Quarry Seminar

April 20th, Nairobi

Steven FAUCHER
Caterpillar System & Application Specialist
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
A Quarry …
Cat machines and solutions in quarries

From small to large quarries,

MANTRAC Loaders
and CATERPILLAR can
offer a full Rigid
Excavators range of products
or articulated trucks and
Dozers Drills solutionsGraders Rehandling Loaders

Vision link Genset

Fuel filtration, hammers, …
New top hammer rock drills
2 models: MD5150C & MD5075C
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
 Selection process for face loading
Production requirements Blast & fragmentation
Existing equipment ROCK Bench height &
Site conditions SITE MATERIAL stability
Future quarry plans Blending
& SET-UP Environment

LOADERS HAULERS
Hydraulic Excavators SIZING & MATCHING Articulated Trucks
Wheel Loaders Rigid Trucks
 • SELECT LOADING UNIT TYPE
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• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
 • SELECT LOADING UNIT TYPE
1
• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
?
Wheel Loaders

FAVORABLE WHEN LIMITATIONS

• Multiple faces • Floors are not flat or clean
• Versatility is needed • High benches
• Benches are medium to low • Narrow loading areas
• No support machines required • Tight material
Hydraulic
Excavator
FAVORABLE WHEN
• Digging below level
• Tight material
• Selective digging
• Bad underfoot conditions
• Tight loading areas
• Mobile crusher feeding
LIMITATIONS
• Excessive travelling
• Low benches
• Muckpiles have low angle of
repose
• Requires a support machine
 • SELECT LOADING UNIT TYPE
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• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
?
Off Highway Trucks

FAVORABLE WHEN LIMITATIONS

• Medium to Long hauls • Tight turns
• Rocks and any other material • Narrow roads /benches
• High speeds • Bad underfoot
• Long lasting projects
• Usually the lowest cost per ton
• Long downhill loaded hauls
Articulated
Trucks

FAVORABLE WHEN LIMITATIONS

• Short to Medium hauls • Top speed, long roads
• Temporary haul roads • Too many rocks
• Short turning radius roads • Payload limited to 41T
• Bad underfoot conditions
• Steep grades
• Well fragmented material:
Overburden/Sand/Gravel
 • SELECT LOADING UNIT TYPE
1
• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
How to select the size of loading unit

?
 Selecting the face loading unit size
Size the unit depending on the output required, think about
backup, blending needs, cleaning needs, ...

When working, you should expect the following:

• 20T excavators, around 200T/hr
• 40T excavators, around 400T/hr
• 75T excavators, around 750T/hr
 • SELECT LOADING UNIT TYPE
1
• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
Sizing Hauling units
 $/t

988 without high lift !! Size

Wheel Loader or Excavator too small: Wheel loader or excavator too big
• Cannot fill the body • Damage to truck because of big loads
• Cannot clear the rail • Constantly changing trucks
• WL pushing on truck wheels • Need many trucks and operators
• Long cycle times, diffult to manage
variations
• Greater distance to find material
• Longer time to lift the bucket

In addition to reach limitations, you have an

optimum of cost per ton.
 TRUCK-LOADER PASS MATCH
730 740ej 745 770 772 773 775 777 785
980 4 4 4 5 6
986 - 4 4 4 5 6 7 - -

Wheel 988 - 3 3 3 4 5 6 - -
Loaders 990 - - - - - 3 4 5 -
992 - - - - - - - 4 6-7
993 - - - - - - - 3-4 5

Not enough passes:

Trucks are changing all the time so time is lost
Too many passes:
Loading unit will have to load further and further from truck
Truck is too big and requires lots of loader lifting time.
 TRUCK-LOADER PASS MATCH
730 735 740ej 745 770 772 773 775 777 785

336 7 8 8 8 -

340 ME 6 7 8 8

349 5 6 7 7-8 - - - - - -

374 - 4 4-5 4-5 4-5 - - - - -

Excavators
390 - - 2-3 2-3 3-4 4-5 5-6 6 - -

6015 - - - - 3 4 5 6 8-9 -

6018 - - - - - 2 3 4 5 -

6030 - - - - - - - 2 3 5
 TRUCK-LOADER PASS MATCH

730 735 740ej 745 770 772 773 775 777 785

385C 4 4 4 5 6

Front 6015 - - - - 3 3-4 4-5 5 7 -

Shovels 6018 - - - - - 2-3 3 4 5 -

6030 - - - - - - 2 2 3 5
 Remember

To maximize productivity, a truck should be filled in 2 min to

2.5 min.
• With excavators, that’s trucks 5 to 6 passes
• With wheel loaders, that’s 4 to 5 passes

If your trucks are too big, your loading unit will experience
waiting time and loose production.
 • SELECT LOADING UNIT TYPE
1
• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
 CALCULATE HOURLY PRODUCTION OF TRUCKS
Haul time
4.50 mins

Loader Cycle
= 2.60 mins Haul
(load + truck
exchange)

TOTAL Cycle
Load time
12.30 mins Dump
Dump time
1.20 mins

Return

Return time
3.50 mins
 CALCULATE THE NUMBER OF TRUCKS

Total truck cycle time

Number of required trucks = _____________________
Load and exchange time
 CALCULATE THE NUMBER OF TRUCKS

Haul

Load Load time is 2.60 minutes

Dump Cycle time is 12.3 minutes

Return 12.3/2.6=4.7
You need 4.7 trucks to reach
production, that means 5 trucks
TOTAL Cycle time
12.3 mins
 • SELECT LOADING UNIT TYPE
1
• SELECT HAULING UNIT TYPE
2
• SELECT LOADING UNIT SIZE
3
• SELECT HAULING UNIT SIZE
4
• SELECT HAULING UNIT QTY
5
Fleet Production & Cost Analysis tool
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
Selecting options
1. Linkage selection
2. Bucket selection
3. Tips selection
4. Truck Body selection
1. Linkage selection:

Reach has a longer stick

(earthmoving, trenching, …)

Mass Excavation has a shorter stick

for higher forces and bigger bucket
(quarries, heavy construction)
2. Bucket Selection:
Choice is based on:
- Density, fill factor
- Abrasiveness
- Digging efforts
The selection is a balance between bucket
durability and productivity
3. Tip selection
4. Truck Body Selection:
Step 1: Body type
- Flat floor to dump in crushers
- Dual slope in case of steep inclines
4. Body Selection:
Step 2: Liner selection
- Material condition ? Well or poorly blasted rocks, …
- Abrasiveness ? Correlate with GET wear
- Density ? Limestone, Coal, Basalt, …
4. Body Selection:
Body Selection Guide
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
Importance of productivity

+10% +50%
 Many factors affect quarry production

ü Blasting, fragmentation, bench height

ü Blending, # faces ü Average haul speeds
ü Loader size
ü Crusher capacity ü Dump conditions
ü Loader cycle times
ü Crusher availability ü Quarry efficiency
ü Bucket fill factors
ü Machine availability, age, condition ü Fuel consumption
ü Support and back-up machines
ü Truck payloads
ü Repair & maintenance practices
ü Shift patterns/changes, meal breaks, other ü Fleet match
ü Supervision
ü Seasons, weather

BENCHMARK
QUARRY
? AVERAGE
QUARRY
 Where are the losses ?
Better work schedule

More trucks, or less Improve operator

cleaning, … efficiency
Loading with a wheel loader
1. Trucks should be placed at 45°
2. Trucks should be coming from the left
Loading with a wheel loader

3. Wheel loader should not have to reverse more

than 1.5 wheel turn
4. The WL should always be ready with a bucket, and truck
park under it
5. Curl as the bucket raises
6. Bucket should be full when arm is horizontal
7. Do not fight, not more than 12 seconds in the pile
8. Do not lift the back of the wheel loader
Loading with an excavator
1. Excavators should be on a bench
2. Bench should be equal to stick height

« Same level loading » « Bench loading »

• Long swings • More efficient
• Sometimes cannot avoid • Short exchange time
3. Minimize swing angles to minimum
4. Safe and efficient truck exchanges

« Over the rail » technique « Drive By » Technique

• Efficient technique • Even more efficient
• Excavator swing 45°to • Very short exchange time
90°for fast loading times • Do not use in rocks !
• Requires good operators
3. Tracks should be facing digging area

« Over the rail » technique Tracks aligned with digging

• Lower digging forces • Higher digging force
• Lower stability • Higher stability
4. Final drives should be at the back

Final drives in the front Final drives in the rear

• Risk of damaging FD • Less risks to damage FD
• More counterweight
Payload placement
 • Effective working time
• Loading Time
• Cycle Time
• Payload
• …

You only improve

what you measure
Quarry Seminar
1. Caterpillar equipment in quarries
2. Selecting a quarry fleet
3. Selecting the proper options
4. Maximize productivity and profit
Thank You !