IPCC
climate mining operations that reduced water
requirements. With FLSmidth’s advanced stacking
capability (machinery working off stacked pile) and
ability to stack tailings at 15% moisture content,
this meant tangible water savings for Karara.
“At Karara, the dry tailings will be stacked in
four lifts to the maximum height approved by the
Western Australia Government. The solution
proposed by FLSmidth also created a smaller
tailings storage footprint, which also meant
improved site rehabilitation potential.”
Karara worked closely with Bis and FLSmidth
to get the project off the ground and make
Karara the first mine in Australia to take full
advantage of this dry-stack technology,
FLSmidth said. The tailings storage facility is fast
approaching the completion of Lift 1 and,
together with Karara, Bis and FLSmidth are
already in the planning stage to lift the
equipment to the second level.
thyssenkrupp on IPCC optimisation
Whenever major miners face mine extension
projects, they frequently discuss pros and cons
about the implementation of in-pit crushing and
conveying into their operations. IM spoke to
Stefan Ebert, Head of Sales Revamps Mining at
thyssenkrupp Industrial Solutions, who says as
part of these, discussions, the perceived
inflexibility IPCC systems carry with them by
nature always comes up. He says: “Without a
doubt mine planning and operational procedures
need to be considered and adjusted to a wide
extent compared to conventional truck and shovel
operation models. However, it is very fair to also
argue the large opportunities these assets have in
upgrades, which allow adjustments during the
lifecycle of an IPCC system as well as reactions on
changing environmental conditions within a mine’s
operation lifetime.”
Compared with the initial investment of an IPCC
system there are many potential opportunities to
optimise these continuous mining operations with
quite limited resources. “Potential for revamps
range from classic capacity upgrades or de-
bottlenecking for increased availability, but also
optimisation of operational expenditures by
analytics of the installed components or
simplification of maintenance efforts.”
Important for optimisation of IPCC systems is
the analysis of the complete system from crushing
plant via conveyor to the stacking or spreading
unit to achieve an answer on the bottleneck of the
said system. “The detailed analytics of those
systems usually start with root cause analyses.
These collect PLC data and monitor developments
over time as well as behaviour of the machines in
certain conditions. These services are performed
either as single service to assess the asset
condition and develop optimisation measures or
as frequent and pro-active monitoring of the
assets as part of a recurring monthly status
assessment reporting. Based on the collected data
digital twinning takes place, which confirms
considered design data with the data set of the
actual equipment and operation in reality. Based
on the digital twin for both, crushing plant or
conveyor lines, recommendations and statements
can be made.”
For example, it can be worked out if there are
reserves for higher capacities or if there are issues
at certain conditions (eg during start-up). Based
on these recommendations and statements
upgrades and revamps can be developed to
increase value of the asset by increasing
performance (eg capacity upgrade) or by reducing
operational expenditures (eg optimised
component selection based on actual conditions).
Implementing a digital twin and ongoing collection
of relevant data also allows the implementation of
predictive maintenance measures which would
increase the overall system availability and
reliability of operations.
“Introducing solution providers like
thyssenkrupp Industrial Solutions benefits the
assessment of the complete IPCC system by an
analysis without prejudice in relation to any
specific component or equipment. This allows an
open-minded approach to develop the optimum
upgrade recommendation, whether it concerns the
crushing plant, conveyor, idler or structural
steelwork.”
Another key argument from miners on the
inflexibility of IPCC systems is the challenge of
relocation procedures and preparation. However,
Ebert says it must be taken into consideration that
there are service providers like thyssenkrupp
Industrial Solutions who can take over the
shutdown planning and scenario engineering to
support the mine operator with knowhow to
properly deal with this temporary challenge. This
would both include the relocation process support
itself (eg advisory services on the transport
crawler operation), but also analytics of the
structural integrity and
modifications of the
equipment to allow its
relocation. “The main lever
of thyssenkrupp’s
involvement nevertheless
would be the scenario
engineering to ensure a
maximum limitation of the
operational shutdown plus
an implementation of
improvements onto the
equipment en-route.”
Ebert concludes:
“Especially when looking
into capacity changes in a mine operation, semi-
fixed or semi-mobile equipment like those found
in IPCC systems have a definite potential to apply
flexibility to a mine’s operation. There are also
measures worth looking at in detail which have
the potential to optimise operational expenditures
to create increased shareholder value in the long
term.
Komatsu launches new IPCC product
Komatsu launched a new reclaim feeder model, the
Stamler RF-5, at the 2020 CONEXPO-CON/AGG
show in Las Vegas earlier this year. Reclaim feeders
are a type of chain feeder that transfers material
from a stockpile and meters it on to a belt conveyor.
The stockpile can be created by a belt conveyor,
wheel loader or with a truck dump. Reclaim feeders
can also work in a dozer trap configuration.
With minimal civil work required for set up,
reclaim feeders offer a low installation cost,
typically sitting on the ground. They can be easily
relocated to be used where most needed, not
requiring any special equipment to relocate. They
provide an operational flexibility by being able to
be dragged into position with dozers.
Coal or cement operations, which sell multiple
grade products, often use multiple reclaim feeders
to blend the products on the belt. They are a low-
cost option to back-up bucket wheel reclaimers in
a heap-leach application. They can also be utilised
in ports for barge and ship loading. More than 500
reclaim feeders have been supplied by Komatsu to
date with capacities ranging from 500 to 4,000
tons per hour.
To maximise productivity, the fully enclosed,
sandwich belt High-Angle Conveyor (HAC) from
Komatsu is capable of elevating high tonnages of
material at steep angles, up to 90°. Komatsu told
IM that it recently commissioned its 164th HAC
system.
The company added: "Sandwich belt high-
angle conveyors incorporate all-conventional
conveyor hardware, including smooth cover
belting, to provide a very reliable, low-
maintenance system with demonstrated high
availability. Utilising the same components, they
Reclaim feeders from Komatsu allow dozers or
wheel loaders to transfer material onto a
conveyor belt
MAY 2020 | International Mining