> Mineral Processing > Engineering Design > Training > Specialist Services > RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services Mobile Crushing and Screening Plant Applications for Small to Medium Sized Iron Ore Projects Presented by Damian Connelly Mineral Engineering Technical Services
40
Embed
Mobile Crushing and Screening Plant Applications for … · Mobile Crushing and Screening Plant Applications for Small to Medium ... Feeders, bins Screens ... was loaded into an apron
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
> M i n e r a l P r o c e s s i n g > E n g i n e e r i n g D e s i g n > T r a i n i n g > S p e c i a l i s t S e r v i c e s > RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Mobile Crushing and Screening Plant Applications for Small to Medium
Sized Iron Ore Projects
Presented by Damian Connelly
Mineral Engineering Technical Services
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
> DISCLAIMER With respect to all the information contained herein, neither Mineral Engineering Technical Services Pty Ltd, nor
any officer, servant, employee, agent or consultant thereof make any representations or give any warranties,
expressed or implied, as to the accuracy, reliability or completeness of the information contained herein,
including but not limited to opinions, information or advice which may be provided to users of the document.
No responsibility is accepted to users of this document for any consequence of relying on the contents hereof.
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Limited capacity
Multiple units required
Complexity
Designs are not as tidy as fixed plant
Mobility varies from manufacturers
Reluctance of operators to embrace the concept
Disadvantages of Mobile Crushing Plants
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Where trucking is >50 km transportable plant stacks up
More suitable for higher grade projects
Project Applications
Source: Crusher Industry website (2013)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Equipment selection, layout, availability, production rate
Lump impact energy on conveyors
Handling dense ores
Types of mobile crushers
Loading arrangements, capacities, lump sizes & belt widths
Comminution characteristics
Ai
CWI
UCS
Design Considerations
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Simplicity
Control rooms
Crib rooms clean up
Service points
Dust issues
Ease of mobility
Operational Considerations
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Availability
Scheduled maintenance
Condition monitoring
Oil analysis
Critical spares
Wear liners
Cranes, contractors
Maintenance Considerations
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Short term projects suit mobile plants
Additional trains, retrofitting
Oversized primary crushers
Good initial solution
Scrap value $$$ benefit
Life of Mine Expansion
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Mobile plants are better suited to dry climates – no
buildings required
Not suited to arctic climates or snow
Issues with tropical wet seasons
Wet sticky clays are problematic
Climatic Considerations
Source: Troy Resources Website (2011)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Off the shelf: no design required
CAPEX for mobile plant is less than fixed plant
No buildings are required
Salvage value higher
Direct capital costs such as earthworks, concrete, structural steel is lower
Indirect costs are lower
CAPEX
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Design Philosophy Small/Medium Plants
> Minimise the number of operations by keeping the flowsheet simple
> Generously size the mechanical equipment, unless we approach a step change in size or the number of units
> Minimise the overall plant footprint and the height of structures – Compact layout especially around low maintenance items such as tanks, thickeners and vessels
– Critically evaluate conveyors angles and lengths
– Use existing bins, tanks as structural support for screens and piping
– Minimise piping and cable runs
> Control the process from one point, minimise the number of control centres
> Don’t over-automate
> Provide a workshop in the work area
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Design Philosophy Small/Medium Plants
(cont.)
> Minimise the operator skills needed to run the plant
> Minimise maintenance personnel and costs – Do not provide extensive on-site maintenance – Short access between maintenance shop-plant-stores – Provide permanent lifting facilities only where regular lifts needed
– Provide ready access around high maintenance equipment – Provide adequately installed stand-by facilities
> Use simple, robust equipment especially for projects in the third world
> Minimise the administrative and management facilities on site
> Optimise working conditions for safety
Note that the real cost of gold projects was approximately halved in the period 1980 to 1990 through application of the above principles
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Typical Closed Circuit Crushing
Source: Grinding Mill website (2013)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Two stage open circuit
Three stage open/closed circuit
Four stage open/closed circuit
Hybrid circuits with HPGR
Flowsheets
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Two Stage Open/Closed Circuit
Source: Grinding Mill website (2013)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Three Stage Open/Closed Circuit
Source: Grinding Mill website (2013)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Four Stage Crushing Circuit
Source: Grinding Mill website (2013)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
New Generation Systems Available
Modular systems with high
capacity
Designed for in pit crushing of
waste
Lower cost than trucking
High volume waste is driving
innovation
Track mounted equipment
for mobility
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Mobile/Semi Mobile
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Crushing plant flowsheet The mined ore contained 50% minus 10mm material. Given the Crushing Work
and Abrasion Indexes, the ore was considered to be not difficult to crush and not overly abrasive
The product from the surface mining did not require primary crushing. The ore was loaded into an apron feeder and fed to vibrating screens. The ore was first screened and the +30mm ore are removed and fed to the secondary cone crushers whilst the -30mm+10mm ore are fed to the tertiary crushers. All crushed product was returned to the screens. The screen undersize (-10mm
fines) reported to the radial stacker for product stockpiling
An automatic sampling station was included on the product stream with samples taken from the conveyor leading to the radial stacker
Examples DSO Iron Ore 5 mtpa Mobile
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Production ramp up
The crushing plant would initially start processing 600 tph
during a single shift. Ramp up was over 18 months to 5 Mtpa
working 24 hours a day seven days a week
The crushing plant included a control room, real time
monitoring and is fully automated
The crushing plant was designed to meet the initial duty
working a single shift of 10.5 hrs/day
Examples Mobile Plant
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
In Pit Crushing Ore
Source: Citic Pacific Website (2010)
In pit crushing and conveying
> 4 mobile in pit crushers
> Largest installation in Australia
> Integrated into mine design
> Advantages
> Reduced atmospheric
contaminants such as dust and
carbon emissions
> Lower overall operating costs
> Fewer trucks required
> Reduced fuel usage
> Reduced manning
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Equipment
The mining contractor supplied the following equipment to feed
the crushing plant:
> Crushing and screening of ore (the contractor crushing and
screening system)
> 3 by vibrating double deck scalping screen (30mm top
deck, 10mm bottom deck); (3.35m by 6.7m)
> 2 by secondary Nordberg cone crushers (CM500)
> 2 by tertiary Nordberg cone crushers (CM 500)
> Automatic sampling station
> 4 by 550 kVa diesel fired generator sets for power supply
> Radial stacker
Crushing Plant Flowsheet
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Bruno Simulation – Mobile Example
Source: Metso website (2008)
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Mobile crushing plants up to 5 mtpa
In pit crushing is driving mobile crushing plants: particularly high volume waste
Advantages are lower CAPEX and better salvage value
For large plants fixed crushing plants
Mobile plant not suitable for some climates
Mobile plants can be moved in less than 7 days
Smaller DSO iron ore projects are ideal
Conclusions
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
Acknowledgement
> Thanks to AusIMM for opportunity to present
> Thanks to various companies, colleagues, engineers.
> METS staff, Vendors and Consultants
> Thanks to laboratory staff
> RESOURCE PROJECTS > TECHNOLOGY > INTEGRATED SERVICES > Mineral Processing > Engineering Design > Training > Specialist Services
> Cape Crushing & Earth Moving Contractors. 2012. Mobile Crushing and Screening Plants. [ONLINE] Available at:
http://www.capecrushing.com.au/index.cfm?objectId=2D78C25D-1422-130F-330268DFA09DDEDA. [Accessed 09 October
12].
> Citic Pacific. 2010. Largest In-Pit Crushing System in Australia. [ONLINE] Available at:
http://www.citicpacificmining.com/articles/latest-news/largest-inpit-crushing-system-in-australia. [Accessed 09 October 12].
> Ferret. 2012. Metso Minerals (Australia) distributes Nordberg HP series cone crushers. [ONLINE] Available at: