Designing, building and launching the next generation of the world’s largest mining equipment represents huge commitment, cost and risk. Komatsu Mining took that step in 2013 when it launched the P&H 4800XPC AC – then and now the world’s largest electric mining rope shovel with a 135 ton payload, designed to three pass load 400 ton ultra-class haul trucks. The design leveraged new Adaptive Controls technology with ultra-class machine structures to enable the larger payload and increase efficiencies.
The shovel is capable of up to 9,000 t/h with other attributes including very robust machine structures and systems such as a wider boom and handle, a new dipper with a higher weight to payload ratio and a new modular counterweight system. The first unit was deployed to Teck’s Fording River coal operation in British Columbia, Canada in 2019 following detailed analysis to understand the potential ripple effect that increased production might have across the mine site.
Specifically, data was collected and assessed to determine how significant gains in shovel productivity might affect the truck allocation, life-of-mine planning and ongoing maintenance. And it has performed very well there working with the 400 ton 980E, displaying high productivity with high availability.
Since then, there has been no news of the 4800XPC AC until now – IM can report that the second unit of the shovel will be going to Anglo American Platinum’s Mogalakwena platinum mine in Limpopo Province, South Africa in 2024. Beyond that a larger order for multiple 4800XPC units has also been placed by a Tier 1 iron ore miner – on which more details will emerge in the coming months.
Back to the unit for Mogalakwena, first off, how did this come about? The mine’s existing large shovel is a Chinese TYHI WK-55 shovel which restarted operations in June 2023 after an extensive upgrade and partial rebuild to increase its performance levels. This machine has been operating at the mine for a number of years but in 2021 Anglo American also began looking for a second large shovel to help meet the needs of its ongoing expansion project.
Initially discussions with Komatsu centred on the 4100XPC AC – this unit weighs 1,500 t and has a payload of 109 t so is more than capable of three pass loading the mine’s 321 t class Komatsu 930E trucks. The 4100XPC would be able to produce around 6,000 t/h with a 930E truck fleet.
But Komatsu South Africa had a novel solution to handle the challenging hard rock mine conditions at Mogalakwena – why not deploy the 4800XPC instead, and take advantage of its considerable extra power – 20% more – but with a scaled down 4100XPC sized dipper to achieve a 7,400 t/h production rate?
Essentially it is still three pass loading the 930Es – but doing so faster with better dig performance. So the higher initial cost is quickly justified in this application. An order for the machine was placed in March 2022 after detailed simulations and TCO determinations, with handover of the units – the second 4800XPC ever built, the first outside North America and first in Africa, is due in April 2024.
And these were not the only considerations in Anglo American Platinum opting for the 4800XPC AC. Charl Coetzer, Strategic Account Manager, Mining at Komatsu South Africa added to IM: “The 4800XPC AC leverages new Adaptive Controls technology with optimised machine structures to enable its larger payload and increase efficiencies. Adaptive Controls is a series of control functions that optimise shovel power usage in different phases of the dig cycle ie crowd, hoist and swing, leading to improved shovel performance while lessening the effect of operating impacts on the machine. Adaptive Controls combined with a stable, optimised structural platform in conjunction with efficient sight lines and refined ergonomics contribute to improved operator effectiveness and reduced operator fatigue. Through the application of innovative engineering and advanced technologies, Komatsu has designed the 4800XPC to be the industry’s most productive electric mining shovel.”
He adds: “The need for the new shovel was a direct requirement due to the mine’s ongoing expansion. The shovel will load ore and waste, but its main focus initially will be on waste. The major factor was the higher production rates available from the 4800XPC shovel, especially with the down-sized dipper. The digging conditions at Mogalakwena are very challenging, due to the nature of ore bodies and formations found in the region.”
Going forward the future for the 4800XPC AC seems bright – in recent months and years large commitments have been made worldwide for new electric drive 400 ton class truck fleets, especially in Latin America, plus Komatsu has just launched its highest powered truck to date – the 980E-5SE equipped with a Cummins QSK95 4,400 hp engine.
