Professional Documents
Culture Documents
Crusher/Conveyor-Systems
Dipl.-Ing. D. Schrder
Krupp Frdertechnik GmbH, Essen, Germany
1. ABSTRACT
New developments in the field of continuously operating mining equipment demand a new way of thinking in
the design and planning of open pit mines. Powerful surface miners and very strong bucket wheel excavators
which dig hard pay material and overburden without drilling and blasting are bridging the gap between the
Bucket Wheel Excavator Systems (BWE), In - Pit - Crushing Systems (IPC) and Shovel - Truck Systems (ST).
Parallel to the new developments in the mining equipment itself we find a lot of other influencing factors which
have to be looked after in the design and layout of open pit mines before the planning group of a mine can be
sure to propose a system which is technically feasible and most economic for the special requirement of the
owner of the mine. The following paper tries to analyze this most complex area from the view of a manufacturer of mining equipment who has to meet all the new challenges to be able to offer always the best mining
systems.
2. INTRODUCTION
Where continuously operating mining systems can be
used in combination with conveyor transport, they are
superior to discontinuously working systems in the
long run as far as costs are concerned. The first topic
of this paper deals with continuous bucket wheel excavator - crusher/conveyor systems. Special emphasis
is given to recent developments in this field.
The design of special equipment for continuous mining, such as the Surface Miner (KSM) and the Truck
BWE (KTB) are also presented.
The paper ends with an economic comparison of
continuous and discontinuous mining systems, while
graphics are presented to demonstrate the fields of
application for these two operating modes, their costs,
and the cases where the individual systems are more
economical compared to others.
Bucketwheel Excavator
KSM-1
Surface Miner
Crusher
(mobile / semimobile)
lignite
Beltwag
en
40
20
30
(Truck)
(Truck)
soft
claystone
marl
Transport
D:\Gew-2en.eps
clay-/siltsto
ne
soft
sandstone
50
100
80
limestone
iron ore
sandsto
ne
12
0
copper
ore
solid
sandstone
natural
stones
crawler
Semimobile Hopper
Spreader
-1-
(Stockpile/
Plant)
1622-D
D:\Schroede\bilder\gew in2e
.eps
6 - 25
20 - 60
40 - 80
effective capacity
[ bm/h ]
service weight
[t]
50 - 1.500
-3-
is
The IPC-System eliminates big portions of the expensive heavy truck transport, especially the expensive ramp haulage.
In figure 11 shown above the truck would have to
move out of the mine over long ramps, while a conveyor system can transport the material over the
shortest distance and inclinations up to 17 - 18 to the
mine border.
Material
hardness
[ MPa ]
Max.
Feed size
[ mm ]
Crushing
ratio
Max.
Quarz
[%]
Water
content at
20% Clas
[ % H2O ]
Hammer
Crusher
4000
100
2000
1 : 70
10
Continuous
Stream
Crusher
3000
50
1200
1: 5
10
Double
Roll
Crusher
7000
100
1800
1: 7
10
25
Impact
Crusher
2000
150
2500
1 : 30
10
10
Jaw
Crusher
1500
350
2000
1: 6
no limit
Gyratory
Crusher
10000
250
2500
1: 6
30
Operating
weight
Max.
Grades
[/]
Under groundpressure
[ N/cm2 ]
[t]
[%]
minutes
50 - 80
300 - 1600
< 10
hours
20 - 50
500 - 1200
< 10
- 300
minutes
10 - 20
200 - 1000
< 10
- 100
hours
< 3
Travelling
Speed
Time for
Movements
[ m/h ]
Wheel - Mounted
400 - 800
Hydraulic Walking
Mechanisms
40 - 100
Crawler - Mounted
Rail - Bound
(Special Applications
only)
Moving System
the service tower, separated from the plant, to accommodate the electrical and hydraulical equipment
and the drivers stand. It is very important that this
tower is separated from the plant, because otherwise
the vibrations caused by the crusher do hardly affect
the operation and the driver inside the stand.
Hopper bin
Apron feeder
Service tower
Gyratory crusher
Crusher discharge
Substructure
el-20
Figure 17 shows the same plant schematically. Important technical advances were made in the last
years regarding the individual components of these
plants, as there are:
- cone crushers balanced by gyrating masses,
- adjustable apron feeders. Apron feeders can be speedcontrolled by hydraulic drives and be moved in their
axis up to 2.5 m for optimum transfer of the material.
The service of such a crushing plant is fa- cilitated
since the apron feeder can be moved off the plant. For
maintenance purposes the crusher cone can be lifted
upwards by a crane.
Normally, a semi-mobile plant is relocated by external traveling mechanisms, such as transport crawlers.
If no transport crawler is available in the mine, a
transporter on wheels can be used, too, as it is offered
by several companies. Formerly, semi-mobile crushing plants were also relocated by walking pads.
Moving System
Adaptable Walking
Mechanisms
Wheel-mounted
Transporters
Transport - Crawlers
Directions
of
Movements
[/]
Travelling
Time for
Speeds
Movements
[ m/h ]
[/]
Under groundpressure
[ N/cm2 ]
Payload
Max.
Grades
[t]
[%]
40 - 100
*)
max. 50
1000
> 5
0 - 400
*)
max. 80
1200
> 10
100 - 300
*)
max. 20
1200
> 10
*) Dependant on travel-distance
6. RENTABILITY ASPECTS
7. Operation Parameters:
A truck operating on a three-shift basis, manned
with 5 persons per truck, costs in a high wage
country, as e.g. Germany nearly 350,000,DM/year.
The same working place, e.g. in the GUS, would
only amount to a fraction of the above costs.
Frequently special energy sources are subsidized
in individual countries, i.e. this has a strong influence on the operating costs.
8 / 9. Financing possibilities and environmental aspects:
A figure is presented in the following to show the
influence of different financing assets to the system decision.
Even environmental aspects, as e.g. blasting vibrations or excessive dust development, are of
de- cisive influence for the system decision.
6. BELT CONVEYORS IN THE MINING SYSTEM
It is in first place the belt conveyor system which
makes a continuously operating mining equipment
pay load of 77 t , this adds to a total of 193 t. The
ratio of pay load to dead load is 193 to 77 = 2.5.
When using a belt conveyor system, 1 m of belt
transports 620 kg of material. The mass rotating and
moving parts, belt, idlers, pulleys, amounts to 154 kg
per meter. Here one obtains the ratio
744 kg to 620 kg = 1.25.
A comparison of the parts to be moved shows that for
a truck unproportionally more dead load has to be
transported than for a belt conveyor system. A further
feature to be considered is that a considerably higher
rolling resistance exits on the truck tires than on the
belt conveyor system. Rolling resistances, even on
well serviced roads, are seldomly lower than 2 %. If
roads are badly maintained and climatic conditions
are unfavorable, the rolling resistance raises quickly
to 4 - 5 %, i.e. related to a transport distance of 100 m
the total material has to be lifted by 5 meters.
This evidences the considerably lower energy requirement of belt conveyors compared to truck operation.
7. SYSTEM COMPARISON
equipment parameters and country specific parameters. On the basis of these data cost comparisons can
be executed for shovel-truck, BWE and for In-Pit
Crushing systems.
As further input to the program the data for the specific project is required, as for example: capacity,
transport distance, fuel cost, interest rates and so on.
The program displays the results for investment costs,
operating costs and the net present value of the project in tabular and graphical charts.
In the following chapters some examples and results
Bucketwheel
Excavator
Bucketwheel
excavator
Beltwagon
Conveyor
shifting equipment
Spreader
Country
Germany
Climate
normal
Type of organization
private
- Transport distance: 5 km
- Lift: 80 m (refer to figure 27)
For a comparison of the system rentability the transport height and the transport distance are much more
decisive.
The lifetime to be expected for a specific project is of
key importance for selection of the right mining system. The calculations have shown that continuously
operating systems should have a longer lifetime
(more than 3 - 4 years) due to their higher initial investment. Since they are in most cases tailored to a
specific application, i.e. can not be so easy resold,
they are only very seldomly cost effective for owners
earning their money with short-term jobs.
In all cases where the sale of the product to be mined,
i.e. to a power plant, cement factory or similar, can be
guaranteed over many years, the continuous systems
will be economic.
Fig. 35 : NPV calculation for 29.2 mio t/a - BWE v. shovel truck
Fig. 36 : NPV calculation for 7,6 mio t/a - IPC v. shovel truck
Fig. 37 : NPV calculation for 30.8 mio t/a - IPC v. shovel truck