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In-Pit Crushing and Conveying 2012 Bali, Indonesia Stuart Miller Director Operations PT P&H MinePro, Indonesia Bernard Guillemin Business Development Manager, IPCC October 24-26, 2012

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  • In-Pit Crushing and Conveying 2012 Bali, Indonesia

    Stuart Miller

    Director Operations PT P&H MinePro, Indonesia

    Bernard Guillemin

    Business Development Manager, IPCC

    October 24-26, 2012

  • Company Overview

    Wyodak Coal Mine Case Study

    System Developments

    Justifications

  • High Productivity Mining Market

    Extraction Service

    Supporting Machinery Transport Sizing/Crushing

    Surface Drilling/Loading/Conveying

  • Indonesian Mining Environment

  • Indonesian Mining Environment

    Increased operating costs Divergence of diesel costs and coal FOB pricing

    Tire shortage for haul trucks

    New stricter environmental regulations Dust and noise

    Carbon foot print

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    Singapore Gasoil vs API4 Coal Price

    Singapore Gasoil (US$/bbl) API#4 (US$/Tonne FOB)

  • Developing a Turn Key Solution

    2006 Stamler Acquisition

    2011 Le Tourneau

    Acquisition

    2008 Continental Conveyor

    Acquisition

    2012 Turn Key IPCC

    System

  • Joy Global IPCC System

    An integration of Joy Global components

  • Wyodak Coal Mine - Background

    Located in the Gillette Energy Complex.

    Mine mouth power station generating 800 net MW.

    Production reached approximately 5.7MT in

    2011.

    Overburden is removed by conventional truck / shovel operations, with average stripping ratios of 2.6:1.

    Multi seam operation with variable coal quality.

    Blending is required to meet end user requirements, blending occurs at CPP.

  • Wyodak Coal Mine - System

    Two (2) Stamler feeder breakers:

    One (1) track mounted; and

    One (1) skid mounted

    2,150TPH overland conveyor powered by twin

    500HP VD DC motors

    2,150TPH feeder conveyor

    High angle conveyor (HAC) inclined at 60 degrees for a 50m lift, powered by 300HP DC motor.

    Two 4,500T coal silos located at CPP.

  • Wyodak Coal Mine - Results

    Efficient, environmentally friendly, low cost solution.

    Computerized communication, command

    and control system enables

    single operator control.

    Feeder breakers;

    OLC; and

    Grasshopper conveyors.

    System has delivered 93% overall availability and has been in operation since 1994.

    Wyodak has seen a reduction in carbon footprint.

    Wyodak has seen a reduction in operating cost per tonne.

  • Other IPCC experiences

    An number of other mines in the powder river basin have

    taken Wyodaks lead.

    To the right can be seen a IPPC system provide to

    Banpu for Mae Moh mine in

    Thailand in the 90s.

  • High Angle Conveyors Have Come Along Way

  • Sandwich Type Belt Configuration

    Pressing Mechanism Top Belt

    Standard Rolls Bottom Belt

    Joy Globals High Angle Conveyor Technology

    Material elevation

    Dust suppression

  • Existing Types of Haulage from Mine to Processing Plant

    Batch Haulage

    Utilizes trucks

    Provides greatest autonomy/flexibility

    Highest cost of ownership, lower tonnes per hour

    Labor intensive

    Semi Mobile Haulage

    Combination truck and IPCC

    Additional mine planning required

    Productivity gains, lowers cost of ownership

    Continuous Haulage

    Maximizes systems, minimizes individual equipment

    Greatest tonnes/hour potential, lowest cost of

    ownership

    Least labor intensive

  • Joy Global Fully Mobile IPCC

    Material-Overburden

    Mobile Mining Crusher-4170C

    Tonnage-12000 stph max

    Matched to production of 4100XPC

    Converyors

    Overland

    High Angle Conveyor (HAC)

    Spreading conveyors

  • Joy Global IPCC System components are linked

    Optimize productivity on a continuous basis

    On-board Analysis

    Continuous Data Collection

    Cycle Time

    Production Rates

    Cycle Time (sec)

  • Joy Global IPCC Remote Monitoring System

    Synchronized maintenance schedules for entire System

    Enables remote access to multiple users

    Supports comprehensive analysis and reporting

    Fault logs and histogram reporting

    Interactive flowcharts

    Electronic manuals, schematics, & parts books

    Real time production analysis

    At-a-glance status

    CONFIDENTIAL

    Operates as a complete integrated system and not as individual components operating in series

    If you cant measure it, you cant improve it.

  • Joy Global Mine Planning Tools

    Joy global has 4D Modeling capability

    3D Topography with 3D Equipment with Time

    Allows mine planners more flexibility to integrate movement of IPCC System with rest of overall mine plan

    18

  • Joy Global IPCC 3D Modeling Capabilities

    Concept to Reality

    Ability to optimize production consistently

    Validate

    Update

  • Total Cost of Ownership (TCO)

    Detail evaluation on a side-by-side TCO sensitivity or what if analysis, which allows one to quickly understand the quantified

    reasoning with respect to a comparative analysis and the resulting

    optimal equipment selection

    Capital acquisition that disregards equipment reliability and performance can pose a significant overall financial risk regarding

    the viability of a given mining application

    Total Cost of Ownership analysis is advantageous over using just capital justification because product price is one of the most un-

    predictable cash flow components

    Conventional Net Present Value (NPV) based analysis requires a full system or complete mine-site study in order to understand the revenue

    associated with a particular mining application.

  • Target key factors in Total Cost of Ownership

    Reliability and Productivity have the greatest impact on TCO ($/ton)

    Reliability= Availability + Component Life + Support

    (Maintenance) (Design Quality) (PT P&H MinePro)

  • Joy Global Partners on Total Cost of Ownership (TCO) Analysis

    Partner in development of detailed TCO sensitivity or what if analysis, which allows quick understanding of the quantified reasoning with

    respect to a comparative analysis and the resulting optimal equipment

    selection

    Work together to analyze capital acquisition with equipment reliability and performance to analyze overall financial risk regarding the viability

    of an IPCC System application

  • Joy Global IPCC System The TCO Advantage:

    EASE OF MAINTENANCE

    PreVail Remote Health Monitoring for data analysis and diagnostics

    Maintenance is performed as a complete integrated system and not as individual components operating in series

    PRODUCTIVITY

    System components linked for continuous optimized production

    SUPPORT

    One stop after market Joy Global Smart Services support for entire System

    SAFETY

    Remote operation technology for complete system

    Fewer operators and support equipment