caterpillar global mining product line hard rock - … · markus frenzel 2012-04-11 caterpillar...

Markus Frenzel

2012-04-11

Caterpillar Global Mining

Product Line Hard Rock CAT Rock Flow System

EXPOMIN 2012, Santiago, Chile

2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

CAT Rock Flow System

CAT Rock Mover: RM900

Hard Rock

Production Conveyor

CAT Rock Feeder: RF300

Dozer Feeder

CAT Rock Flow System Hard Rock

Haulage System

System

Products


CAT Rock Flow System – Feeder and Mover

Production drift

CAT Rock Feeder

CAT Rock Mover Service drift

: Extraction

: Haulage


Rock Feeder and Rock Mover in a Continuous Haulage

System Video


CAT Rock Flow System in comparison to conventional

Block Caving Video


Moving Dozer Plate

Pushing Device

CAT Rock Feeder – RF300 – I

Pushing Cylinder

quantity: 2 stroke: 1,000mm pressuretotal: 5147kN Weighttotal: 13.0 t

Video


Dozer Plate Cylinder

quantity: 4 stroke: 1350mm cycle time: 112.5 sec. pressuretotal: 4,021kN

4300 mm

2000 m

m

10

50

mm

Maintenance:

Dozer Feeder can be removed from draw point at any time for service and hang up

removal. And can be repositioned in drawpoint at any time after work completion.

CAT Rock Feeder – RF300 – II


CAT Rock Mover – RM900 – I

Chain Conveyor

Performance: 900 t/h Chain speed: 0.15 m/s Drive power: 2 x 90 KW Pan width: 1,800 mm Pan length: 3,000 mm Conveyor length: 77 m Chain length: 156.066m Flight bar: 268 (distance=4)

Chain size: 42 x 146 mm

Wear elements can be changed easily


Hydraulic Concept

Central Hydraulic Supply System Individual Supply System (Oil)

WATER HYDRAULICS (HFA) INDUSTRIAL HYDRAULICS (Oil)

Hydraulic System

Trial No.3


CAT Rock Flow Feeder

CAT Rock Flow System: Primary Crusher

CAT Rock Feeder

Primary Crusher

Impact Roll Crusher Sizer

• compact construction; installation on top of RM900 • no foundation and dedicated chambers required • applicable for low medium abrasive rock

• applicable for higher abrasiveness


Electronic control at each single Dozer Feeder: - providing automated operation - recording of operational characteristics (pressures, strokes,…)

Server that links all Dozer Feeders with a central control room

Control room PC: - remote control and remote changing of sequences of the Dozer Feeders - Visualization of the operational data from each Dozer Feeder - Draw control: Steering and recording the amount of ore taken from each draw point

Specifications

CAT Rock Flow Feeder

CAT Rock Flow System: Automation I

CAT Rock Feeder


CAT Rock Flow System: Automation II

Specifications

Control System - One data world (EIP) - Control and visualization of

other subsystem - Load depended conveyor

control

Draw Control - Selective extraction - Flexible sequence / Mix of qualities - Easy Hang-up detection

Subsystem - Communication with pumps,

conveyor and monitoring of chain tension

Data Base - Data storage in SQL database - Real time data logging

State of the Art Automation due to highest level of Functionality and Flexibility

Remote control Draw Control Integration of Subsystems

Data Storage


Reference List of Components

• broad range of expertise based on nearly 100 years of experience in underground mining

Hard Rock Modifications: • adapted to use in abrasive hard rock

Rock Flow Mover

Rock Flow Feeder

Rock Flow Automation

• established system due to substitution in former “Westfalia Lünen” bunker discharge conveyor systems

Hard Rock Innovation: • Pushing Device

• actually operating in several CAT systems (longwall)

Hard Rock Modifications: • customized software for Rock Flow System


CAT Rock Flow System - Review

Technical & Financial Values

Technical HSE Aspects

• Multiplied production when compared to conventional technology (LHD)

• Continuous operation continuous haulage

• Less staff, ventilation, air conditioning, energy and infrastructure

• Mobile feeder (RF300) can be removed from and reinserted into the drawpoint at any time for maintenance or hang-up removal

• Reduced face costs

• Increase of productivity and equipment utilization Reduction of TOC

• Reduced number of active drawpoints reduction of infrastructural efforts and staff

High level of safety

High grade of automation in

mining process

Manless production process

No diesel fumes & heat

Environmentally friendly

Block Caving Mines can improve their production by generating a continuous haulage stream from the draw points by using the CAT Rock Flow System

Financial


CAT Rock Flow System – Trial No. 2

Trial No.2

- Functionality Test -


Haulage System



*CC capacity rated.: 900 t/h

CC capacity mean: 700 t/h

CC capacity max.: >1000 t/h

engine performance: 2 x 75 kW

velocity of CC: 0,15m/s

• 1 Chain Conveyor (75m)

• 4 Rock Feeder (one-sided)

• Impact Roll Crusher

• Central Hydraulic Station

System Components

Specification Chain Conveyor

Codelco “El Salvador” mine

Location

Geology

• volume extracted total : 122,120 t

• extraction rate mean : 260.4 t/h (each RF300)

• extraction rate max. : 880.0 t/h (each RF300)

Test Results

• Porphyritic Copper deposit

• copper content: Ø 0.6%

• deposit: Andesite & Quartz-Andesite

• surrounding rock: Felspar, Bornite,

Chalcopyrite Molybdenum, Gypsum & Quartz

σC = 35 – 270 MPa (Ø 140 Mpa), ρOre = 2.7 t/m³

*CC= chain conveyor



Test Assembly for Trial No.2 , Lünen, Germany , 2007



Codelco- El Salvador Mine -trial No. 2, 2007 -



Codelco- El Salvador Mine -trial No. 2, 2007 -

Video



Trial No.3

- First Industrial Application -


Haulage System


CAT Rock Flow System – Industrial Application

RM900 Capacity: 900t/h

Engine Performance: 2 x 90 kW

Velocity of Chain Conveyor: 0.15m/s

• 4 Chain Conveyor à 75m

• 8 Rock Flow Feeder per

Production Drift (32 in total)

• 16 Hydraulic Stations

• Volume of 5,000 tpd

Trial No.3 System Setup ~

System Details

Production Target

Technical Data

Start of Trial: 2013-July

Period: 18 Month

Production Target

http://www.codelco.cl/prontus_codelco/site/edic/base/port/inicio.html


CAT Rock Flow System – Industrial Application

Conveyor

Sizer

footprint

RF300


Thank you for your attention

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