Caval Ridge Reclaimer Automation
Unlocking the Full Potential of Yard Machines
Following Pipar’s upgrade of the train load out automation system at the Caval Ridge Mine (CVM) it became clear that the outloading bottleneck had shifted to its product reclaimer. Through the addition of 3D lidars, a digital twin-based control system was deployed which has effectively removed reclaim delays. This upgrade has taken the reclaimer from a heavily supervised yard machine to a reliable autonomous workhorse.
THE CHALLENGE
Despite having the nameplate capacity, the bucket wheel reclaimer at CVM’s product stockyard struggled with air swinging when facing up to the pile, inefficient slew turnarounds, and frequent bucket wheel overtorques. This meant there was an almost constant need for manual intervention and many reclaim delays which led to long train loading times and, ultimately, empty wagons being railed.
THE APPROACH
The reclaimer's existing control system relied solely on bucket wheel torque feedback and basic stacking and reclaim modelling, giving it no real visibility of the stockpiles. The solution started with addressing that gap.
3D oscillating lidars were selected to provide continuous, high-resolution scanning of the stockpile surface, with a range of up to 300 m, during all reclaim operations. This sensor data feeds directly into a stockyard digital twin: a real-time, precise representation of all stockpiles and yard machines that the control system then uses to make intelligent reclaim decisions.
With an accurate understanding of where the product is at all times, the reclaimer can now automatically adjust bench heights, optimise slew turnarounds, and execute multi-axis relocations. Facing up delays and bucket wheel overtorque events, which previously required constant manual intervention, have been reduced to near zero.
The digital twin also delivers value beyond automation. An intuitive 3D visualisation of the stockyard gives operational and production teams a clear view of site conditions at all times, including automatic alerts when slumped material is detected. This removes the need for operators to physically access potentially unsafe areas to assess the stockpiles.
THE POINT OF DIFFERENCE
Since commissioning, the reclaimer’s performance has vastly improved and reclaim delays have been effectively eliminated. Train loading times have been reduced by 15%, with most trains now loaded in under 2 hours, and the empty wagon rate has halved.
Beyond the clear productivity improvements, this project highlights Pipar’s ongoing commitment to understanding and acting on what customers value most. Upon completion of the upgraded train load out automation system, the Pipar team turned their attention to the next bottleneck: the product reclaimer – and resolved that too. Caval Ridge now has the best outloading performance of any mine in the Bowen Basin.
Want to improve your outloading and unlock your yard machines' full potential? Contact the Pipar team.
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