A fleet of 140 haul trucks keeps things moving at Carajas. Weighing in at 181 tons and capable of hauling 240 tons of ore, Komatsu 830E trucks are commonly seen crawling up and down the winding roads of the mine pits. At more than two stories high, the trucks are hard to miss. And the deep rumble of their diesel engines is unmistakable. Komatsu 830E trucks are designed to operate 24/7/365. But no engine lasts forever—especially in the hot, dusty conditions of northern Brazil. Fortunately, when the time comes, new life can be attained—with an engine repower.
Finding a better way
In 2016, two of Vale’s Komatsu 830E truck engines approached their maximum number of operating hours before overhaul. The end was near. And the risk of a breakdown was growing every day. Both Komatsu 830E trucks were powered by an mtu competitor’s engine. Always on the lookout for a better way, Vale explored their options.
Since the mtu Series 4000 powers many wheel loaders at Carajas, Vale was familiar with the advantages of mtu engines. “Vale recognized the mtu Series 4000 was the right fit, with the right technical factors,” says Marcio Etrusco, service manager, mtu Brazil. “They had a great experience with the engine’s reliability and fuel economy with their wheel loaders. The combination of productivity and low lifecycle costs really appealed to them.”
Vale selected 16-cylinder Series 4000 C21 engines, providing up to 2,500 bhp, for the repower project. For mining companies, productivity is everything. At the same time, they must keep a watchful eye on costs. It’s a tricky balance. Haul trucks maximize productivity by operating at all hours. But the steady workload consumes a lot of fuel and puts a strain on engines. For Vale, the Series 4000’s fuel efficiency, high time between overhaul and exceptional availability would pay off over the long run.