Global mining companies need machines that maximise value extraction safely with the lightest possible carbon footprint and at the lowest cost per tonne. This requirement was met with Anglo American’s recent commissioning of a Komatsu P&H 4800XPC.

The investment is core to enabling Mogalakwena mine – already the world’s biggest producer of platinum group metals, to achieving the ambitious production targets it has set for itself, while setting new standards in the reduction of emissions.

“This asset embodies our commitment to innovation, growth, and prosperity and enables us to both create value and seize opportunities in a dynamic market,” said Mogalakwena Senior General Manager Willie Noordman at the machine’s April unveiling in the resource-rich Limpopo province of South Africa.

He added that the unit would enable the mine to remain the lowest cost producer in the world and increase total volumes by 35 million tonnes a year.

The Komatsu P&H 4800XPC ushers in a new era of productivity and was commissioned following more than three years of close collaboration between Komatsu, the mine and manufacturing partners.

“It is a symbol of our joint pursuit of innovation and stands as a testament to Komatsu’s commitment to creating value for its customers. As we embark on this new journey of enhanced efficiency and sustainability, let us set new benchmarks and shape the future of mining together,” said Hermann Hollhumer, General Manager, Komatsu Mining Operations, South Africa.

Creating value together

With only one other unit in operation at Teck Fording River coal mine in Canada, the machine was acquired to keep pace with Mogalakwena’s growing fleet of ultra-class haulers, namely 54 Komatsu 930E trucks, 17 of which have been built and delivered over the past nine months.

Both the shovel and trucks share a commonality in that they can be electrically driven, either via the green grid or by hydrogen. The shovel’s greenhouse gas emissions amount to only 90 grams of carbon dioxide per tonne moved, in comparison to 273 grams for a diesel-powered hydraulic excavator and 136 grams for an electric hydraulic excavator. 

Manufacture, transportation and assembly

The ‘gentle giant’ was trammed into the pit safely, on time and within budget following a meticulously planned and impeccably coordinated effort, from the initial build, shipment and transportation of components to assembly. This is the first time that all parts of a machine of this magnitude have been assembled on site, which exemplifies the quality and integrity of Komatsu’s innovative and precision design, engineering and manufacturing processes.  

Built over a one-year period in Milwaukee in the US, parts were shipped to Durban Harbour and then transported to Mogalakwena mine in 54 link trucks, 21 of which were abnormal loads requiring dedicated police escorts.

The total consignment amassed to 794 crates containing 63 770 parts, of which the largest individual component was a 122-tonne revolving frame.

To understand the sheer magnitude of the endeavour, one must comprehend the colossal scale of the undertaking involved. Weighing in at a total of 1 650 tonnes (equivalent to the combined weight of four jumbo jets) and standing 22 meters high (equivalent height to a seven-storey building), it exemplifies the epitome of engineering prowess. The bucket alone is large enough to shift the equivalent weight of 40 Toyota Hilux bakkies.

It took the project team, including up to 43 team members from 11 companies at peak, four months to assemble. This saw the pooling of the additional expertise of 22 engineers, product support and key technical partners from South Africa, Australia and the United States.

The primary consideration had to be safety and the job was concluded in 41 327 injury-free manhours. This exceptional performance was aided through the completion of 127 separate job risk assessments, extensive visible felt leadership and almost 200 planned task observations. 

Setting new benchmarks

The shovel has the brute power and capacity to feed a fleet of highly efficient haul trucks and can load a 360-metric tonne hauler in just three passes.

The new arrival is meeting expectations with its ability to shift 9 000 tonnes of material in the space of an hour. Adaptive control technology is one of the key features that enables an up to 20% increase in productivity and a 10% reduction in cost per tonne. It comprises a series of control functions that optimise shovel power usage in different phases of the dig cycle, adjusting parameters and behaviour to external changes in real time to maintain stability and performance. It also learns from experience to continually enhance productivity and lessens the effects of operational impacts on the machine.

“As a leader in the manufacture of mining equipment that generates sustainable value for customers in the mining, construction, forestry and agricultural industries worldwide, we understand that the world requires equipment to meet the needs of society and the environment. That is why we’re dedicated to creating a sustainable future where people, businesses and the planet all thrive together,” says Hollhumer.