IPCC TECHNOLOGY
IPCC operations are possible with compromises regarding operational flexibility – but the success of an IPCC system can also benefit from combinations with trucking – where truck technology changes are on the way with pure battery driven , trolley assisted and less fuel consuming hybrid drives , combined with more autonomous fleets and better fleet management .”
Talking about another important application of continuous conveying technology - dry tailing handling , he pointed out that as in production mining , every tailings project has its own special design criteria – material properties , capacities to be achieved , permitted dumping areas of all kinds and shapes , whether flat surfaces , valleys or something in between , “ and last but not least , the possible dumping height of single lifts and the overall dump height is important for the development of a feasible and cost effective scheme and the related equipment selection .”
A second important aspect is the consideration of the final steps of tailings processing in connection with the development of a tailing disposal system . “ Dry stack tailings as a means towards safe and environmentally sound final storage of tailings requires the relevant equipment to produce conveyable and stackable material with sufficient slope stability and permissible ground pressure to enter with mobile equipment , even after a certain time of settlement for multi lift dumping solutions .” TAKRAF , together with DELKOR , offers combinations of equipment for dewatering of tailings and different alternatives for dry stacking such as shiftable conveyors or mobile bench conveyors with stackers / spreaders of all kinds as well as mobile stacking bridges .
Semi-mobile gyratories at the heart of high throughput IPCC
Staying with the semi-mobile theme , thyssenkrupp Industrial Solutions has an enviable reference list for large semi-mobile crushing stations equipped with gyratories , with its focus on high performance but with ease of serviceability . The designs run up to the KB 63-130 Pro , which is capable of 14,000 t / h in certain applications . Features include hydraulic main shaft adjustment for overload protection and to adjust the crushing gap to compensate for wear . And the additional “ Pro ” design features a maintenance friendly design due to easy access to all heavy components from above , easy modification of eccentricity , adjustable pinion gear , etc . They form the key part of semi-mobile crushing stations in many of the world ' s IPCC systems , equipped with feed hopper , feed conveyor ( applicable for indirect feed SMCP ), discharge conveyor and material transfer belt .
A good example of a repeat customer for these in-pit semi-mobiles is First Quantum Minerals ,
which has entrusted TK with its in-pit crusher needs across several of its key copper operations . Most recently this has included four direct feed semi-mobile crushing plants with gyratory crushers at FQM ’ s Cobre Panama copper mine . Two of the four crushing plants are equipped with a 4,500 t / h KB 63-89 gyratory crusher , while the other two plants are equipped with the largest gyratory crusher KB 63 -130 Pro , which , thanks to its compact design , has the same overall height as its “ smaller brother ” and thus enables the same plant concept with higher throughputs up to 11,000 t / h at only a slight additional weight .
Over at Sentinel mine in Zambia the fourth inpit crusher at Sentinel , a similar design to Cobre Panama ’ s SMCP 63-130 , was commissioned in December 2021 , which will enable the plant to increase throughput to 62 Mt / y in 2022 . It adds to three commissioned in 2014 , all equipped with a powerful KB 63-89 gyratory and handling -250 mm copper ore . Kansanshi is also set for a major 25 Mt / y expansion known as S3 , which is yet to be finally approved but if it goes ahead will bring production to 52 Mt / y . It will require two more semi-mobile crushers ( either KB 63-89 or thyssenkrupp KB 63-130 ) operating in open circuit . One of these will be installed near-surface , on the south western side of the Main Pit , and the other will be installed near-surface on the south western side of the South East Dome Pit .
On maintenance , thyssenkrupp told IM that its gyratory crusher services not only enable increased production and cost-optimised processes but also ensure a longer service life and more safety . These services include : n Rock-Box Spider Cap & Arm Liner Optimisation n Crushing Chamber Optimisation by usage of improved concave design n Wear Parts Optimisation including Metal Matrix Composite ( MMC ) technology n Advanced Concave Change Outs by usage of Mounting Racks , Dismantling Devices and Spare Shells n Reporting & Consulting to optimise crusher performance . Detect and rectify faults at short notice through analysis of plant operating and process data
Semi-Mobile Sizing Stations in China
Construction of two MMD Semi-Mobile Sizing Stations has recently been completed in China ' s northeast Inner Mongolia Autonomous Region . Xilinhe Coal Chemical Co Ltd , part of China Energy Group , also known as CHN Energy and the largest coal producer in the world , placed the order with MMD China through Ningxia Coal Construction Company in February 2021 to help meet the mine ’ s expansion goals . This will see annual production increase from 3 Mt / y to 15 Mt / y . The mine ’ s estimated 652.92 Mt coal
reserve is forecast to serve for a minimum of 39.5 years .
Temperatures within the mine can drop as low as -42.1 ° C during the coldest months of the year . MMD has machines operating in colder environments around the world , but this is one of the coldest within China . Fed by trucks each Semi-Mobile Sizer Station features a MMD 1150 Series Sizer and a D7 Feeder , capable of processing coal at a rate of 2,200 t / h . Manufacturing of the components has been a collaborative effort from several MMD facilities worldwide . For ease of installation , final assembly is being conducted on site with prefabricated sections . The sizer stations are fully assembled and installed and are due to be commissioned in June 2022 .
MMD has been producing semi-mobile In-Pit Sizing and Conveying ( IPSC ) units since the early 1980s . Generally fed by a small fleet of trucks transporting material short distances from the mine face , the Sizer™ unit reduces material in preparation for efficient conveyor haulage out of the mine . As the mining face progresses these units are relocated occasionally to minimise the truck haulage distance . Semi-Mobile Sizer units leverage the flexibility of truck haulage together with the efficiency of conveyor haulage . This provides the ideal efficient solution for many mining scenarios where mining flexibility is vital , such as selective mining ( blending ), heavily faulted seams or irregular shaped orebodies . Semi-mobile units are constructed in easy-toassemble modules that can be relocated closer to the mine face by the MMD Atlas Transporter . To deliver the best IPSC solution for each project the MMD Sizer Station is tailored to the application . From concept designs through to detailed optimisation , MMD says it uses the latest software and technologies in combination with many years of experience to adapt the design to the material , environment and mining parameters as well as providing simple and efficient relocations and safe convenient access for inspection and maintenance . With some of the latest specialist software , engineers at MMD can build an accurate simulation of material dynamics and material flow to validate the design and optimise the capabilities and efficiency of a Sizer station . " The MMD Sizer is a core tailored component of each Sizer station - reliably reducing material and producing a consistently sized product ready for long haul by conveyor . Since the Sizer ’ s inception in 1980 , MMD has developed the technology to be successful in a wide range of applications , from soft , wet and sticky materials through to harder and more abrasive materials . Recent developments have seen the MMD Sizer successfully process even harder and more abrasive material , such as granite , copper ores and platinum ores amongst
APRIL 2022 | International Mining 43