Surface Mining of Iron Ore with Komatsu's Largest Mining Machines | Full Documentary

in the heart of the earth beneath layers of rock and stone lies a hidden world shrouded in mystery a world where machines Roar and drills cut through the Earth like hungry beasts but the world beneath our feet is not just a realm of riches it's also a perilous Place cave-ins toxic gases and Equipment failures are constant threats pushing miners to the limits of human Endurance on the other hand Cutting Edge technology autonomous vehicles and advanced machines are transforming the way we extract minerals from the Earth's crust join us on a captivating exploration into the depths of the Earth where humans and Machinery converge in an unwavering pursuit of valuable resources witness the awe inspiring power of the mining beast from kamasu deep in the heart of Austria lies the urg iron mine a testament to the tenacity of human Endeavors in open pit mining this is the longest running or extraction site anywhere in the world producing up to 2,1 153,000 tons of iron or per year miners primarily employ the method of surface mining to extract buried ore approximately 85% of global ore extraction is conducted using this technique at any open pit mine the process begins with explosions this is done to break the Hard Rock in which Treasures are hidden firstly the site is prepared using dozers that remove the upper rocks and any kind of vegetation after that a blast hole drill is brought to the site for drilling holes in the ground to fill the explosive material kamasu has built several blast hole drills perfect for this purpose for example the kamasu z55 is truly a paragon in this regard it can create 10 5/8 in hole 55 ft deep in the ground while drilling different drill bits are used according to the composition of the material it takes a lot of time to change a drill bit this is why kamasu has included an Innovative Auto bit Carousel in it it not only reduces bit change downtime but allows The Operators to seamlessly adapt the drill pattern this blast hole drill also features an intelligent compressor control that regulates the amount of air entering the hole and helps manage power and fuel consumption moreover they have high Precision GPS for a reason this feature allows the operator to drill holes precisely where they should be it also allows the movement of the drill between Holes without the operator inside the cap once the holes are drilled a crew of experts fills them with explosive material with the aim of detonating all at once in bombing a strip of land is cut into the side of an open pit mine this provides a systematic removal of the top layer after after blasting when the dust settles an unsung hero is called again to the Forefront of the mining industry it pushes tons of material with its Metal Blade makes New Roads there and maintains them with an 80-year history and expertise in designing a dozer kamasu set a world record the company started manufacturing the d575 in 1991 which is so far the world's largest Dozer this Dozer is 3846 ft long 10 1/2 ft wide and stands as tall as 16 ft with a staggering 19 ft wide blade it can take away tons of rocks in minutes the operating weight of this Behemoth is 285,000 lb it has a 54.8 gallon fuel tank too with that amount of fuel a Boeing 737 can fly 702 Mi under its Mighty frame the undercarriage boasts a track gauge of 10.57 ft and a notable shoe size of 29.93 in but it's not just about Dimensions the heart of this machine is a turbocharged and emission certified engine commanding an onping 1,65 horsepower as it shifts through its three forward in Reverse gears this Behemoth can attain speeds of 7 1/2 mph going forward and 8 1/2 mph in Reverse despite having those impressive features zero new unit of this Dozer has been manufactured since 2012 the reasons are new deal breaker factors such as sustainability and efficiencies now owners want not just a powerful pushing machine but an energy efficient Dozer that can work for long hours with less fuel consumption and minimum or zero carbon emissions the kamasu d475 and the d375 meet all the new standards of the current age one of the astonishing features they have is their long lasting undercarriage as as dozers move on rugged terrain hard material gets caught between the parts of the undercarriage and exacerbates its wear this is why modern Dozer undercarriages come equipped with lubricated track rollers these are resiliently mounted to the track frame with a bogey suspension system whose oscillating motion is cushioned by Rubber pads their unique seals prevent the entry of foreign abrasives into pin and pushing clearances providing an extended service life track tension is easily adjusted with a grease gun too other than that the manufacturing process of each and every component plays an important role especially the heat treatment technology which significantly enhances their durability in the world of heavy machinery the undercarriage system lays the foundation but it's the engine that breathes life into the Dozer consider the kamasu d475 with its robust 890 horsepower engine that achieves its utmost capacity at 2,000 RPM not to be overshadowed the d375 parade raes with a 609 horsepower engine offering maximum power at 1,800 RPM to meet emission standards and reduce fuel consumption kamasu packs its machine's engines with a number of features for example diesel engines emit particulate matter which primarily consists of unburned carbon and sulfates and poses a serious health risk to humans and the environment this is why kamasu has designed special filters that capture more than 90% of particulate m likewise kamasu has included a variable geometry turbocharger system in its engines to modulate air flow to match variable nozzle performances with load conditions another problem with engines is that a portion of their exhaust gases are recirculated back into the combustion chamber causing the emission of nitrogen oxides to prevent it kamasu has developed an exhaust gas recirculation system it cools down the temperature of the exhaust gas which results in a reduction of the form of nitrogen oxides likewise Modern Diesel features a high press common rail hpcr fuel injection system it maintains a constant supply of pressurized fuel to injectors allowing for better control over injection timing and quantity a vehicle's transmission acts as a bridge between the engine and the undercarriage system it transmits the mechanical Power from the engine to the undercarriage in modern vehicles an automatic transmission is installed that automatically changes the gear ratios as the vehicle moves eliminating the need for the operator to manually shift gears but heavyduty machines like dozers require a consistent amount of torque to function appropriately this is why the lockup torque converter is included by locking up the torque converter reduces the slippage that's typical in non-lock up systems thereby allowing for a more efficient and direct power transfer the kamasu torque flow transmission has a water cooled three elements one stage one-phase torque inverter with a lockup clutch and a planetary gear multiple disc clutch transmission that is hydraulically driven and force oil to get rid of heat as efficiently as possible the gearshift lock lever and neutral safety switch help prevent accidental starts owing to such Cutting Edge features kamasu offers a 10% reduction in fuel consumption with automatic transmission with lockup torque converter compared to operation in manual gearshift mode a dozer without its blade can't be called a dozer after the kamasu d575 which is capable of pushing 125 cubic yards the d475 is the second largest in this regard offering blade capacity of up to 44 yard squared dozer blades come in different shapes and we have covered them in our previous documentary video yet it's not just the blade that commands attention the Ripper holds its own significance especially in surface mining acting as the Dozer powerful Ally the Ripper pierces and fractures the tough terrain Paving the way for smoother excavation by tackling the compacted layers of Earth the Ripper ensures that the land's Hidden Treasures are more readily exposed for extraction together the Dozer and its Ripper showcase a Synergy of force and finesse vital to the mining Symphony while dozers carve pathways on the harsh land of a mining site various types of loading machines are used to not just remove the remnants of blasted rocks but also to exract The Ore the loading equipment includes excavators shovels and wheel loaders depending on various factors such as sight conditions cost of working and functionality each type of loading machine is preferred over the other for example the p& 4800 xpc is one of the world's largest electric rope shovels and with its huge 92 yards Cube Dipper it can load a 400 ton mining truck in just three passes but electric infrastructure is required to run such a a large mining Beast these shovels are used in mining operations and have a lifespan of at least 20 years if there are not enough mining truxs to receive each pass in a timely manner the shovel would not be beneficial hydraulic excavators can be used for the same purpose but the key consideration is the digging capability of the loading machine consider the extraction of hard ores like platinum in such tough terrain it's not just about having a sizable bucket but also processing the sheer power to penetrate the compacted Earth come on answer to such demanding conditions is the kamasu PC 8006 equipped with a 420 horsepower engine and advanced Hydraulics this giant is adept at handling the rigorous demands of hard ore extraction however both machines are Behemoth of their kind standing as large as a several story tall building therefore the safety features of these machines are taken as a matter of life and death for instance when the Dipper of a rope shovel moves down there's a chance of its collision with the under Carriage this is the reason kamasu has installed track Shield 2 in its rope shovels this system monitors the movement of the Dipper and warns the Ripper if by any chance the Ripper goes beyond its critical point this system automatically stops the Ripper movement to prevent serious damage likewise for operators seated high above the ground navigating these Giants isn't a mere task it's a responsibility they need eyes everywhere that's why these machines come equipped with seven cameras offering a panoramic view and ensuring every move is made with precision and awareness the story of surface mining does not end here instead it's just a beginning for dump trucks they carry the extracted material on their backs and move across the mining site to transport it to the crusher the energy consumption of these trucks is directly related to their payload capacity terrain and the distance they travel as dump trucks laboriously make their way uphill they carry the extracted ore to The Crushers this uphill Journey demands a significant amount of energy especially considering the weight of their heavy loads recognizing this Challenge and making their trucks more environmentally friendly companies have sought innovative solutions to optimize energy consumption one such solution is the trolley assistance system this system uses overhead electrical lines similar to those in urban tram systems to power the trucks by tapping into this electrical source trucks can reduce their Reliance on diesel fuel during the most demanding parts of their Journey significantly reducing both energy costs and carbon emissions according to calculated data the trolley assist system saves 50% diesel consumption among the various machines the dump truck is the first machine that has undergone a transformative Evolution for several reasons they operate on highly predictable routes that can be easily mapped and enable them to operate autonomously companies also wanted to make this job completely safe with improved efficiency recognizing these Trends kamasu installed its first autonomous Hollow system AHS in 2008 since then their autonomous trucks have hauled over two billion tons of materials statistically the company revealed that its truck performed 15% better in terms of productivity they noted a 133% reduction in overall maintenance of the truck and zero system related incidents happened during the 10 years apart from these massive mining trucks another type of vehicle plays a crucial role in surface mining the articulated dump truck these are notably different from the larger rigid mining trucks articulated dump trucks have a hinge between the cab and the dump box granting them enhanced maneuverability they shine in navigating challenging terrain with wet and muddy conditions where larger mining trucks might falter their adaptability makes them ideal for transporting materials in smaller more confined surface mining operations or in situations where the ground is less stable in the midst of these arduous tasks the role of the operator becomes Paramount a well-designed ergonomic environment for the operator directly influences the uptime and productivity of these trucks ergonom omics ensures that controls are intuitively placed reducing the time the operator spends searching or reaching this is the reason these machines come equipped with spacious Interiors adjustable air suspension seats that reduce vibrations intuitive control placements and an advanced climate control system to maintain optimal cabin temperatures moreover wide- angle windows and strategically placed mirrors enhance visibility while noise reducing materials help diminish the cabin's noise levels the integration of these features minimizes operator fatigue ensuring that drivers remain alert and efficient throughout their shifts as articulated dump trucks operate through challenging terrain they're often paired with wheel loaders while massive loading machines like shovels are efficient for loading the larger mining trucks wheel loaders are more suitable for Rapid precise loading in areas with space contraints or less stable terrain from removing waste material to road maintenance and loading ore wheel loaders play a multifaceted role in open pit mining operations let's have a look at the wa 9008 with an operating weight of 26,6 18 lb and a bucket capacity of 19 yds cubed this wheel loader is a perfect match for 70 to 150 ton Hall trucks its variable traction control system counteracts Tire slippage particularly in challenging environments like wet or slippery terrain operators can fine-tune the machine's Rim pole with an adjustment range between 12% Tractive effort this adaptability ensures optimal grip reducing unnecessary wear and tear on the tires and ultimately prolonging their lifespan the wheel loader has three automated features automatic dig semi-auto approach and semi-auto dump systems these sophisticated systems are tailored to reduce the manual input required from operators subsequently easing their workload by doing so they not only diminish operator fatigue but also enhance overall operational efficiency ensuring tasks are executed seamlessly and [Music] proficiently for large wheel loaders kamasu has built the SR hybrid drive system during braking or retarding the system can use electrical drives as generators and feeds power back into the electrical system this allows for up to 45% less fuel consumption than comparably sized mechanical Drive wheel loaders as the arduous process of excavation and Hauling reaches its culmination the momentum occasion arrives when the dumper with unwavering Precision proceeds to discharge the precious ore into the awaiting Crusher Crushers break down large chunks of raw material into manageable sizes for processing and transport generally a Crusher comprises three main components drag chain conveyors a rotary Crusher and a surge Hopper the drag chain conveyors guide The Ore ensuring a smooth transition the heart of the system the rotary Crusher grinds and polarizes with sheer power transforming large trunks into manageable sizes and overseeing this process The Surge Hopper stands Sentinel regulating the flow and ensuring that neither excess nor girth interrupts the process the crushed material can then be transferred through miles of long conveyors to the Milling machines where it's ground into a fine powder the powdered ore then goes through a series of benefication processes where include flotation magnetic separation gravity concentration or leeching during these processes the desired minerals are separated at from The Unwanted materials or Gage once the minerals are concentrated they are usually subjected to smelting or refining in smelting the concentrated ore is heated to high temperatures often with a reducing agent to extract the pure metal in refining any remaining impurities are removed resulting in a final product that's ready for sale or further [Music] manufacturing from its deep roots in terrestrial mining kamasu is now gazing Upward at the Moon in in 2019 the Forward Thinking company boldly stepped into the future by joining NASA's Artemis program leveraging its extensive expertise kamasu plans to engineer machines capable of functioning in the moon's unique conditions the lunar environment presents novel challenges temperatures Plumbing to 170° C unpredictable terrains and the considerable communication lag between the Earth and the moon with these Endeavors kamasu is not only pushing the boundaries of innovation but also playing a part in Mankind's next Monumental chapter in space as well as on Earth

Channel: Lord Gizmo

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Keywords: mining machines, mining, mining equipment, top 10 largest mining dump trucks in the world, world's largest machines, machines, largest machine in the world, world’s largest and most powerful machine, komatsu mining, underground mining machines, documentary, mining excavator, mining machine, largest machine ever built, largest mining trucks, biggest machine in the world, full documentary, iron ore, heavy machinery, top 10, worlds largest machines, heavy equipment, LORD GIZMO

Id: nskUK9EFCz8

Length: 19min 5sec (1145 seconds)

Published: Wed Oct 25 2023