John McCarthyProduct Manager, Joy Global

Employing mobile and semi-mobile crushing equipment designed for quicker, easier and less-expensive moves, Joy Global offers mining operations the ability to shorten truck routes and decrease associated material handling costs. In many applications, the compact design also provides multiple loading options. Haulage equipment can discharge directly into the feeder hopper. Ramps or costly elevating and discharge conveyors are eliminated.

In a coal application, Joy Global is supplying a new feeder-breaker and 8.3 km conveyor system. The crushing and conveying system includes a 200t truck dump hopper and a push pocket for dozer feeding from existing stock piles. A Montabert rock breaker attachment was included as part of the feeder-breaker design to handle any large coal lumps that could possible stall the feeder-breaker. For this project, Joy Global is providing a complete, turn-key solution including equipment, earth moving, civil works, installation and commissioning. The new conveyor has four horizontal curves, multiple crossings of wetlands and public roads and will transfer material to an existing conveyor.

Earlier this year, Joy Global was awarded a contract for a 2500 tph mobile feeder-breaker mounted on crawlers. This equipment will be delivered in 2017. The machine will be loaded by two wheeled loaders. This customer is already operating two similar tracked

mobile feeder-breakers which have been operating for 23 years. The geometry of the feeder-breaker hopper allows both wheeled loaders to be in a dump position on either side. Unlike most crushing options, material flows horizontally in a feeder-breaker which lowers the machine height. This allows more capacity in a compact package and improves the productivity of the loader because it doesn’t have to elevate the bucket as high. Wheeled loaders work well with mobile crushing and conveying systems because their mobility allows them to operate a reasonable distance from the crusher and still maintain good production. Mobile crushers working with excavators must stay in the swing arc of the bucket, which requires the crusher to move with every excavator relocation. The mobile feeder-breaker has a discharge belt conveyor which can luff to transfer the sized material to a series of conveyors in the pit. A Joy High Angle Conveyor (HAC) system is used to load the coal silo.

Other Joy Global options include a semi-mobile feeder-breaker with earth works hopper. In this application, the angle of repose forms a natural hopper as it draws material down. Civil and installation costs for this type of installation are minimal. Typically the civil and installation costs for a crusher dump station are also incurred with every relocation. By minimizing installation costs, the feeder-breaker can economically be relocated more frequently, which reduces the truck haulage costs. Joy Global has multiple feeder-breakers working with this configuration and is currently working on new projects in the feasibility stage.

Joy Global offers Smart Material Handling solutions unique to every mining situation, including high angle conveyor (HAC) systems that can save open pit mining operations up to 50% in material handling costs.

BY MINIMIZING INSTALLATION COSTS, THE FEEDER-BREAKER CAN ECONOMICALLY BE RELOCATED MORE FREQUENTLY, WHICH REDUCES THE TRUCK HAULAGE COSTS

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SMART MATERIAL HANDLING SOLUTIONS

JOY GLOBAL HAS BEEN WORKING WITH CUSTOMERS TO LOWER THEIR TOTAL COST OF OPERATIONS WITH SMART MATERIAL HANDLING. SMART

MATERIAL HANDLING INCREASES TRUCK UTILIZATION AND EFFICIENCIES, WHILE MAINTAINING MATERIAL HANDLING FLEXIBILITY.

JOY GLOBAL OFFERS MINING OPERATIONS THE ABILITY TO SHORTEN TRUCK ROUTES AND DECREASE ASSOCIATED MATERIAL HANDLING COSTS

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