Robert Bauer
The Shift Towards Mechanized Cutting
Technical innovations such as more efficient cutting technology, modern cutting tool developments, the integration of advanced levelling system and their seamless interaction with modern GPS technology, and the implementation of telematics resulted in more cost-effective and advantageous capabilities of mechanized cutting technologies in soft to medium hard mining and construction applications. The application of mechanized cutting in combination with these technical innovations allows mining and construction projects to finish way ahead of time, to meet strict budget requirements and to accomplish these tasks more safely with significantly less manpower. Mechanized cutting offers a more sustainable way of mining, eliminating the cyclical nature of traditional D&B methods.
The Operational and Economic Case for Mechanized Cutting
While D&B is inherently cyclical, requiring distinct stages for drilling, loading explosives, blasting and clearing fumes, modern mechanized equipment operates continuously, significantly increasing overall advance rates.
The implementation of modern telematics allows for remote access to monitoring, planning, analyzing and maintaining the equipment.
Mechanized cutting supports safety and environmental mitigation by eliminating the need for explosives, thereby reducing dust, fly rock, vibration, noise and toxic pollution (nitrogen and carbon oxides) that are related to traditional D&B operations.
Mechanized cutting allows for a precise removal of layers of rock, creating predictable shapes, thereby eliminating overbreak and reducing the overall cost of excavation. Furthermore, the reduction in dilution of the ore results in a better recovery rate, thereby extending the economic life of a deposit.
Even after prolonged time periods, the highwalls surgical cut by mechanized cutting does not show any spalling, and the precise shape lends itself to easy revegetation.
The dilution-free extraction of ore can be windrowed or side cast behind the machine, allowing for visual inspection and subsequent convenient blending of varying ore qualities.
The continuous advance of mechanized cutting means a noncyclical operation that lends itself to the application of various levels of automation, which results in a streamlined operation, thereby reducing the overall manpower required.
“Mechanized cutting offers a more sustainable way of mining, eliminating the cyclical nature of traditional D&B methods.”
Mechanized cutting equipment produces a rather uniform gradation, removes the oversize rock produced, and thereby eliminates the need for a primary crusher. Under certain circumstances, it allows the plant to use the ore directly from the machine.
The smooth and even surface left behind by mechanized cutting means a significant reduction of the wear and tear of the whole infrastructure under any given mining scenario.
Overcoming Challenges by Taking Ownership of New Technology
There are several challenges organizations face when transitioning from conventional ripping or blasting to advanced cutting technologies.
The existing mine layout is not conducive to mechanized cutting. Necessary service and maintenance capacities are not in place and need to be implemented.
Organizations need to overcome the mentality that only old mining methodologies will work since they were applied in the last century. All stakeholders must be on board to ensure ownership and assume responsibility for the new technology.
The Future of Mechanized Cutting
The continuous, mechanical cutting, crushing and loading process provides an excellent opportunity for automatization with a high potential for various cost reductions. The trend goes towards more autonomous machines that further reduce the need for human interaction, thereby reducing labor costs. AI supported predicative maintenance programs that are easy to operate, allow for a proactive identification of service and maintenance issues.
Digital solutions platform will be enablers to manage entire mining and construction sites anytime, anywhere, including planning, monitoring, maintenance and analysis, from a remote area.
The continuous development and improvements of ever more efficient, longer-lasting and cost-effective cutting tools will further widen the vast field of applications.
Advice for Mining Leaders Evaluating New Technologies
My advice to mining leaders would be to keep an open mind, embrace new technologies and investigate alternatives to traditional mining methods.
Once new technologies are adapted make sure that the necessary resources and the knowledge are in place and ready, which will allow the new technology to flourish.
Expect resistance to change and confront it in a timely manner proactively with the proper education and the inclusion of all stakeholders involved and affected by these changes.
