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MINExpo 2016: Cummins offers solution to reduce TCO

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World Coal,

Cummins launched several new initiatives focused on reducing miners' total cost of ownership (TCO) related to engine operation at MINExpo 2016 in Las Vegas.

"Faced with challenging economic conditions, our customers are keenly focused on conserving cash and optimising equipment operation,” said Zach Gillen, Executive Director of Cummins’ Mining Business. “Over 60% of a miner's TCO is tied to fuel, parts and service, and we have developed solutions that can be applied in a wide range of mining applications. These upgrades lower fuel and servicing costs, and are available for engines currently in use, providing immediate cost savings to cash-strapped miners around the world."

Reducing fuel consumption

Cummins fuel consumption reduction initiative, called Fuel Saver, is currently available for QSK50 and QSK60 engines, with plans to extend it to other high-horsepower engines. There are a number of options to reduce fuel consumption for mining trucks by 1 – 5% annually, which equates to an average annual saving of US$6000 t – US$30 000 per vehicle. The fuel-economy improvement also generates an equivalent percentage reduction in CO2 emissions of approximately 10 kg (22 lb) CO2 per gallon of fuel saved.

"The improvements are achieved through base engine modifications, fuel system upgrades and electronic calibration changes,” Gillen continued. “Our technicians will offer a tailored solution based on the customer's specification to achieve the best possible savings. They are available for Tier 1 and Tier 2 engines in service now."

Filtration technology

Cummins is also able to reduce engine-servicing costs with the latest air, lube, fuel, hydraulic and water filtration technology, along with proprietary coolants. Nanofibers with a diameter smaller than a human hair are combined with a cellulose-based media to capture particles at a submicron level before they can reach engine components such as pistons, rings and liners.

Field studies around the world have successfully validated TCO improvements of over 60%, by extending service intervals to a minimum of 1000 hours. In addition, the NanoNet technology has helped miners reduce costly equipment downtime.

Date-enabled mining

Cummins also revealed its newest offering at the show: Data Enabled Mining Solution. This prognostic capability allows Cummins to monitor engines and deliver accurate, real-time operating information, enabling a quicker and more focused response to potential issues. The solution ultimately allows miners to lower TCO by extending engine life, preventing catastrophic failures and decreasing unplanned maintenance expense.

The Cummins Data Enabled Mining Solution operates over cellular networks, and, in the near future, satellite communications systems. The system is able to stream real-time, high-frequency data which, when coupled with support from the expertise in our solutions center, allows continuous monitoring of the entire fleet.

"We are very excited by the new technological advances that Data Enabled Mining Solution offers our mining customers,” said Lori Cobb, Vice President of Connected Solutions at Cummins. “By reducing the time to intervene on fault notifications, equipment availability can be improved, and progressive damage can be avoided. Additionally, adaptive learning approaches will be incorporated on an ongoing basis to improve the mine's productivity."

"Our technology leadership, coupled with a collaborative focus on helping customers win, is putting us in a position to deliver market-leading total cost of ownership. Our latest TCO improvements are a good example of our commitment to the mining industry, and we will have experts on our stand at MINExpo to talk with anyone interested in learning more," concluded Gillen.

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