CONVEYORS
There is more competition within the sector now with Schulte Strathaus joining the ranks of full-service suppliers.“ We can re-engineer complete conveying systems, including sheet metal work on the chutes”, added Hanke.
Hatch deploys EDEM BulkSim to explore“ what-if” scenarios, while performance testing and verifying complex conveyor transfer point designs. Hatch was contracted to upgrade the conveyor transfer point at an existing coal preparation plant. Hatch’ s client required upgrades to accommodate a scheduled increase in production.
The conveyor carried coarse product coal, topped by a layer of filter cake with high moisture content. The existing chute was prone to material build-up of this“ sticky” filter cake, often plugging during surges in flow rate and causing costly downtime.
Although a relatively small conveyor, at 1,200 t / h, it was critical to ensuring constant product throughput to truck-loading bins.
Hatch deployed EDEM BulkSim to design and validate a new transfer point for use under various operating scenarios and levels of filter cake moisture.
The redesign of the transfer chute was accomplished using the EDEM BulkSim Solution, including Material Testing and DEM Material Model Calibration services.
Dynamic flow testing was performed on actual samples of the product coal and filter cake that were representative of actual materials on site. DEM Material Models were quickly calibrated by comparison of physical test results with simulations, using automated parameter sweeps on a cloud computing platform.
Hatch’ s new transfer point design included a flop gate, hinged at the top, to direct flow onto one of two flow paths.
Virtual performance testing of design options was performed under a range of material flow conditions and included highly cohesive materials. This enabled Hatch to quickly select the optimal configuration for production of the detailed design.
EDEM BulkSim simulation showed that the proposed new transfer point design would provide increased throughput and perform better than expected when dealing with highly cohesive materials and at surge in-flow rates.
Hatch was able to verify the performance of the transfer point before fabrication, and simulations showed low wear rates on the receiving chute.
The use of calibrated DEM Material Models provided Hatch with accurate, fit-for-purpose DEM simulations, resulting in a re-design with substantial benefits in equipment reliability during plant start-up and commissioning, and
EDEM BulkSim simulation of material flow for Hatch’ s new design, running at surge in-flow rate( 1,228 t / h). Reliable flow is maintained with flop gate in raised and lowered positions
further benefits of increased plant quality, yield and performance for the client.
New systems
One of the world’ s great copper deposits will soon be accessed with the help of high-capacity gearless driven conveyors from thyssenkrupp. As one of the leading global providers of mining systems, the Industrial Solutions business area has won a contract to supply a material handling system for the new Oyu Tolgoi underground mine in Mongolia. The contract value is in the higher double-digit million euro range. thyssenkrupp will supply a total of nine conveyors with a combined length of 9.5 km as well as seven transfer towers operating at a design tonnage of 7,100 t / h. First production from underground is expected in 2020. The Oyu Tolgoi mine complex is a joint venture between the Government of
Mongolia and Turquoise Hill Resources, which is majority-owned by Rio Tinto.
From a depth of nearly 1,400 m beneath the Gobi Desert in the south of Mongolia, the new underground material handling system is planned to transport 95,000 t / d of copper ore to surface. The main components are four high lift conveyors each equipped with 1.6 m wide steel cord belts and dual 5,500 kW gearless drives from Siemens. Further conveyors will feed the main incline conveyors and tie the new underground system into the existing process facility.
Torsten Gerlach, CEO of the Mining Technologies business unit of thyssenkrupp Industrial Solutions:“ This order again proves that thyssenkrupp is a strong player in the mining and materials handling industry. We are proud to contribute to this project with our intelligent belt conveyor technology and our strong global project execution capabilities. The system will help the Oyu Tolgoi mine set standards in terms of productivity and safety.”
The underground construction activities will transform Oyu Tolgoi into one of the most significant copper mines globally.
The order given to thyssenkrupp includes the engineering, design, and supply of the new material handling system as well as required site support services during the construction and commissioning phases. It will be designed with an emphasis on ease of maintenance. This includes, for example, the ability to quickly replace chute sections as well as idler rolls and belt cleaners. The drive components are massive in terms of size and weight, so great attention will be paid to safely transporting them underground and to ensuring they can be safely exchanged in the future. Overhead bridge cranes are strategically located to not only service the equipment, but also to aid in the erection of the major structures.
thyssenkrupp belt conveyor systems are individually planned and constructed to ensure the best possible solution for every material, every climate zone and, every topography. This downhill conveying system installed in Peru transports 4,500 t of crushed iron ore from mine to the port
50 International Mining | FEBRUARY 2018