Engineering & Mining Journal

JUN 2019

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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Page 61 of 115

MATERIAL HANDLING 60 E&MJ • JUNE 2019 In the mining industry, material at rest doesn't make money. Regardless of whether it's newly mined ore, concen- trates or even tailings, a near-constant, smooth progression of raw feed, finished product and waste from one location to another is necessary for planning, produc- tivity and profits. An exception to the rule might apply to heap-leach operations, but even those depend on material being in the right place, at the right time, and in the right condition or blend. That's why successful mine operators are masters of material handling. In an industry that moves billions of tons of dirt and rock annually at surface operations and where new underground projects are targeting mining rates of 100,000 tons per day (t/d) or more, a few percentage points of material-handling inefficiency can translate into lower profit margins. The expanding scope and functionality of digitally oriented, comprehensive bulk handling packages offered by major play- ers such as thyssenkrupp Industrial Solu- tions, Tenova TAKRAF, FLSmidth, Metso and others seems to point to a shift in vendor and end-user focus away from solv- ing material-handling challenges by appli- cation of sheer physical-equipment force, to a digitalized, collaborative and often cloud-based approach that provides wider, deeper insight into bulk operations and allows end users to detect and alleviate bottlenecks, while optimizing the use of existing assets and requiring fewer workers on the ground. However, despite the trend toward digitalization, there will always be a need for new "iron" — the latest genera- tion of conveyors, feeders, stacker/reclaim- ers and custom-designed special-case ma- terial handlers in a market that is expected to grow at an annual rate of 4.5% or more during the coming years. A sampling of re- cent material handling projects bears out this projection. For example: Siemens and thyssenkrupp Industrial Solutions announced they will collaborate to provide high-capacity conveyors for Anglo American's new Quellaveco copper mine in the Moquegua region of Peru. thyssenkrupp will supply a 4,700-meters (m)-long, 1,830-mm-wide overland con- veyor featuring dual Siemens 5.5-mega- watt (MW) gearless drives operating at a design tonnage of about 11,000 t/h. The scope of supply also includes the com- plete material handling system for the concentration plant, comprising eight in- plant conveyors and 11 belt feeders. The new conveyor system will initially move 127,500 tons of primary crushed ore per day from the pit to the stockpile adjacent to the copper concentrator. The conveyor will pass from one valley to an- other through a 3.2-km-long tunnel. At the stockpile end, the system's stacker is designed to allow the mine to replace the discharge pulley without the need to clear out the stockpile for crane access. First production from the new mine is expect- ed in 2022. thyssenkrupp also designed similar systems for the Antapaccay and Las Bambas mines in Peru. Rio Tinto selected FLSmidth to supply key equipment for a new iron ore mine in Western Australia. The turn-key contract, valued at $56 million, is for design, sup- ply, installation and commissioning of bulk material-handling equipment for the Koodaideri greenfield project. FLSmidth said it will design the equipment to cur- rent Australian standards and incorporate smart 3D design and a variety of advanced engineering solutions such as BulkExpert, the company's well-established stockyard and train load-out automation package that uses 3D laser-scan technology. Construction at Koodaideri will begin this year. Full annual production capacity will be 43 million metric tons (mt) of iron ore. A recent technical report described the general scope of the project's plant-re- lated materials handling requirements: Fi- nal product will be conveyed and stacked separately on to lump and fine product Making the Most of Material Gains Moving massive volumes of mine ore, waste or product is never easy, cheap or trouble-free, but new material handling tech can help smooth the bumps, cut costs and break bottlenecks By Russell A. Carter, Contributing Editor Boliden's Aitik mine installs new horizontal apron feeders designed by Metso and powered by twin Hägglunds hydraulic motors to meet the high throughput demands of a new crushing plant. The twin-motor configuration provides increased reliability and better maintenance access, along with a boost in reserve power and maximum plant capacity of 9,000 t/h.

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