caterpillar global mining product line hard rock - … · markus frenzel 2012-04-11 caterpillar...
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Markus Frenzel
2012-04-11
Caterpillar Global Mining
Product Line Hard Rock CAT Rock Flow System
EXPOMIN 2012, Santiago, Chile
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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
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CAT Rock Flow System – Feeder and Mover
Production drift
CAT Rock Feeder
CAT Rock Mover Service drift
: Extraction
: Haulage
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Rock Feeder and Rock Mover in a Continuous Haulage
System Video
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CAT Rock Flow System in comparison to conventional
Block Caving Video
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Moving Dozer Plate
Pushing Device
CAT Rock Feeder – RF300 – I
Pushing Cylinder
quantity: 2 stroke: 1,000mm pressuretotal: 5147kN Weighttotal: 13.0 t
Video
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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
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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
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Hydraulic Concept
Central Hydraulic Supply System Individual Supply System (Oil)
WATER HYDRAULICS (HFA) INDUSTRIAL HYDRAULICS (Oil)
Hydraulic System
Trial No.3
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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
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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
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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
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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
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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
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CAT Rock Flow System – Trial No. 2
Trial No.2
- Functionality Test -
CAT Rock Flow System Hard Rock
Haulage System
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CAT Rock Flow System – Trial No. 2
*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
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CAT Rock Flow System
Test Assembly for Trial No.2 , Lünen, Germany , 2007
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CAT Rock Flow System
Codelco- El Salvador Mine -trial No. 2, 2007 -
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CAT Rock Flow System
Codelco- El Salvador Mine -trial No. 2, 2007 -
Video
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CAT Rock Flow System – Trial No. 3
Trial No.3
- First Industrial Application -
CAT Rock Flow System Hard Rock
Haulage System
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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
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CAT Rock Flow System – Industrial Application
Conveyor
Sizer
footprint
RF300
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Thank you for your attention
&
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