Alkane Resources started digging for gold in the heart of New South Wales in 2014, leveraging the latest in underground loaders and technology to lower costs and increase productivity.
Now producing more than 57,000 ounces of the precious metal at its Tomingley Gold Operations each year, the company has an underground fleet, including four Cat R2900G Underground Loaders, working hard to extract gold every day.
When these underground loaders were ready to be replaced, Alkane Resources had a choice – rebuild the existing machines or replace them with new technology.
Opting for the latter, Alkane Resources General Manager of Operations Jason Hughes turned to WesTrac to identify the best underground loader to suit their operations – both now and into the future.
The team was recommended the Cat R2900 XE Diesel-Electric Underground Loader – a hard-working machine capable of enhancing productivity by 20%, improved breakout force by approximately 35% and increasing fuel efficiency by up to 30%.
As Jason explains, the productivity and efficiency advantages of this new model, compared to its predecessors, immediately caught Alkane’s interest.
“There are a number of advantages to these new machines; they are a step change from the old Cat 2900G series and the smarts on these machines will see us get a lot longer life and lower operating costs,” Jason explains.
“We realised if we made the decision to change in another three years’ time after we had rebuilt the current series, the waitlist probably would have been a lot longer and we would have missed three years of lower cost production.”
One of the greatest benefits of the Cat R2900XE is its exceptional fuel efficiency, providing the power needed by operators while also reducing RPM, fuel burn, heat generation and exhaust emissions.
Alkane Resources Technical Services Superintendent Dylan Ullyett says this fuel efficiency will make the company’s operations more sustainable, while also creating a better working environment for the 260 workers on site.
“We’re consuming less diesel, so we don’t have to use as much ventilation [underground], which is a benefit for us in the long run,” he says.
“Our carbon footprint has been reduced as well by using those Cat R2900 XE Loaders, we should be seeing a reduction of about 30% across our fleet in fuel consumption – that’s huge.”
Alkane has become one of the first mining companies in New South Wales to utilise this next generation machine, which Alkane Underground Manager Andrew Brown believes will benefit the company.
“It’s an upgraded loader with an upgraded system; so we are expecting upgraded performance, efficiency, and cost reduction. Being one of the first enables us to lead the way,” Andrew explains.
“It’s being able to show that we can, as a group, implement something that’s new and different and be successful, so not only do we see benefits from costs and productivity, we also then potentially see benefits from attracting talent to come to Tomingley and be part of an operation that’s known for doing things not only differently, but better.”
But it’s not just the machine doing the heavy lifting. Alkane Resources also invested in Cat MineStar™ Command, which Jason first witnessed in use at the Caterpillar Proving Grounds in Burnie, Tasmania.
“The technological gains that this new Command system has from where it was in the underground space even three or four years ago is a large change,” Jason says.
“We’ve used an aftermarket remote system previously, but when we went down to Burnie and saw how Caterpillar have fully integrated the remote system with the technology upgrades on the Cat R2900 XE, we then realised the benefits of using the technology as the OEM intended rather than as an aftermarket setup .”
Cat MineStar Command allows workers to operate the machines remotely, improving navigational accuracy, boosting productivity and optimising shift changes – ultimately reducing downtime.
Caterpillar Senior Regional Representative Terence Reeves says while relocating operators from the cab of loaders improves site safety, the ability to customise the system has been an additional benefit for mining companies.
“It’s no secret that underground mining presents special challenges when it comes to safe and efficient operation,” Terrence explains.
“That’s why Caterpillar tailors the MineStar solution to the unique needs of the environment – no matter the size, type or complexity of the underground operation."
“We put it on a building block approach, so depending on what the customer needs; they could have a base level of technology all the way up to full autonomy."
“Especially in an underground environment, the safer we can make operations, the better.”
According to Jason, this customised approach to the Cat MineStar Command solution, along with the improvements to productivity and uptime, were key for Alkane.
“Caterpillar were very open to our suggestions on some of the other things we wanted to do on the remotes within the operation,” he says.
“We were very happy that Caterpillar wanted to work with us to develop other areas of remote capability on other machines in our operations.”
WesTrac Mining Sales Manager Richard Peck worked hand in glove with the company and Caterpillar to find and deliver solutions with reduced greenhouse gas emissions for Alkane’s underground operations.
He believes more mining companies will soon be turning towards diesel-electric machines like the Cat R2900 XE and supporting systems like Cat MineStar Command, as the industry increases its focus on safety and sustainability.
“As mining customers try to remove people from underground operations, more are going to an autonomy type system or having remote operations where we can have the machines being operated from the surface or from a safer area,” Richard explains.
“I can see autonomy being rolled out a lot more. We're already talking to a lot of other customers and using Tomingley as a stepping stone to show them that we can do it.”
This next generation of mining equipment also complements Alkane’s sustainability strategy, as the company works towards making its operations more sustainable for years to come.
“Sustainability is important to Alkane, as with all mining companies, and we see the Cat R2900 XE as a step in the right direction for being able to use this new technology and show that not only does it have an economical saving, but an environmental benefit as well,” Jason explains.
Jason’s advice to other mining companies is to talk to WesTrac about the benefits of introducing Cat R2900XE’s to improve their operations.
“The professionalism and the working relationship we’ve had with WesTrac and Caterpillar through this whole process has been very commendable,” Jason explains.
“We have done step changes in the levels of the technology with new equipment with other OEMs and haven’t had this sort of backing and support."
“They actually know what’s required to make the implementation of these new machines successful, and without Caterpillar and WesTrac’s help, it wouldn’t have been the success it is.”
As one of the largest authorised Cat equipment dealers in the world, WesTrac provides customers with a wide range of mining and construction equipment as well as comprehensive whole-of-life management solutions designed to make owning and operating equipment as easy, profitable and safe as possible. With more than 4,500 staff, WesTrac is focused on long-term customer relationships and a dedication to customer service, safety, quality and the environment.
To achieve this, we commit to building better together through collaboration and collective action. Helping customers achieve their own ESG objectives to reduce emissions through product advancements and technology solutions. This shared goal of a sustainable future for all is why we are focused on Responsibility, Advancement, Community, Inclusivity, Development and Solutions, as a means to deliver long-term positive success for the environment, customers, team members, stakeholders and the wider community.
Alkane's projects and operations are primarily located in Central West New South Wales.
Alkane own and operate Tomingley Gold Operations, an open pit and underground gold mining development, located 50km southwest of Dubbo. This residential operation has a workforce of more than 250 employees and contractors. Following the approval of the Tomingley Gold Extension Project in February 2022, the operation is approved until the end of 2032. Tomingley’s 1Mtpa processing facility poured 70,253 ounces of gold in FY23.
Alkane is headquartered in Perth, Western Australia, and their exploration team is based in Orange, NSW. The company was incorporated in 1969 and is listed on the Australian Securities Exchange (ASX:ALK).
Caterpillar Inc. is one of the world’s leading manufacturer of construction and mining equipment, off-highway diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives.
For 100 years, Caterpillar have been helping customers build a better, more sustainable world and are committed and contributing to a reduced-carbon future. Caterpillar’s Innovative products and services, backed by a global dealer network, provide exceptional value that helps customers succeed.
Caterpillar does business on every continent, principally operating through three primary segments – Construction Industries, Resource Industries and Energy & Transportation – and providing financing and related services through Financial Products segment.
