IPCC
They are designed for high throughput rates and high crushing ratios at low operating and maintenance costs . With seven gyratory crushers of the size KB 63-130 , which have already been installed in various mines throughout the world and have proven themselves in the most efficient and economical way , thyssenkrupp still provides the largest gyratory crusher in the market . Two of four thyssenkrupp semi-mobile crushing plants at First Quantum ’ s Cobre Panama operation are equipped with a KB 63-130 .
Komatsu Mining - operational flexibility with low TCO
For a low-capital mining method that helps keep IPCC operations productive , Komatsu Mining says dozer traps take advantage of high productivity dozers pushing material downhill to reclaim feeder , that collectively moves material . To maximise efficiency , dozer traps require a feeder that is easy to locate . Reclaim feeders are an ideal solution , being typically skid-mounted and dragged or pushed into position by dozers . No foundations are required , and they normally sit on a flat , firm mine floor . The low capital cost of a reclaim feeder often justifies having an extra machine in operation , which is set up in advance of the next move — allowing near-continuous production . If the run of mine material is too coarse for belt conveying , a feeder breaker can be used instead , which is basically a reclaim feeder with the addition of a breaker shaft to crush the oversized material .
Komatsu reclaim feeders meter a stockpile of mineral onto a conveyor belt . The simple , robust design uses a dual-strand chain feeder with different flight bar configurations . The reclaim feeders move material en masse across a wearresistant deck . There are no pans in the machine , so fines leakage is not an issue . The reclaim feeder is an ideal addition for IPCC operations mining with a dozer trap , to efficiently and cost-effectively move material . In December 2020 , IM had reported that Metso Outotec was complementing its line of mobile and modular stationary crushing solutions with a sizer option specially designed for soft ore and aggregate applications . The new additions to Metso Outotec ’ s mobile Lokotrack product line are equipped with Komatsu ’ s sizer technology , and are available in five models ranging from 500 to 4,500 t per hour . Metso Outotec is also offering Komatsu sizers as an option on its FIT stationary crushing stations . The first collaboration between the two companies was for crushing and conveying shale for cement production at TPI Polene , in Thailand . Prachai Leophairatana , TPI ’ s CEO , is focusing on lowering the carbon footprint of cement production at TPI , which IPCC can achieve .
A mobile Lokotrack with a sizer is directly loaded by a hydraulic excavator . Metso Outotec mobile Lokolink conveyors transfer the crushed material to a shiftable conveyor system . A secondary sizer is located at the first transfer point of the fixed conveyors , crushing the material down to less than 50 mm . Sizers were chosen because the feed is a combination of soft , sticky and hard material , depending on the conditions . Material hardness varies between 20 to 200 MPa .
But Komatsu is also streamlining its offer , announcing on March 11 , 2021 that “ recognising the opportunity for its US and Australian-based conveying businesses to develop new capabilities and diversify , Komatsu has signed an agreement to sell those business units to Stellex Capital , an investment company focused on middle-market companies with improvement and growth potential .” The businesses were part of Joy Global Inc which Komatsu acquired in April 2017 .
The sale concluded on March 31 and includes the stock of Joy Global Conveyors Inc and the assets of Komatsu ’ s Australian-based conveying business , which includes assets and facilities in Winfield , Alabama , USA and Somersby , New South Wales , Australia and a transfer of employees . It covers most of the Continental Conveyor business that was founded in 1963 and which Joy Global acquired in 2008 when it bought Continental Global . It includes belt conveyor systems and components for mining applications , including general underground , overland , tunnel , curved , heavy duty , open pit , High Angle Conveyor ( HAC ), and steeply inclined conveyors . It also includes the Goodman-Hewitt brand that includes idlers and pulleys .
LHB ’ s new high angle approach with IBEX
Unlike conventional belt drives , the IBEX system from LHB Mining Solutions GmbH uses a formfit connection to drive the belt . The forces required for operation are introduced via an additional tooth profile which must be
The first Metso Outotec Lokotrack , with a sizer provided by Komatsu , operating at a limestone operation linked to a cement plant in Thailand
vulcanised onto the pulley side of a standard belt . The individual drive modules consist of a drive belt which is driven by two standard geared motors with integrated disk brakes .
The company told IM : Modular , decentralised , drive units initiate the forces required for operation into the belt at specific intervals along the conveyor line , thus completely replacing a head drive . At each unit , the tension in the belt is relieved and the maximum is therefore drastically reduced . This reduction in belt force allows the use of a belt with comparatively low strength . Large asynchronous motors (> 1.000 kW ) are expensive custom-made products and are therefore not stocked as spare parts . Therefore , a failure of a head drive leads to very costly shutdowns . In contrast , failures of individual drive modules of the IBEX system can be temporarily taken over by the remaining motors without affecting the conveying capacity . The standard drives used can be stored as spare parts and therefore enable rapid replacement or maintenance .”
The progressive depth of a deep surface mine also brings with it another problem . “ In order to use a continuous conveyor system , it must be possible to extend its length . If a belt conveyor with head drive is used , a more powerful drive than before would have to be used when the conveying distance is extended ( increasing depth ). By using a modular system , the conveying distance can be extended as required by splicing the belt and adding the necessary amount of drive units . This means that the permissible belt tension is not exceeded , nor does a more powerful head drive need to be purchased .”
Rods attached to the drive belt engage with the vulcanised rubber toothing , thus enabling positive drive . Moisture and contamination can affect the coefficient of friction of force-locked
42 International Mining | MAY 2021