CURRENT TRENDS
A l l a n D. F e r n i e
Wright E n g i n e e r s L i m i t e d
Vancouver, B . C . , Canada
Abstract.
Growing i n t e r e s t i n p i t c r u s h i n g
and conveying i s e v i d e n t from t h e m y
a r t i c l e s , t e c h n i c a l p a p e r s , and new equipment
development r e c e n t l y presented.
A p p l i c a t i o n o f a p i t c n u h i n g and conveying
system is complex, as many f a c t o r s puch as
mine d e s i g n , p r o d u c t i o n s c h e d u l i n g as w e l l as
i n i t i a l and ongoing capitel. and o p e r a t i n g
c o s t s must be thoroughly and r e a l i s t i c a l l y
examined.
T h i s paper w i l l a d d r e s s t h e fundamentals t o
b e considered and review s e v e r a l approaches t o
developing a t o t a l system f o r a new and e x i s t i n g mine s i t u a t i o n .
The p l a n n i n g f u n c t i o n
w i l l be o u t l i n e d and o p e r a t i n g and d e s i g n
c r i t e r i a d e f i n e d t o i n t e r f a c e t h e mining opera t i o n and t h e p i t c r u s h l n g conveying system.
Introduction
I n - p i t c r u s h i n g and- conveying (ICC) is n o t
t h e u n i v e r s a l panacea f o r r e d u c i n g t h e opera t i n g c o s t s o f open p i t mining o p e r a t i o n s ;
however, economic f o r c e s have caused a move
towards ICC due t o t h e r a p i d i n c r e a s e i n
l a b o u r , f u e l and maintenance c o s t s .
As a l l open p i t mines a r e d i f f e r e n t , and
s i n c e p l a n n i n g a multi-system method o f o r e
and waste e x t r a c t i o n i s far more complex t h a n
f o l l o w i n g t h e t r a d i t i o n a l t r u c k / s h o v e l method
w i t h i t s b u i l t i n f l e x i b i l i t y , a n independent
e v a l u a t i o n o f s e v e r a l mining schemes i s
required
to
select
t h e most
economical
operation.
Hine P l a n n i n g
There a r e two p l a n n i n g s c e n a r i o s f o r ICC t o
c o n s i d e r i n t o d a y ' s changing mining scene,
The first i s f o r a new mine and i n v o l v e s
d e v e l o p i n g b a s i c c o n c e p t s and l o n g r a n g e
p l a n s ; t h e o t h e r i s f o r an o p e r a t i n g mine, and
i n v o l v e s developing c o n c e p t s which can be
worked i n t o t h e e x i s t i n g p i t w i t h o u t i n t e r f e r e n c e w i t h d a i l y production.
Both
planning
functions
may
require
e v o l v i n g s e v e r a l d i f f e r e n t schemes t o f i n d t h e
most p r a c t i c a l and c o s t e f f e c t i v e method o f
t r a n s p o r t i n g t h e o r e from p i t t o p l a n t .
There a r e a number o f b a s i c fundamentals
which must be a d d r e s s e d i n t h e development o f
a n I C C system, whether i t i s planned f o r a new
mine o r an e x i s t i n g o p e r a t i o n . For example:
can a permanent h i g h w a l l b e e s t a b l i s h e d ,
is i t mandatory t h a t t h e p i t develop a s a
cone
no f i x e d wall,
can t h e p i t be mined w i t h push backs,
a l t e r n a t i n g from s i d e t o s i d e ,
c a n a permanent ramp be e s t a b l i s h e d p a r t o f
t h e way i n t o t h e p i t , o r t o t h e p i t bottom,
is t h e s u r f a c e topography and p l a n t s i t e o r
w a s t e dump such t h a t a system o f o r e p a s s e s
and a conveyor ramp t o an a d i t would be
practical.
I n p l a n n i n g t h e p i t i t must be remembered
t h a t a c c e s s o r Bervice ramps need n o t be a s
wide a 3 h a u l a g e ramps and do n o t have t o
t o l l o w o r e production.
The p i t ramp e x i t i s
n o t a s c r i t i c a l f o r a s e r v i c e ramp a s f o r a
haulage road b u t should provide ready a c c e s s
t o t h o p i t shop.
I n d w e l o p i n g a n ICC s y s t e a , c o n s i d e r a b l y
more d e t a i l e d long-term p l a n n i n g is r e q u i r e d .
It i s p o s s i b l e t h a t more i n i t i a l d r i l l i n g
might have t o b e done i n o r d e r t o e s t a b l i s h
confidence i n being a b l e t o reach t h e ore with
a conveyor system and moveable c r u s h e r , s a y 20
t o 30 y e a r s hence. Tbis does n o t mean l o s s of
f l e x i b i l i t y , it i s t o prove t h a t i t is
possible.
It i s p o s s i b l e t h a t phased developnent w i l l
become p w t o f t h e o v e r a l l scheme. iUso f o r a
new mine, i t i s q u i t e l i k e l y t h a t a p i t r i m
c r u s h e r ( f i x e d o r moveable) w i l l be r e q u i r e d
f o r a p e r i o d of t i m e , a s t h e economics of I C C
hinge on r e p l a c i n g t h e h i g h l i f t and long
t r u c k h a u l a g e ramp.
I n o r d e r t o e s t a b l i s h a f l x e d ranp f o r sone
l e n g t h i n t o t h e p i t , it nay be n e c e s s a r y t o
remove a d d i t i o n a l waste d u r i n g pre-production
o r d u r i n g t h e first few y e a r s o f mining. T h i s
a d d i t i o n a l c o s t may be o f f s e t i n l a t e r y e a r s
by p r o v i d i n g extended p i t l i f e w i t h mineable
o r e a t d e p t h by t h e u s e o f ICC.
One n o t a b l e d i f f e r e n c e i n ore/waste haulage
by conveyor v e r s u s t r u c k i s t h e much narrower
conveyor ramp a t 20-25s s l o p e r a t h e r than t h e
7-81 limit placed on t r u c k ramps.
This
r e s u l t s i n a much s h o r t e r o v e r a l l d i s t a n c e
from t h e s h o v e l a t t h e f a c e t o t h e p i t r i m .
I n some c a s e s t h e s e r v i c e ramp f o r p i t
equipment a c c e s s and conveyor ramps t o g e t h e r
a r e t h e same c o s t a s t h e much wider main
h a u l a g e ramp.
An i m p o r t a n t p a r t of t h e concept planning
process i s t h e application of
financial
a n a l y s e s f o r t h e v a r i o u s schemes p r o j e c t e d f o r
a minimum o f 20 y e a r s . Comparative system and
f i n a n c i a l a n a l y s e s w l l l i n d i c a t e t h e concept
most s u i t e d t o t h e mine.
Further detailed
p l a n n i n g on t h e s e l e c t e d scheme can then be
done t o prove t h e f e a s i b i l i t y and v i a b i l i t y
through t h e v a r i o u s phases of t h e o p e r a t i o n .
h e o f t h e more s e n s i t i v e economic f a c t o r s
i n the f i n a n c i a l projections r e l a t e s t o petroleum f u e l c o s t compared t o e l e c t r i c power
cost.
The h i g h e r t h e p r i c e of e l e c t r i c i t y ,
This
t h e l e s s c o s t advantage t h e r e i s t o I C C .
can i n f l u e n c e a d e c i s i o n i f o r when t o proceed
w i t h a system.
Taking t h e complexity o f t h e p l a n n i n g
f u n c t i o n o f I C C i n t o a c c o u n t , i t is n o t
p r a c t i c a l t o develop a p i t and then t r y t o f i t
a n I C C i n t o i t . The planning must be an i n t e g r a t e d process.
H a t e r i a l s Handling
Large volume movement o f ore/waste by t r u c k
from a n open p i t i s u s u a l l y c l a s s i f i e d a s
c y c l i c o r non-continuous a s compared t o c o n t i nuous systems such a s a bucket wheel e x c a v a t o r
combined w i t h moveable conveyors.
The combination o f a t r u c k / s h o v e l o p e r a t i o n
w i t h ICC b r i n g s t h e m a t e r i a l s h a n d l i n & system
v e r y c l o s e t o continuous.
The e l i m i n a t i o n of
long up-hill
h a u l d i s t a n c e s , t r a v e l time,
d e l a y s on t h e ramp, t r u c k queuing a t t h e
c r u s h e r and s h o v e l , means t h a t with s h o r t h a u l , f a s t - c y c l e t r u c k haulage, and a f e e d e r
ahead o f t h e c r u s h e r , c o n t i n u o u s movement of
m n t e r i a l from t h e p i t c a n be achieved.
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Crushing P l a n t (s
Crusher f i x e d , moveable, mobile (walking o r
crawler mechanism)
o Type
jaw, impact, r o l l gyratory
o S i z e r e l a t e d t o p i t equipment
o S e t t i n g r e l a t e d t o p l a n t requirement
o Feed arrangement
double t r u c k dump
apron o r b e l t f e e d e r
o Discharge arrangement
feeder
"take zway" conveyor
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- -
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Conveyors
There a r e two major components t o be
c a r e f u l l y considered
i n t h e design and
selection
of
high
tension
conveyors,
p a r t i c u l a r l y f o r high l i f t , long c e n t r e p i t
conveyors.
The most c o s t l y p a r t of t h e system
f o r both c a p i t a l and o p e r a t i n g a r e t h e b e l t s ,
t h e second being t h e i n i t i a l c o s t of t h e
drives.
Horsepower and b e l t t e n s i o n must be
optimized t o reduce t h e number of b e l t t e n s i o n
r a t i n g s t o one o r two, a s a s p a r e b e l t is a
high c o s t inventory item. The use of m u l t i p l e
d r i v e s reduces t h e s p a r e s inventory and a l s o
allows continued o p e r a t i o n of a conveyor a t
reduced tonnage should a d r i v e f a i l .
When
lengthening o r s h o r t e n i n g conveyors within t h e
p i t , d r i v e u n i t s may be added o r reduced
accordingly.
Conveyor design must address f u l l y , tempera t u r e c r i t e r i a , a s w e l l a s c h a r a c t i s t i c s of
t h e m a t e r i a l t o be handled. This paper i s not
intended t o t r e a t t h e s u b j e c t of conveyor
design but t h e success of an i n - p i t conveyor
system hinges on many component, s e l e c t i o n
f e a t u r e s which a r e highlighted f o r consideration.
Conveyor S e l e c t i o n :
B e l t Width
To avoid s p i l l a g e from a b e l t
c a r r y i n g c o a r s e crushed ore/waste, p a r t i c u l a r
a t t e n t i o n must be paid t o t h e load p o i n t s and
b e l t edge d i s t a n c e t o t h e load on t h e b e l t .
Based on 305 mm, maximum lump s i z e (which
could have a long dimension o f 457 mm), a
minimum of 203 mm edge d i s t a n c e a t t h e load
p o i n t should be allowed.
For c o a r s e o r e
b e l t s , i t i s d e s i r a b l e t o keep t h e crosss e c t i o n a l load t o l e s s than 80% of t h e
Conveyor Equipment Manufacturers Association
s t a n d a r d s (CEMA) when c a r r y i n g t h e design
tonnage.
T h i s means t h a t flowsheet tonnage
w i l l be 65-702 of CEMA depending on c o n t r o l o f
feed t o t h e conveyor system. Peak tonnage can
The crossbe a s high a s 85% of CEMA.
s e c t i o n a l load should then be c a l c u l a t e d using
a 20 degree surcharge a n g l e using 35 degree
A s t h e m a t e r i a l is
equal l e n g t h i d l e r r o l l s .
conveyed over a long d i s t a n c e , t h e dynamic
s e t t l i n g of t h e load can o f t e n reduce t h e
surcharge a n g l e t o 15 degrees.
This reduces
t h e edge d i s t a n c e t o 198 mm which is adequate
t o c o n t a i n t h e load.
For c o a r s e o r e conveyors 4 t o 5
Speed
For overburden conveyors 5 t o 8 m/s.
m/s.
I n c l i n e k n ~ l e A 25% ramp i s considered
maximum f o r maintenance access.
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