Alkane Resources discovers gold standard with Cat® underground loaders

Four new Cat R2900 XE Diesel-Electric Underground Loaders have joined Alkane Resources’ (ASX: ALK) fleet.

The miner started digging for gold in the heart of NSW in 2014 and is now producing more than 57,000ozpa of the precious metal at its Tomingley Gold Operations.

When the underground fleet including four Cat R2900G underground loaders were ready to be replaced, Alkane Resources had a choice – rebuild the existing machines or replace them with new technology.

Alkane Resources general manager of operations Jason Hughes turned to WesTrac to identify the best underground loader to suit their operations.

The team was recommended the Cat R2900 XE Diesel-Electric Underground Loader – a hard-working machine capable of enhancing productivity by 20%, improved breakout force by approximately 35% and increasing fuel efficiency by up to 30%.

“There are a number of advantages to these new machines; they are a step change from the old Cat 2900G series and the smarts on these machines will see us get a lot longer life and lower operating costs,” Mr Hughes said.

“We realised if we made the decision to change in another three years’ time after we had rebuilt the current series, the waitlist probably would have been a lot longer and we would have missed three years of lower cost production.”

One of the greatest benefits of the Cat R2900XE is its exceptional fuel efficiency, providing the power needed by operators while also reducing RPM, fuel burn, heat generation and exhaust emissions.

Alkane Resources technical services superintendent Dylan Ullyett says this fuel efficiency will make the company’s operations more sustainable, while also creating a better working environment for the 260 workers on site.

“We’re consuming less diesel, so we don’t have to use as much ventilation [underground], which is a benefit for us in the long run,” he said.

“Our carbon footprint has been reduced as well by using those Cat R2900 XE Loaders, we should be seeing a reduction of about 30% across our fleet in fuel consumption – that’s huge.”

Mr Hughes agrees that the productivity and efficiency advantages of this new model caught the mining company’s attention.

Alkane has become one of the first mining companies in NSW to utilise this next generation machine, which Alkane underground manager Andrew Brown believes will benefit the company.

“It’s an upgraded loader with an upgraded system; so we are expecting upgraded performance, efficiency, and cost reduction. Being one of the first enables us to lead the way,” Mr Brown said.

“It’s being able to show that we can, as a group, implement something that’s new and different and be successful, so not only do we see benefits from costs and productivity, we also then potentially see benefits from attracting talent to come to Tomingley and be part of an operation that’s known for doing things not only differently, but better.”

But it’s not just the machine doing the heavy lifting. Alkane Resources also invested in Cat MineStar™ Command, which Mr Hughes first witnessed in use at the Caterpillar Proving Grounds in Burnie, Tasmania.

“The technological gains that this new Command system has from where it was in the underground space even three or four years ago is a large change,” he said.

“We’ve used an aftermarket remote system previously, but when we went down to Burnie and saw how Caterpillar have fully integrated the remote system with the technology upgrades on the Cat R2900 XE, we then realised the benefits of using the technology as the OEM intended rather than as an aftermarket setup .”

Cat MineStar Command allows workers to operate the machines remotely, improving navigational accuracy, boosting productivity and optimising shift changes – ultimately reducing downtime.

Caterpillar senior regional representative Terence Reeves says while relocating operators from the cab of loaders improves site safety, the ability to customise the system has been an additional benefit for mining companies.

“It’s no secret that underground mining presents special challenges when it comes to safe and efficient operation,” he said.

“That’s why Caterpillar tailors the MineStar solution to the unique needs of the environment – no matter the size, type or complexity of the underground operation.

“We put it on a building block approach, so depending on what the customer needs; they could have a base level of technology all the way up to full autonomy.”

“Especially in an underground environment, the safer we can make operations, the better.”

Mr Hughes comments further.

“We were very happy that Caterpillar wanted to work with us to develop other areas of remote capability on other machines in our operations.”

WesTrac Mining sales manager Richard Peck worked hand in glove with Alkane and Caterpillar to find and deliver solutions with reduced greenhouse gas emissions for the miner’s underground operations.

He believes more mining companies will soon be turning towards diesel-electric machines like the Cat R2900 XE and supporting systems like Cat MineStar Command, as the industry increases its focus on safety and sustainability.

“As mining customers try to remove people from underground operations, more are going to an autonomy type system or having remote operations where we can have the machines being operated from the surface or from a safer area,” Mr Peck said.

“I can see autonomy being rolled out a lot more.

“We’re already talking to a lot of other customers and using Tomingley as a stepping stone to show them that we can do it.”

This next generation of mining equipment also complements Alkane’s sustainability strategy, as the company works towards making its operations more sustainable for years to come.

“Sustainability is important to Alkane, as with all mining companies, and we see the Cat R2900 XE as a step in the right direction for being able to use this new technology and show that not only does it have an economical saving, but an environmental benefit as well,” Mr Hughes said.