Use of simulators to improve mine safety, productivity increasing despite sector’s slowdown
Despite continued cautiousness and a slowdown in the mining industry, investments in operator competence, including safety and productivity, continue to grow, according to heavy equipment training simulator supplier ThoroughTec Simulation executive VP of global business development Greg Lew, who says advanced training simulators are seen as an increasingly important part of mine operations globally and a sound investment.
“More and more mine operators are realising the advantages that simulation can bring to their mine sites around the world, and that the technology upskills employees and uplifts the surrounding community’s skills base,” he says.
Some big players and projects recently bought into simulation to enhance their core fundamental performance measures, says Lew, who adds that ThoroughTec experienced another year of growth in 2013. The company’s range of advanced military-standard Cybermine training simulators is now in its fourth generation.
“We are continuously receiving reports from mines about how simulation is aiding in the recruitment process and improving productivity and reaction times in emergency situations,” he says.
In 2013, ThoroughTec broke into several new markets, including India and Kazakhstan. The world’s largest integrated producer of zinc, Hindustan Zinc, of India, took delivery of a Cyber-mine mining simulator for a Sandvik drill rig, as well as a load haul dumper (LHD) underground loader and an articulated dump truck (ADT) surface hauler for its Sindesar Khurd mine, in Rajasthan, India.
Kazakhmys, the world’s largest copper producer and one of the largest mining companies in Kazakhstan, is currently involved in two major copper projects – Aktogay and Bozshakol. They have recognised the benefits of simulation and its ability to support these big projects ,with Aktogay ordering a simulator for a Cat haul truck and wheel loader and a Hitachi shovel and excavator. Bozshakol will be receiving a simulator for a Cat dozer and haul truck, a Hitachi shovel and excavator and a Sandvik drill rig.
“Because mine vehicles are being used for fewer training tasks, the associated running costs of training are greatly reduced,” says Lew, adding that damage, and wear and tear, on mine vehicles decrease as green operators are able to familiarise themselves with the controls of the machines and eliminate their mistakes on the mining simulator instead of the real machine.
“This means less unscheduled maintenance and lower maintenance and training costs,” he says.
Expansion in Latin America continued last year with the company’s entry into the lucrative copper-rich Collahuasi region, in Chile, and the further enhancement of ThoroughTec’s reputation with training schools in the country.
The University of Santo Tomas, one of the largest education insti- tutions in Chile, bought a fixed facility simulator for a Komatsu haul truck, while Peru, one of the world’s largest producers of base and precious metals and home to Volcan Compana Minera, ordered a fixed facility simulator for an Atlas Copco twin boom drill rig at its training school in Yauli, which is also home to three of its mines.
Continued growth was also seen in Southern Africa, with Anglo American’s Mogalakwena platinum mine, in Limpopo, ordering a simulator for a TZ rope shovel. Assmang’s Black Rock manganese mine now has a total of five simulator base units after receiving a unit for an Atlas Copco underground truck and bolter.
Kumba Iron Ore’s Sishen mine, in the Northern Cape, now operates the largest number of ThoroughTec simulators, with ten now on site. Last year, it bought simulators for a Cat ADT, haul truck and grader and three Komatsu haul trucks. Construction and engineering company Murray & Roberts Cementation bought a fixed facility simulator for its Bentley Park training facility, near Carlton-ville. This order is for a Sandvik drill rig, an LHD, a bolter and an underground ADT.
Further evidence of large-scale mining oper-ations recognising the benefits of simulation is Namibia-based Swakop Uranium’s acquisiton of three Cybermine mining simulators for a Cat rotary blasthole drill rig, a hydraulic shovel and rope shovel and a Komatsu haul truck for its Husab mine, near Swakopmund. This is currently one of the biggest uranium mining projects in the world.
Meanwhile, in North America, military- standard mining simulation has penetrated the oil sands market in the form of the largest oil sands company in the world, Syncrude, which bought a simulator for a Cat truck, dozer and grader, a Liebherr truck and a P&H shovel.
“Syncrude chose ThoroughTec owing to its capability to customise every cab using standard operating procedures,” Lew notes. Syncrude also has a large hiring expansion over the next four to five years, for which they will be looking to hire experienced operators.
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