balanço
 Carregamento
 Retorno
 Posicionamento,
requerido em algumas
vezes
Typical Dig to Dump Cycle
Digging
Accelerating
Smoothly

Coasting

Decelerating

Dumping
 Critérios de Seleção

 Técnico
 Operacional
 Características do Depósito
 Escavação e Carregamento
 Produtividade
 Manutenção
 Impacto Ambiental
 Considerações Comerciais
 Technical

Adaptabilidade a Temperatura
Ambiente
Prioridade: Alta

Atributos EH
 A viscosidade do fluido
hidráulico varia com a
mudança de temperatura
 Baixa temperatura do fluido
pode parar a máquina
 Alta temperatura pode
acelerar desgate dos
componentes
Atributos EC
 Motores podem trabalhar
em temperaturas de –50 ºC
a +55 ºC
 Mundanças na viscosidade
do fluido tem impacto
mínimo no desempenho da
EC

EC é mais adaptável a
temperaturas extremas.
 Technical

Força de Escavação
Prioridade: Alta
Atributos EH
 Gera forças de escavação através do
cilíndro (força de empurrão) e força de
desagregação via cilindro da caçamba

 Força adicional gerada pelo cilindro

de carga

Atributos EC

 Gera forças de escavação via

cabos e braço de empurrar
 Technical

Forças de Escavação (cont)

Prioridade: Alta
Atributos EH
 Enchimento melhor da caçamba em bancos baixos

 Operador precisa escolher uma

trajetória específica para caçamba
e frequente reposição

Atributos EC
 Mesma força em bancos altos
ou baixos
 Capaz de manter escavação
profunda e fluxo de material A EC é mais capaz de
em todos os tipos de consistentemente gerar uma alta
força de escavação.
escavaçãp
 Technical

Pressão de Rolamento (Estática)

Priority: High

Atributos da
EH
Tem pressão estática de
rolamento relativamente baixa
 46 j3 (35.2 m3)  225.8kPa
(32.8psi)
Atributos EC
 Alta pressão estática de
rolamento
 Equipamentos opcionais
oferecem baixa pressão
estática de rolamento
 46 j3 (35.2 m3)  424.0kPa
(61.5psi)

A baixa pressão no terreno exercida pela EH faz com que este

equipamento seja mais apropriado a minas com condições de
terreno de base “macios”.
 Technical

Machine Assembly Time

Priority: Low
HMS
Attributes
 Assembly typically takes 10-20
days, with an eight-person crew
working a 10-hour shift

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

Peso do Equipamento
Prioridade: Alta

Atributos EH
 Projetada para minimizar
peso estrutural  baixa
pressão e maior mobilidade
 Menor peso  menor vida útil
Atributos EC
 Projeto robusto 
durabilidade, estabilidade e
longevidade
 Pesa mais que a EH para
uma igual capacidade

EC pesa mais  maior vida útil do

equipamento.
 Technical

Mobilidade
Prioridade: Muito Alta
Atributos EH
 Menor e mais leve
 Relativamente rápida e maior
mobilidade
 Propusoures longos podem causar
superaquecimento

Atributos EC
 Corpo robusto e estrutura
pesada

 Velocidade de propulsão relativamente baixa O menor tamanho da EH gera um

vantage quanto a vulnerabilidade.
 Technical

Power Selection Options

Priority: Low

HMS EMS
Attributes
Offers the option of either Attributes
Only option available is an
diesel or electric power electronic drive system
matched with AC or DC
electric mining duty motors

The HMS offers both diesel and

electric power options, whereas an
EMS offers only electric drive.
 Technical

Power Supply Requirements

Priority: High
HMS
Attributes
 Diesel machines typically require
no power cable connections
 Electric powered HMS have
similar requirements as electric
shovels

EMS
Attributes
 Requires power substations
 Requires cable support infrastructure
The absence of trail cables on most
hydraulic shovels allows them
greater mobility and flexibility.
 Technical

Technology Change Adaptability

Priority: High
HMS
Attributes
 Short life limits opportunity for
retrofit of new technology
 Purchase of new machine
provides latest technology

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 of mining shovel cab provides greater
haul trucks visibility and an added sense of
security for the operator.
 Machine Operation

Digging Phase Controls

7
Priority: Very High
HMS 6

Attributes
Seven steps are typically required 5
to position and fill a bucket 1 2 3
4

 Operator skill determines

efficiency of digging 4

EMS 3
Attributes
 Four steps are typically required 1 2
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

Digging Phase Controls (cont)

HMS Control Functions
Extend Stick Boom Lower

Swing Swing Curl Curl

Left Right Out In

Retract Stick Boom Hoist

LEFT HAND RIGHT HAND

 Machine Operation

Digging Phase Controls (cont)

EMS Control Functions
Crowd Extend Lower Dipper

Swing Swing
Left Right

Crowd Retract Hoist Dipper

LEFT HAND RIGHT HAND

 Machine Operation

Ergonomics HMS
Operator’s
Priority: High Cab
HMS
Machinery
Attributes
 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

Use of Propel to Maximize Fill Factors

Priority: High
HMS
Attributes
Has limited boom reach
 Typically uses propel to
maintain digging position
and provide optimal bucket
fill factors

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

Digging Material Layer by Layer

Priority: Low
HMS
Attributes
 Can remove material layer by
layer, working from top to
bottom

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

Drilling and Blasting Requirements

Priority: High
HMS
Attributes
 Typical Mining/Processing Cost Split
Can dig in a variety of
conditions, working from
Load and
top to bottom Haul 30%
 Requires less drilling and Processing
Drill and ljklj60%
blasting
Blast 6%

EMS
Attributes
 Takes advantage of blasted
material with dipper placement
at the best spot
 Most effective in benches
appropriately drilled and blasted
Ancillary
Costs 4%
It is more cost effective to spend
time and money on drill and blast
activities than to use the loading
tool to pick away at layers.
 Geology and Deposit Characterization

Following Layers Up a Grade

Priority: Low
HMS
Attributes
 With three independent
movements on front-end
equipment, the operator can
follow thin layers up a grade
with the bucket

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

Selective Mining Face Digging

Priority: Low

HMS
Attributes
Can dig in a variety of
conditions, attacking the face
at the most suitable point
EMS
Attributes
Can dig into any mining
face at the most suitable
point, within reach of the
machine

Both the HMS and EMS, when

digging with good practices, can
load out the material.
 Digging and Loading

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
The greater reach of the EMS
maintain an optimal swing arc
provides optimal swing arcs,
while minimizing propelling 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

Digging Below Ground Level

Priority: Low
HMS
Attributes
 Can dig below ground level
 Preparing a ramp to a lower
bench is a normal type of
operation

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 Heaped
Attributes
Quote bucket capacity in “heaped”
standard per SAE 2:1 or 1:1 Struck

 Buckets are well-suited for

material described as easy and
medium digging

EMS Struck
Attributes
 Quote dipper capacity in “struck”
standard
 Dippers are well-suited to
provide maximum fill factors
in all materials
 Digging and Loading

Fill Factors (cont)

Priority: Very High
Discussion
 Diggability is the amount of
Material Approximate Dippe
resistance a particular material Fill Factor
Diggability
presents to being extracted
from a working face EMS HMS
Easy Digging 1.05 - 1.20 .95 - 1.05
 Fill factor is the ratio of actual 1.00 - 1.15 .90 -
loose cubic yards or meters of a Medium Digging 1.00 .90 - 1.00 .85
material in the dipper or bucket Hard Digging - .95 .85 - .95 .80
compared to the dipper or Very Hard Digging .90
bucket’s rated volume Bucket or Dipper Fill Factor = Loose Volume Per Load
Bucket or Dipper Rated Volume

HMS and EMS manufacturers use different accepted

standards for rating bucket and dipper capacity.
What matters is tons moved.
 Digging and Loading

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

Floor Level Digging Reach

Priority: High
HMS
Attributes
 Can keep the bucket parallel to
and on the ground

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
33.0 yd3 (25.2m3) 16.5m 21m
falling bank sections and rocks 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

HMS
Attributes
Has reach limitations that
require the machine to work
closer to the digging face
EMS
Attributes
Achieves more reach by
extending only the dipper
and handle rather than the
entire attachment
 Long reach enables the
machine to sit farther back
from the digging face

The reach on the electric mining

shovel provides a distinct digging
advantage.
 Digging and Loading

Removal of Large Rocks from Digging Face

Priority: Low
HMS
Attributes
 Can use curl or roll capabilities to
remove a large rock from a
hazardous position on the high
wall
 Isolated boulders can be pried
from the face without difficulty
EMS
Attributes
 Can use the retract motion of
the dipper handle in
combination with the hoist
motion to dislodge a boulder The high location of the EMS
from its bank position operator’s cab provides a definite
safety advantage when removing
large rocks.
 Digging and Loading

Removal of Obstructions from the Mine Floor

Priority: Low
HMS
Attributes
 Front-end geometry allows the
teeth to be in direct contact with
the ground right in front of the
tracks for a prying action if
required

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

Rock Handling Capability

Priority: Low

HMS EMS
Attributes
Large rocks can easily and Attributes
Limited to the geometric
carefully be dumped into the size of the dipper as to the
haul truck size of the rock it can load

The HMS has an advantage when

offloading large debris, yet it is
questionable whether this ability
would be used in an HPLC
operation.
 Digging and Loading

Truck Compatibility
Priority: Very High

HMS
Attributes
Larger machines 46yd3
(35m3) capacity match up well
with smaller haulage units
and can 3-pass load 190-ton
and 205-ton trucks
EMS
Attributes
Various capacity machines
match up well with most
HPLC trucks, efficiently
3-pass loading 290 metric
ton (320 US ton) trucks or
larger

The wide range of electric mining

shovels offered make it the best
match for most mining haul trucks.
 Digging and Loading

Truck Compatibility (cont)

HMS Truck/Shovel Match-Up
Ljlk
Truck Rated Capacity Shovel Capacity
Metric Ton (US ton) 21m3(28 yd3) 25m3(33yd3) 35m3(46yd3)
44m3(57yd3) 56m3(73yd3)
154 (170) 5 pass 4 pass 3 pass
172 (190) 5 pass 4 pass 3 pass
186 (205) 5-6 pass 4-5 pass 3 pass
218 (240) 6-7 pass 5 pass 4 pass
231 (255) 6-7 pass 5-6 pass 4 pass
290 (320) 7 pass 5 pass
327 (360)
363 (400)
EMS Truck/Shovel Match-Up
Truck Rated Capacity Shovel Capacity
Metric Ton (US ton) 21m 3(28 yd3) 25m3(33yd3) 35m3(46yd3)
44m3(57yd3) 56m3(73yd3)
154 (170) 5 pass 3-4 pass 3 pass 2 pass
172 (190) 5 pass 4 pass 3 pass 2-3 pass 2 pass
186 (205) 5-6 pass 4-5 pass 3 pass 3 pass 2 pass
218 (240) 6-7 pass 5 pass 3-4 pass 3 pass 3 pass
231 (255) 7 pass 5-6 pass 4 pass 3 pass 2-3 pass
290 (320) 7 pass 5 pass 3-4 pass 3 pass
327 (360) 8 pass 5-6 pass 4 pass 3-4 pass
ddd
363 (400) 8 pass 6 pass 5 pass 4 pass
 Digging and Loading

Truck Loading
Priority: Very High

HMS
Attributes
Propelling may be required to
properly discharge a load
EMS
Attributes
Excellent operator visibility
 Large dipper capacities
make it ideal for single
back-up, double back-up, or
drive by loading methods
 High truck spotting
tolerance range

Greater operator visibility and truck

spotting tolerance make the EMS
the ideal loading tool in an HPLC
operation.
 Digging and Loading

Truck Loading (cont)

COMPARATIVE DIGGING
ENVELOPE
 Digging and Loading

Truck Loading (cont)

COMPARATIVE SHOVEL REACH
 Digging and Loading

Working Dimensions
Priority: High

HMS EMS
Attributes
Can work in relatively tight Attributes
 Larger size places the
spaces operator higher up and
farther from the digging face
and haulage units
 Longer reach provides
greater truck spotting
tolerance and visibility

The larger dimensions of the EMS

put the operator and supporting
equipment in positions that
maximize safety and productivity.
 Digging and Loading

Working Dimensions (cont)

Priority: High

Operator Sight Angle

) )

Operator Position
Tail Swing
Truck Truck
Spotting Spotting
Tolerance Tolerance
 Productivity

Availability
Priority: Very High

HMS
Attributes
Has improved availability
numbers nearing that of
electric shovels
 Fueling time typically not
counted as “downtime”
EMS
Attributes
Has a proven availability
record in the 90%+ range
well into its life

While HMS availability values are

increasing, the EMS continues to
have higher availability in a variety
of digging conditions.
 Productivity

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)
73.0yd3 (55.8m3)
ton) trucks Large 46.0 yd3 (35.2m3)

EMS
Attributes
 Can 3-pass load 290 metric ton
(320 US ton) truck
 Large machines, such as the P&H The EMS has much greater
4100XPB, produce approximately capacity, and the trend in HPLC
twice the output of large HMS mines is to use larger and more
efficient loading and hauling tools.
 Productivity

Reliability
Priority: Very High

HMS EMS
Attributes
Has achieved reliable Attributes
Has proven to be highly
performance of about 90% reliable when digging in all
availability in easy and medium types of materials
digging materials
 Becomes significantly less
reliable as digging becomes
harder

The EMS is generally acknowledged

to have less unexpected downtime
and to be more reliable.
 Maintenance

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

Planned Component Replacement

Priority: Very High
HMS
Attributes
 Components (pumps, motors,
valves, cylinders, diesel
engines) move at high speeds
and must be replaced regularly
to reduce the possibility of
catastrophic failure

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

Preventive Maintenance Schedules

Priority: Very High
HMS
Attributes
Components have a low tolerance
for mining environment
contaminants
 Components require frequent
maintenance to ensure cleanliness
and peak operation

EMS
Attributes
 Components are less sensitive
to the mining environment and
require minimal maintenance
Due to the sensitivity of hydraulic
 Dust ingress by electric motors
systems to contamination from the
and systems is managed by normal dust and dirt in the mining
house filters and pressurized air environment, the HMS requires
systems more frequent maintenance.
 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 with a higher level of cleanliness and
filtered air to ensure a clean working reduced potential for
environment contamination.
 Environmental Impact

Fluid Disposal
Priority: High

HMS EMS
Attributes
Gear case oil in transmissions Attributes
Gear cases contain oil
must be replaced requiring periodic change
 Uses engine oil, coolant and
hydraulic fluid, which must be
replaced frequently

An HMS typically requires the

disposal of more than 7,500 liters
of oil each year, adding significant
operating expense.
 Environmental Impact

Greenhouse Gas Emissions

Priority: Very High
HMS
Attributes
 Diesel engines produce high
carbon dioxide emissions
Greenhouse Gas Emission Comparison
 Some manufacturers offer Equipment CO2 Released/Yr.
electric powered machines
EMS 50
HMS yd3 (38.2m
(diesel) 50 yd33) (38.2m3) 7,540 US
13,230 UStons
tons

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 3rd HMS $7,000,000

Attributes
 Largest size machines may cost HMS

U.S. Dollars (in millions)

US$7,000,000 or more 2nd HMS $7,000,000

 Machine life approximately Upgrades $2,000,000

7-9 years EMS $9,000,000

EMS
HMS $7,000,000

EMS
Attributes
 Largest size machines may cost
Years

US$9,000,000 or more
 Higher price attributed to the While the initial cost of an EMS is
much greater use of steel higher than an HMS, the long-term
and electronic technology capital investment for an HMS is
 Machine life over 20 years higher, due to replacement
intervals.
 Commercial Considerations

Cost Per Unit Loaded

Priority: Very High

HMS EMS
Attributes
Has a lower capital cost Attributes
Higher productivity and
 Provides flexibility that may reliability
help reduce the cost per ton  Longer life

Considering digging and loading

attributes and long-term reliability,
the EMS is the lowest cost per unit
alternative for most HPLC mining
situations.
 Commercial Considerations

Cost Per Unit Loaded (cont)

Courtesy of the SME publication Mining Economics Strategy by Ian C.

Runge
 Commercial Considerations

Fuel Cost
Priority: Very High

HMS
Attributes
Future cost of diesel fuel is
uncertain
 A 35m3 capacity HMS running
in Australia has an average
fuel cost 45% greater than a
larger 56m3 capacity EMS
EMS
Attributes
With a variety of methods
for electricity generation,
power prices should remain
competitive
 Electric power is typically
cheaper in unit cost than
diesel fuel

The fuel cost for an electric mining

shovel is typically lower and more
stable.
 Commercial Considerations

Insurance Liability
Priority: High

HMS
Attributes
Typically has several thousand
liters of combustible liquids
onboard
 Under high heat or open flame
conditions, liquids can ignite and
cause safety issues or loss of
the machine
EMS
Attributes
Has few, if any, combustible
liquids onboard, making the
risk of fire negligible
 Fire insurance rates are
significantly lower

There is a higher risk of fire on

the HMS, pushing insurance rates
to three times that of the EMS in
some areas.
 Commercial Considerations

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

HMS EMS
Attributes
There are a number of HMS Attributes
There are only two electric
manufacturers mining shovel manufacturers
 Some have global distribution  Both have global support
and service networks organizations

There is no clear advantage for

the HMS or EMS in the number of
manufacturers providing
equipment.
 Commercial Considerations

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 that 7 or 8 years, and the used electric
can be applied to projects of less shovel market is a viable
than 8 years alternative for shorter projects.
 Commercial Considerations

Project Risk
Priority: High

HMS
Attributes
Small size used for aggregate
loading and quarrying has proven
to be a solid performer
 Larger machines for HPLC mining
operations require a much higher
level of technology and complexity,
creating a significant risk factor
EMS
Attributes
Offers a low level of project
risk due to its track record
over the past 50 years and
proven technology
 Provides greater confidence
of achieving planned
production and cost targets

Due to its simplicity and proven

technology, the EMS provides a
higher chance of success and
lower risk of failure for HPLC
mining projects.
 Commercial Considerations

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 equipment market A used electric mining shovel
provides the best value for an
HPLC mining operation.
 Long life provides excellent ROI
on used EMS
 Commercial Considerations

Support Infrastructure
Priority: Low

HMS EMS
Attributes
Requires a fuel truck and Attributes
May require extra dozer
service truck time to assist in floor clean-
 May require a lighting plant up
for night work  Requires service vehicles to
transport, pick up and
relocate trail cable

Both HMS and EMS require a

certain level of support
infrastructure that would typically
be available at HPLC mines.
 Commercial Considerations

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
 Manufacturers provide customer
technical training on maintenance and There is no clear advantage with
repair either the HMS or EMS, as
specialized skills are required to
operate and maintain both.
 Key Selection Variables

 Anticipated Life of the Mine

 Capital Availability
 Mine Infrastructure
 Electrical Reticulation
 Blasting Requirements
 Mobility Requirements
 Truck Availability
 Equipment Relocation Requirements
 HMS Key Advantages

 Smaller size yields a mobility

advantage
 Minimal assembly time
 Has greater control of material
discharge
 Can dig layer by layer and
remove large rocks from the
digging face
 Less capital expenditure
required
 EMS Key Advantages

 Provides maximum fill factors in all

material, and has a longer reach
 Matches well with most haul truck
sizes and has excellent truck
spotting tolerance
 Provides higher availability,
greater capacity, and less
downtime
 Easier to maintain
 Generates lower emission levels
 Has a lower cost per unit loaded
 Conclusion

 Selecting excavation equipment is a complex process

 Hydraulic and electric shovels each have inherent key
advantages for some excavating situations
 All selection factors should be considered in the context of
an HPLC mining environment
 2003 Joy Global Corporation