10.29-31.2013, PRESENTATION, SANDVIK In Pit Crushing & Conveying (IPCC), Doug Turnbull

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

SDSUDR

SharkHydramatic

ExtecVoest AlpineTamrock

Sandvik Rock ToolsDrillmaster

MissionBrøyt

Beltreco

FintecExtec

Prok Aubema

1998

MissionMGT BPI

SvedalaKawasaki

1998

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


4

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.


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


Change over from shovel/truck to conveyor mining

It really is a mindset change


8

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


…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.


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


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


13 Sandvik Mining Systems

Conveyor systems in all climatesConveyor systems in all climates

Sandvik Mining SystemssDoug Turnbull

14 Sandvik Mining Systems

Over 200 IPCC Sites WorldwideOver 200 IPCC Sites Worldwide


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


Steps in Planning for IPCC


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.


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

20

9. Dust emissions impact


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


IPCC developmentsIPCC developmentsFully-mobile crusher PF300Semi-mobile crusher steel stations


Blasting near IPCC equipmentBlasting near IPCC equipment

Blast above in-pit crusher – note creation of 3 free faces during blast


23

Conveying system enclose or not?high winds, snowdrifts, heavy rain events?high winds, snowdrifts, heavy rain events?


24

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


25

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)


26

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

27

cap. 2500 t/hDangote, Nigeria - 2005


Conveyor sleepers / footingsConveyor sleepers / footingsTrack shiftable conveyors with steel sleepers and rails

Fixed conveyors with concrete sleepers

Typical conveyor transfer point

28

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


29

Anchoring sections whilst track shiftingAnchoring sections whilst track shifting


30

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


31

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


Three main sources for misunderstandings/disappointments

1. Available operation time


3 System implemented but not operated as required3. System implemented, but not operated as required


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



1. Available operation time in continuous and semi-continuous mining operations


3. System implemented, but not operated as required


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


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


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?


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

40

All this influences the long term system outputSandvik Mining SystemsDoug Turnbull


1. Available operation time in continuous and semi-continuous mining operations


3. System implemented, but not operated as required


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!

43

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”


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


[email protected]

10.29-31.2013, PRESENTATION, SANDVIK In Pit Crushing & Conveying (IPCC), Doug Turnbull

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Transcript of 10.29-31.2013, PRESENTATION, SANDVIK In Pit Crushing & Conveying (IPCC), Doug Turnbull