“Production time was not affected with these improvements and we believe, with a conservative estimate, we can save $500,000 per year through this training initiative.”
Within the mining industry it is becoming increasingly important to focus on fuel preservation to control the cost of production as well as to meet increasingly stringent environmental requirements. Immersive Technologies has worked closely with major miners and Original Equipment Manufacturers to deliver a solution designed to give equipment operators the skills and knowledge they need to operate in a productive manner while assessing and eliminating behaviors that cause excess fuel consumption.
The simulator technology includes detailed monitoring of operator behaviors which directly relate to excess fuel consumption including levels of throttle and brake application for specific situations. This has resulted in an enhanced assessment tool for managers to determine which fuel inefficient operator behaviors are most prevalent on their site and represent the greatest opportunities for savings.
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Faced with staffing pressures from Covid-19, the training department sought to demonstrate increased productivity and reduced costs.
A proof-of-concept project demonstrated an 8.4% increase in tons per liter of fuel and 8.7% increase in distance travelled per liter of fuel.
Underground Gold Mine, Colombia
A lack of qualified local underground mining workforce necessitated site to develop a training program for green operators operating site’s underground trucks and rocket boomers.
Immersive Technologies developed a simulator training plan to onboard equipment operators. The rocket boomer training group achieved in a 34% reduction in fuel consumption and 24% hammer consumption reduction.
Facing falling commodity prices and increased economic pressure, Capão Xavier mine site needed to reduce their fuel costs, which were accounting for 24% of the total fleet budget.
A fuel consumption pilot project was completed, which delivered an 8% fuel reduction, compared with a 1% reduction in the control group.
Vale needed to adopt cost cutdown and productivity improvement strategies to respond to economic pressures. Diesel fuel consumption by off-highway haul trucks was identified as one of the largest costs at Sossego Mine.
After successful implementation of a fuel consumption pilot project at Capão Xavier mine, the same methodology was used at Sossego, resulting in a 7.5% reduction in fuel use. An extension on the project delivered an average of 12% reduction in fuel use over figures prior to the pilot project.
NEMISA was looking for industry support to boost training efforts in the areas of maintenance cost and machine damage.
The training initiative decreased fuel cost by 10.4% and delivered tire and transmission abuse cost reductions.
Vostochnaya Technica, Russia
Faced with an ageing workforce in the region, Vostochnaya Technica (VT) sought to develop a new generation of equipment operators using the latest technology.
VT invested in Immersive Technologies’ simulators for operator training, which resulted in loading time decreased by 9 seconds, 16% of operators improved skills leading to better fuel efficiency, and a 1% productivity improvement.
Open-pit Gold Mine, USA
The mine site identified that if they were able to save 3% on haulage diesel, this would equate to $1M USD in savings annually.
Following a Continuous Improvement Project focusing on haul truck fuel efficiencies, the project delivered a 6% fuel reduction for the 793 fleet (savings of $1.1M USD).
Mining Contractor, Indonesia
The Mahakam Sumber Jaya site was over budget on monthly fuel consumption costing the site an additional $100,000 AUD/yr.
After a four-month training period, fuel consumption was reduced by 6.9% below the site budget, saving the site an estimated $500,000 AUD annually. Fuel savings were obtained while maintaining the tonnes per hour production rate.