31.10.2013 sandvik in pit crushing & conveying (ipcc), doug turnbull
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SANDVIK In Pit Crushing & Conveying (IPCC)HOW DO YOU MAKE AN IPCC SYSTEM FUNCTIONOctober 2013
1 Sandvik Mining SystemsDoug Turnbull
Safety firstSandvik Mining (130 countries)LTIFR 2.5TRIFR 9.3AIFR 31.2 (38.8m manhours approx half factories and half sales/service pa)
EmergencyExit
Sandvik’s objective is zero harm to our people (incl contractors), the environment we work in our
Sandvik Mining Systems (MH Projects)LTIFR 1 1the environment we work in, our
customers and our suppliersLTIFR 1.1TRIFR 5.1AIFR 14.8 (over 60 projects with 8.2m manhours
per annum)
Protective Equipment
EmergencyEmergencyNumber
Every country, every city, every hotel, every minesiteis slightly different
Germany 112,USA 911,
AssemblyPoint
Alarm
2
g y,UK 999Australia 000
Our brand historySandvik Mining and ConstructionToro
yDriltechEIMCO
EJC
Hagby-AsahiImplemin
SDSEJCSecomaRammer
RoxonVoest-Alpine
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SharkHydramatic
ExtecVoest AlpineTamrock
Sandvik Rock ToolsDrillmaster
MissionBrøyt
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MissionMGT BPI
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Sandvik Mining SystemsDoug Turnbull
IPCC – not rocket science, not new, poorlyexecuted in Aust - BUT a viable alternative to traditional trucks
Spreader DumpingCrusher
Area
ConveyingSystem Capacity : 20MBCM/yr
Ramp Conveyor slope: 25%Conveyor width: 1800mm
In-Pit Crushing and Conveying(IPCC)
Crushing & SizingTechnology
ConveyingKnow-how
Sandvik Mining SystemsDoug Turnbull
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IPCC classifications
Shovel/Truck operations
IPCC classifications
Shovel Trucks Dump/Mill
p
Shovel Trucks Dump/MillCrusher Conveyors
Semi-mobile, semi-fixed or fixed crushing plant concept
Fully-mobile crushing plant concept
5Shovel Dump/MillFully-Mobile Crusher Conveyors
IntroductionIn Pit Crushing & Conveying (IPCC)In Pit Crushing & Conveying (IPCC)
1. Continuous mining is common in lignite & soft coal mines for decades – loading using bucket wheel excavators, continuous haulage by conveyors, waste dump spreaders
22. In hard rock applications – truck and shovel is prevalent
3. Development of crushing technology has enabled IPCC in all rock applications
4. IPCC has many economic & environmental advantages over truck and is increasingly competing
5. 4 types of IPCCFixed IPCC (crusher at or near pit rim versus plant)
Semi fixed IPCC (moved every 5-10 years) *** This is what some of the industry knows well***
Semi mobile IPCC (moved more frequently, steel construction only)
Fully mobile IPCC (truly truckless main production mining)
6. Equipment & mine scheduling/planning completely different to traditional truck/shovel – so h f d dtherefore – modest acceptance to date.
Sandvik Mining SystemsDoug Turnbull
6
IPCC History
• Mining history has many IPCC failures
IPCC History
• Many pretend to know all about IPCC
• Is it Continuous Mining?
• Crushing technology has changed
• Companies - no trust in IPCC – believe it is a viable solution (1st to be 2nd syndrome and they know trucks)
• IPCC teaching in universities?
• Commercially available IPCC scheduling software?Commercially available IPCC scheduling software?
• Some companies are embracing and making IPCC work far more competently than others – why? We know what
we do NOT want
7 Sandvik Mining SystemsDoug Turnbull
Change over from shovel/truck to conveyor mining
It really is a mindset change
Sandvik Mining SystemsDoug Turnbull
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mindset change
Why the interest in IPCC?Why the interest in IPCC?1. IPCC can reduce manning requirements
2 IPCC is already automated from single control room2. IPCC is already automated from single control room
3. Mining industry is faced with newer issues:• Increased waste stripping
• Ageing workforce
• Fuel prices continually increase
• Tire supply still not easy to get, especially large E/M tires
• People no longer attracted to mining for the money prefer lifestyle choices
• More cost burdens to mining (carbon tax, emissions tax, higher profits tax, free carried share % etc)
• Logistics on bulk commodities (eg fuel/tyres) more difficult & more expensive
• The need for opex reduction to allow mining for our future generations to improve standards of living
Sandvik Mining SystemsDoug Turnbull
…So why does IPCC help out???…So why does IPCC help out???1. Conveying is arguably safer (less vehicle interactions for starters)
2 Conveying uses electric motors (more efficient than diesel)2. Conveying uses electric motors (more efficient than diesel)
3. Conveyors have a high % of load relative to their weight
4 IPCC reduces the manning requirement (smaller camps & FIFO)4. IPCC reduces the manning requirement (smaller camps & FIFO)
5. IPCC reduces the infrastructure needs (smaller workshops & warehouses)
6. IPCC cuts down the amount of ancillary equipment needed and this6. IPCC cuts down the amount of ancillary equipment needed and this further reduces emissions and costs
7. Crushing waste could be considered “dead” money but the cheaper ope on con e ing & disposal normall far o t eighs the cr shingopex on conveying & disposal normally far outweighs the crushing.
Sandvik Mining SystemsDoug Turnbull
and,
Truck
Que
ensl
aic
sm
ent o
f Qta
tisti
Gov
ernm
Min
es
LTI S
tSo
urce
: GD
ept o
f M IPCC Equipment
L S D
Surface Mining Energy Use and Operating CostEnergy Use and Operating Cost
Biggest consumers of energy at a surface mine are:Haul Trucks andMills in the plant (lets focus on the pit relevant trucks as shown in pie graph)Mills in the plant (lets focus on the pit relevant trucks as shown in pie graph)
Mine Operations Approx Cost Split
DrillingBlastingDigging
>50%
<10% <10%<10%
<20% DiggingHaulingAncillary
Sandvik Mining SystemsDoug Turnbull
W t th li it i d t ith diff t f t d hContinuous Mining systemsWe want the lignite industry with a different front end – a crusher
Sandvik Mining SystemsDoug Turnbull
13 Sandvik Mining Systems
Conveyor systems in all climatesConveyor systems in all climates
Sandvik Mining SystemssDoug Turnbull
14 Sandvik Mining Systems
Requires firm planning NOT flexibility
IPCC Risks
Operating hours must be achievedensure crusher and conveyor relocations realisticensure material parameters (especially on waste) well known
DamagesBlasting near conveyors (it can be done down to 70m)
Electricity requirement is high – do not just assume it will be therey g j
Key mine planning criteria must be understood AND IS THE KEYNo Software for IPCC scheduling available yetDump development schedulingIntra department planning for relocationsIntra department planning for relocationsPlanned throughput is nearly always overly optimisticSystem implementation is mostly underdone
16 Sandvik Mining SystemsDoug Turnbull
1 - Crusher TypeRelative Crusher Throughput vs Rock Strength
12000
14000
Throughput also effectedby input fragmentation, density, moisture and output product size required
8000
10000
hput
tph Gyratory
Hybrid 14-30
Hybrid 18-40
4000
6000
Thro
ugh Hybrid 18 40
Double Rolls
Sizer
0
2000
0 25 50 75 100 125 150 175 200 225 250
Rock Strength MPaRock Strength MPa
2 – Crusher Location2 Crusher LocationSemi Mobile Conveyor
t l
Criteria to define the best Crusher Area:
Crusher Station
tunnels1. Low Preparation Demand regarding:
1. Crusher Box2. Conveyor Routes
2. Accessible before Mining Operations starts3. Protected from Ground Water / Surface Water4. Minimize Truck & Shovel Operations interference.5. Maximum of geotechnical / operational / Human
Safety6. Minimum of Haulage Distances. (between shovel
and crusher), according with the bulk material allocation flow.
7. Relocation ready / prepared.
19 Sandvik Mining SystemsDoug Turnbull
3 – Dump Location3 Dump Location
Criteria to define best Spreader Location1 All it b kfill1. All ex pit or backfill2. Low downtime due to dump conveyor
shifting (<12 Shift/year)3. Large dump volume4 Long d mp con e or length4. Long dump conveyor length5. Large spreader boom/bridge to suit
geotechnical parameters and max width6. Maximum deep cast height7 Preparation on higher layers during7. Preparation on higher layers during
dumping operations on lower levels8. Maximum of geotechnical / operational /
human safety9 Dust emissions impact
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9. Dust emissions impact
Sandvik Mining SystemsDoug Turnbull
4 – Conveyor Route is actually the last thing you do but not the least important as 60% of cost4 Conveyor Route is actually the last thing you do but not the least important as 60% of cost
Criteria to define Conveyor route:1. Maximize Dump Conveyor length
2. Optimize Head Conveyor length according to
volume needed.
3. Minimize Ramp Conveyor length
CrusherCrusher
adC
Vad
CV
Dump ConveyorDump ConveyorCrusher
adC
V
Dump Conveyor 4. Maximize Ramp Conveyor gradient.
5. Minimize transfer stations number.
6. Minimize preparation volumes.
Ramp/Overland CVRamp/Overland CV
Hea
Hea
Ramp/Overland CV
Hea 7. If FM - Maximize Bench Conveyor length.
8. If FM – Create CDP
21 Sandvik Mining SystemsDoug Turnbull
IPCC developmentsIPCC developmentsFully-mobile crusher PF300Semi-mobile crusher steel stations
22 Sandvik Mining SystemsDoug Turnbull
Blasting near IPCC equipmentBlasting near IPCC equipment
Blast above in-pit crusher – note creation of 3 free faces during blast
23 Sandvik Mining SystemsDoug Turnbull
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Conveying system enclose or not?high winds, snowdrifts, heavy rain events?high winds, snowdrifts, heavy rain events?
Sandvik Mining SystemsDoug Turnbull
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NEVER use soft loading on material with clayg y• No grizzly bars
• No rock boxes
• No spoons or lobster back chutes
• Maximise vertical discharge
• Take the replacement impact idlers as best option
• Use flexible curtains with no sticking points
• Ensure that the chute can handle the required tonnage
• All counter to “normal” conveying practice
Sandvik Mining SystemsDoug Turnbull
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Overland Conveyors- regeneration of power for downslope conveyingregeneration of power for downslope conveying
“The largest regenerative long distance “The largest regenerative long distance conveyor in conveyor in BrazilBrazil””
350 TC 03yy
- Length: 2,493.5m
- Lift: -197m - Speed: 6 0m/s
350-TC-03 (3,188.66mx1200mm)
- Lift: -197m
- Capacity: 6,100t/h
Speed: 6.0m/s
- Power: 2,700kW
350-TC-03
350-TC-02 (4,683.85mx1200mm)
340-TC-02(1,735.10mx1200m)
(3,188.66mx1200mm)
Sandvik Mining SystemsDoug Turnbull
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Overland conveyors in straight lines?Example: DangoteExample: Dangote
Radii as low as 1600mare possible
Overland conveyors (limestone)triangular tubular structurebelt width 1200 mm, length 9000 mcap 2500 t/h
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cap. 2500 t/hDangote, Nigeria - 2005
Sandvik Mining SystemsDoug Turnbull
Conveyor sleepers / footingsConveyor sleepers / footingsTrack shiftable conveyors with steel sleepers and rails
Fixed conveyors with concrete sleepers
Typical conveyor transfer point
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Conveyor haulage – Track shifting• Reloaction of shiftable conveyors by “track shifting“• Reloaction of shiftable conveyors by track shifting
• Pipe layer equippped with track shifting head
• TSH is connected to rail
• Lifting of module and lateral movement while travelling along conveyor
• Passes of about one half a metre at a time to achieve final position
• Very fast – typically 2km moved 80m in 1 x 12hour shiftVery fast typically 2km moved 80m in 1 x 12hour shift
Sandvik Mining SystemsDoug Turnbull
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Anchoring sections whilst track shiftingAnchoring sections whilst track shifting
Sandvik Mining SystemsDoug Turnbull
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Waste dump Spreader boom/bridge length determined by material parametersdetermined by material parameters
Dump failures or settlement is of no effect to spreader designed to suit
Sandvik Mining SystemsDoug Turnbull
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Lets revisit – the three main sources for misunderstandings/disappointments
1. Available operation time
2. Calculated and expected tonnage per hour
3 System implemented but not operated as required3. System implemented, but not operated as required
32 Sandvik Mining SystemsDoug Turnbull
Three main sources for misunderstandings/disappointments
1. Available operation time
2. Calculated and expected tonnage per hour
3 System implemented but not operated as required3. System implemented, but not operated as required
33 Sandvik Mining SystemsDoug Turnbull
Available Operation TimeIPCC miningg
• Max operating time per year in IPCC mining operations is between 5000 and 5900 hours, not more.
• Numbers above 6000 hours will lead to• Numbers above 6000 hours will lead to problems in the calculated yearly output.
• Every rule has exceptions, but do not plan with this.
34Sandvik Mining SystemsDoug Turnbull
Available Operation TimeContinuous and semi-continuous miningg
8,760
196150 250
150
360500
392460
EXAMPLE SM
1505,702600
460
Moving in the pit, on the dump, extensions
Complete Planed Weekly Daily Transportation public Shift Belt Shifting Available Unexpected Bad
the dump, extensions in the pit, on the dump
35
year Shutdowns MaintenanceMaintenance holidaysChange op timedowntimeweather
Sandvik Mining SystemsDoug Turnbull
Three main sources for misunderstandings/disappointments
1. Available operation time in continuous and semi-continuous mining operations
2. Calculated and expected tonnage per hour
3. System implemented, but not operated as required
36 Sandvik Mining SystemsDoug Turnbull
Calculated expected tonnageCombination truck size, shovel size to meet the crushing plant g p
Semi-mobile or fixed crushing plant concept
Shovel Trucks Dump or Mill
Crusher Conveyor
g p p
Shovel Dump or Fully Mobile Crusher Conveyor
Fully mobile crushing plant concept
Shovel MillFully Mobile Crusher Conveyor
37 Sandvik Mining SystemsDoug Turnbull
9000.0 mtph
Shovel Classification by Mass Flow(Rock Buckets)
working time: 50 min/h
7000.0 mtph
8000.0 mtph
g /swing angle: 120°material: well shot rock, lumps up to 1 mdensity: 2.2 t/m³swell factor: 1.2conditions: average
5000.0 mtph
6000.0 mtph
3000.0 mtph
4000.0 mtph
EBHE
RR R
984
C
OM
ATSU
PC1
250-
7
&H 1
900
AL
&K R
H 90
-C
&H 1
550
SD
UCYR
US 1
95-B
II
OM
ATSU
PC1
400
EBHE
RR R
994
OM
ATSU
PC1
800-
6
&H 2
250
SD
UCYR
US 2
90-B
II
&H 2
100
XPB
&H 2
100
XPA
OM
ATSU
PC3
000
&K R
H 17
0
&K R
H 12
0-E
UCYR
US 2
95-B
II
EBHE
RR R
994
B
UCYR
US 5
95
UCYR
US 2
95-B
III
&H 2
300
XP
OM
ATSU
PC4
000
OM
ATSU
PC5
500
UCYR
US 3
95-B
I
&K R
H 20
0
EBHE
RR R
995
EBHE
RR R
996
UCYR
US 3
95-B
II
&H 2
800
XP
OM
ATSU
PC8
000
UCYR
US 4
95-B
&H 4
100
BOSS
&H 4
100
&H 4
100
XPB
&H 4
100
XPC
&H 4
800
XPC?
1000.0 mtph
2000.0 mtph
38
LIE
KO P& O&
P& BU KO LIE
KO P& BU P& P& KO O&
O&
BU LIE
BU BU P& KO KO BU O&
LIE
LIE
BU P& KO BU P& P& P& P& P&
0.0 mtph
Sandvik Mining SystemsDoug Turnbull
Calculated expected tonnageCombination truck size, shovel size, crushing plant g p
Dump or
Semi-mobile or fixed crushing plant concept
Shovel Trucks Dump or Mill
Crusher Conveyor
• How many truck ramps?y p
• How long are the truck ramps?
• Size of trucks (truck fleet composition)?
• Size of bunker?Size of bunker?
• Do we have metal detection?
39 Sandvik Mining SystemsDoug Turnbull
Calculated expected tonnageCombination shovel size, crushing plant g p
Fully mobile crushing plant concept
Shovel Dump or Mill
Fully Mobile Crusher Conveyor
• Can the FMCr deal with instanteneous peaks?
• Does the crusher have to deal with it?
• Is the FMCr really fully mobile (relocation time)y y ( )
• Is the connecting link fully mobile?
• Is the positioning of the FMCr to the shovel optimized?
All thi i fl th l t t t t
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All this influences the long term system outputSandvik Mining SystemsDoug Turnbull
Three main sources for misunderstandings/disappointments
1. Available operation time in continuous and semi-continuous mining operations
2. Calculated and expected tonnage per hour
3. System implemented, but not operated as required
41 Sandvik Mining SystemsDoug Turnbull
System ImplementationChange over from shovel truck to conveyor miningg y g
Paradigm shift
42Sandvik Mining SystemsDoug Turnbull
System ImplementationChange over from shovel truck to continuous mining
C h l tig g
Requirements towards mine planning require STRICT adherence – operations is NO longer kingIf bi diff i d l h i
Crusher relocation
If big differences in ore grades or constantly changing layers of coal/overburden/interburden then this is more complicatedThi l i h t f th IPCC tThis explains why most of the IPCC systems are WASTE removal.Change of conveying routes needs lots of manpower for planning and preparation of multi departmentsfor planning and preparation of multi departments upfrontGeology must be well knownBlasting is the same but different near structures!
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Blasting is the same but different near structures!Sandvik Mining SystemsDoug Turnbull
System ImplementationChange over from shovel truck to continuous miningg g
Maintenance in IPCC is also different
Sh d f i di id l li i d ( d iShutdowns of individual lines required (means: no production from this line). This why in FMIPCC we need a CDP.Mining people learning the regimen of process plant shutdowns
if thi b k h td f d b– if something breaks – shutdown comes forward – be prepared – no longer can mining be a free-loader (belt splicing, capital and insurance spares…)Regular chute maintenance requiredRegular chute maintenance required Think of OEM Maintenance & Performance contracts at least for 1st critical years until “knowledge transfer complete”
44 Sandvik Mining SystemsDoug Turnbull
Sandvik Mining – Sales Area Mongoliag gManaging Director
Jamie Ruddy
CFO/ITPeter Wong
HR & EHS ManagerGerelmaa Dagva
Rio Tinto Global Account Manager Tuula Puhakka
Sales ManagerAmarmend Damdinsuren National Service Manager
D id HLogistics Manager
Ulziikhishig Davaadagva
AccountantUurtsaikh Galbadrakh
AccountantAmarjargal Ulzii
MarComsAmarmend
Damdinsuren
Office & IT AssistantYanjinlkhamDashtseren
SupervisorBatsaikhan Ulziisaikhan
David Hope Ulziikhishig Davaadagva
Sales RepresentativeEnkhbat Tsedenjav
Service EngineerNaidandorj Naidansuren
Superintendant Underground
Brian Courtney
Service EngineerSod-Erdene Ochirbat
Service Clerk & Order DeskMunkhtsatsral
Bat-Erdene
Customs Officer Odgerel
Margad-Erdene
W h
UG Service AdvisorMarkku Oksanen
Ulziikhishig DavaadagvaOrder Desk
Munkhtsatsral Bat-ErdeneService Clerk & Order Desk
Superintendent-Conveyors
Scott McCown
Key Account Manager Michael Zirbel
j WarehousemanAmarbat Altangerel
UG Service TechnicianOtgonbayar Enebish
UG Service TechnicianBatsaikhan Ulziisaikhan
UG Service TechnicianGanbat Dashtseren
UG Service TechnicianBold Tsogt
UG Service TechnicianErkhembaatar Byambadorj
UG Service TechnicianErdenebat Amarjargal
Ankhbayar G.Bat-Erdene
Battsetseg O.Bat-Erdene
Tsogtsaikhan Ganbayar
PuntsagMyagmardorj
Sandvik Mongolia LLC 45
gMyagmardorj
Naranbold Bat-OchirTrainee
Ochirbat Ishjamts
Thank YouThank Youhttp://www.youtube.com/watch?v=1eqA8d3OuCo
www.mining.sandvik.comdoug turnbull@sandvik com
46 Sandvik Mining SystemsDoug Turnbull