“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.
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.
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).
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.
Mining Contractor, Indonesia
The Mahakam Sumber Jaya site was over budget on monthly fuel consumption costing the site an additional $100,000 AUD/yr.
Existing operators were assessed on the simulator then evaluated and trained on behaviors affecting fuel consumption. After a four-month 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.
NEMISA was looking for industry support to boost training efforts in the areas of maintenance cost and machine damage.
After the training was delivered in the simulator, trainers spent time in the field to confirm and reinforce the best practices learned on the simulator.
The training initiative decreased fuel cost by 10.4%.