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 73 of 115

IN-PIT CRUSHING 72 E&MJ • JUNE 2019 High stripping ratios, difficult ground conditions that af- fect truck operation, and high personnel costs also have a role to play in the decision-making process, as material transport costs form a large part of overall mine OPEX. S11D Leads the Way Vale's S11D operation located in southeast Pará, Brazil, is the current poster child for IPCC. Vale announced at an event in London, U.K., last November that it would be injecting a further US$770 million into the project to boost its produc- tion from 90 million metric tons (mt) to 100 million mt. The company has already sunk US$14.3 billion into the fully-truckless mine which is widely billed as the world's biggest mining project. The mine utilizes four PF200 fully- mobile crushing stations from Sandvik Mining Systems paired with Cat 7495 rope shovels and around 30 kilome- ters (km) of conveyors instead of a fleet of 100-ton capa- city trucks. Vale said that, in addition to reducing waste gen- erated through consumables such as tires, filters and lubri- cants, the use of an IPCC-based system has cut its fuel costs at S11D by 77%. ABB masterminded installation of the S11D control system in 2014 to a tune of US$103 million. Using a high degree of automation and, with the aim to cut energy consumption, smart devices are employed to inform downstream equipment about raw material supply, helping to optimise processing operations. The network controls all variables, deactivating unnecessary equipment and consumption points in case of low demand or load. Drones are also used at the mine to survey work areas, plant and ore stockpiles, with the images generated used to support short-term mine planning. FLSmidth inherited management of S11D's IPCC system in 2018 with its takeover of Sandvik's assets, and reports on progress from the site have been quiet of late. Nonetheless, Jabs believes the mine is a solid example of what can be achieved using an IPCC system. "No question that Vale's S11D mine is the lighthouse op- eration when it comes to IPCC," he told E&MJ. "The selection of fully truckless mining with a high degree of automation and digitalization is certainly remarkable. But there are also COMPANY PROFILE-PAID ADVERTISEMENT An MC3000 crusher from thyssenkrupp Industrial Solutions at the YiminHe coal mine in inner Mongolia. (Photo: thyssenkrupp) Alimak Industrial Elevators Alimak is a global leader and pioneer in the design and manufacture of vertical access solutions for indus- trial and construction indus- tries. The company provides permanent and temporary high-quality elevators, con- struction hoists and work platforms built on rack and pinion and traction technol- ogies. The company offers one of the world's most com- prehensive industrial eleva- tor portfolios covering a wide range of car sizes and capac- ities in both non-hazardous and Ex environments. Designed and built to with- stand the most extreme conditions of the world's toughest environments, Alimak elevators rank one of the first choices across industries such as mining, oil & gas offshore and onshore, ports, steel works, cement and power. Alimak's technical expertise built from delivering products across the globe from the Antarctic to the Sahara is available to all users of Alimak elevators, even those in the most least demanding of environments. Elevators for the Mining Industry Alimak has provided industrial rack and pinion drive technology elevators to the mining industry for more than 50 years. In fact, the company has an install base of over 23,000 rack and pinion solu- tions for different industries worldwide, such as mines, pelletizing plants, smelters, concentrators, and other ore processing plants. The deepest Alimak elevator goes 640 meters below ground at the Grasberg mine, Irian Jaya in Indonesia. It is also the highest, situat- ed at an altitude of 4,100 meters. The lowest situated Alimak eleva- tor is in the Sudbury Neutrino Observatory in Canada, about 2,000 meters below ground level. All of the elevators are designed to withstand the harsh environments and abrasive conditions in mines, providing reliable vertical access, anytime, anywhere it is needed. Pioneer of Shaft-less and Machine-room-less Elevators In 1962 Alimak pioneered the rack and pinion drive system that, within a few years, helped establish the company as the world's leading specialist in this technology. It was also Alimak that invented the Raise Climber and the "Alimak Method" of raising in the mid 50's. Alimak rack and pinion elevators are shaft-less and machine- room less. The drive unit is placed on the roof of the elevator car. The elevator climbs on guide rails, which are anchored to the rock wall or structure with expansion bolts. The Alimak rack and pinion elevator can travel vertically as well as at an incline or curve. The size and shape of the car can be adapted to the requirements of the site.

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