IPCC
TAKRAF is building a 55 Mt / y IPCC system project at the Lebedinsky GOK iron ore operations of Metalloinvest
self-propelled TAKRAF maintenance cart on the 14.5 ° inclined pit ramp conveyor for an efficient conveyor maintenance solution . IPCC systems build operational resilience as well as reducing OPEX , increasing safety and providing environmental benefits . With this project , TAKRAF says it has entrenched itself as a leading global partner for customer specific , sophisticated and reliable mining & materials handling solutions .
thyssenkrupp progress with Bogatyr Komir
The huge Bogatyr Komir mine , the largest coal mine in Kazakhstan , located in the Ekibastuz coal basin , is a joint venture company between Rusal and Samruk Energy . It has total commercial reserves of about 3 billion tonnes of coal and provides 42 % of the total coal production in Kazakhstan . The “ Bogatyr ” opencast coal mine was built in nine stages from 1965 to 1979 .
The operation made a choice for a climatefriendly technology already in December 2014 , when they signed a contract for one of the most modern IPCC-systems in the world to date to be supplied by thyssenkrupp Mining Technologies . Guido Hesse , Head of Mining Technologies Russia at thyssenkrupp recently outlined the background to the project and the deal in an article titled : Top Green Solution for Open-Pit Mines – Inpit-Crushing & Conveying Systems .
Hesse states : “ It was a matter of prudence and clever strategy , when the biggest coal mine in CIS , Bogatyr Komir , headed during that time by Viktor Konstantinovich Shchukin , General Director , started a tender for a new Inpit-
Crushing and Conveying System , including a stockyard and train loading station . In principal it was the aim to reduce dust emissions significantly , thus achieving an ecological much greener balance and healthier operation with less CO 2 pollution and major reduced operational costs . Bogatyr intended to change the mine design and to avoid a further increase of rail wagon handling in their open-pit mine in Ekibastuz .”
Another significant character of the new system , Hesse says , is an online coal quality measurement system . “ It was a strict requirement for thyssenkrupp Mining ( tk Mining ) and their partnering company for the electrical / automation part , BEA / Actemium , to enable the achievement of a defined coal quality level .” Directly after the infeed and crushing section a first measurement of the bulk material takes place using radiometric analysis . From the four individual crusher discharge conveyors the coal is transported to a collecting and redundant mine conveyor system . Enroute the material is analysed again using a PGNAA sensor . These conveyors transport the bulk material some kilometres away to a stockyard , which is devided in a left and right wing . The stacking , effected by the Chevron-method , enables Bogatyr to reclaim the coal with the required quality level . This is done by two drum reclaimers . Here another sampling station using EDXRF technology is included . Finally the coal is further conveyed to a two-station train loading system .
“ During contract negotiations from 2013 till end of 2014 Sergey Opanasenko , Vice General Director Bogatyr Komir , pointed also out that the entire system must be designed for deep temperatures . Minus 45 ° Celsius is a normal condition during the long winter season . The winter in Ekibastuz is known for very harsh conditions .” Hesse , who was the commercial leader of the project , adds : “ We had to pay special attention to it , as it was required to install also an automatic wagon detection and loading system . It was challenging as the wagon loading station is positioned on top of the mine , where we are facing adverse weather and unknown wagon sizes with their individual conditions . But we made it and designed a perfect fully automatic solution .”
Compared to a railway system the IPCC system from thyssenkrupp Mining has significant high cost advantages , says Hesse . “ The Return-On-Investement ( ROI ) is remarkable . In principle all mines around the globe with a certain distance from a possible inpit crushing point to the stacking or dumping area as well as a certain conveying volume , should definitely think about an investment in such a system . It is the perfect time to achieve two major goals . The one point is a clear financial advantage with a possible very short amortisation time , and the other point is the
The TK IPCC system at Bogatyr Komir coal mine will be one of the largest and most extensive in the world
36 International Mining | MAY 2021