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In-Pit Crushing and Conveying 2012 Bali, Indonesia
Stuart Miller
Director Operations PT P&H MinePro, Indonesia
Bernard Guillemin
Business Development Manager, IPCC
October 24-26, 2012
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Company Overview
Wyodak Coal Mine Case Study
System Developments
Justifications
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High Productivity Mining Market
Extraction Service
Supporting Machinery Transport Sizing/Crushing
Surface Drilling/Loading/Conveying
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Indonesian Mining Environment
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Indonesian Mining Environment
Increased operating costs Divergence of diesel costs and coal FOB pricing
Tire shortage for haul trucks
New stricter environmental regulations Dust and noise
Carbon foot print
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US
$/T
on
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OB
US
$/B
arr
el
Singapore Gasoil vs API4 Coal Price
Singapore Gasoil (US$/bbl) API#4 (US$/Tonne FOB)
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Developing a Turn Key Solution
2006 Stamler Acquisition
2011 Le Tourneau
Acquisition
2008 Continental Conveyor
Acquisition
2012 Turn Key IPCC
System
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Joy Global IPCC System
An integration of Joy Global components
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Wyodak Coal Mine - Background
Located in the Gillette Energy Complex.
Mine mouth power station generating 800 net MW.
Production reached approximately 5.7MT in
2011.
Overburden is removed by conventional truck / shovel operations, with average stripping ratios of 2.6:1.
Multi seam operation with variable coal quality.
Blending is required to meet end user requirements, blending occurs at CPP.
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Wyodak Coal Mine - System
Two (2) Stamler feeder breakers:
One (1) track mounted; and
One (1) skid mounted
2,150TPH overland conveyor powered by twin
500HP VD DC motors
2,150TPH feeder conveyor
High angle conveyor (HAC) inclined at 60 degrees for a 50m lift, powered by 300HP DC motor.
Two 4,500T coal silos located at CPP.
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Wyodak Coal Mine - Results
Efficient, environmentally friendly, low cost solution.
Computerized communication, command
and control system enables
single operator control.
Feeder breakers;
OLC; and
Grasshopper conveyors.
System has delivered 93% overall availability and has been in operation since 1994.
Wyodak has seen a reduction in carbon footprint.
Wyodak has seen a reduction in operating cost per tonne.
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Other IPCC experiences
An number of other mines in the powder river basin have
taken Wyodaks lead.
To the right can be seen a IPPC system provide to
Banpu for Mae Moh mine in
Thailand in the 90s.
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High Angle Conveyors Have Come Along Way
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Sandwich Type Belt Configuration
Pressing Mechanism Top Belt
Standard Rolls Bottom Belt
Joy Globals High Angle Conveyor Technology
Material elevation
Dust suppression
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Existing Types of Haulage from Mine to Processing Plant
Batch Haulage
Utilizes trucks
Provides greatest autonomy/flexibility
Highest cost of ownership, lower tonnes per hour
Labor intensive
Semi Mobile Haulage
Combination truck and IPCC
Additional mine planning required
Productivity gains, lowers cost of ownership
Continuous Haulage
Maximizes systems, minimizes individual equipment
Greatest tonnes/hour potential, lowest cost of
ownership
Least labor intensive
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Joy Global Fully Mobile IPCC
Material-Overburden
Mobile Mining Crusher-4170C
Tonnage-12000 stph max
Matched to production of 4100XPC
Converyors
Overland
High Angle Conveyor (HAC)
Spreading conveyors
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Joy Global IPCC System components are linked
Optimize productivity on a continuous basis
On-board Analysis
Continuous Data Collection
Cycle Time
Production Rates
Cycle Time (sec)
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Joy Global IPCC Remote Monitoring System
Synchronized maintenance schedules for entire System
Enables remote access to multiple users
Supports comprehensive analysis and reporting
Fault logs and histogram reporting
Interactive flowcharts
Electronic manuals, schematics, & parts books
Real time production analysis
At-a-glance status
CONFIDENTIAL
Operates as a complete integrated system and not as individual components operating in series
If you cant measure it, you cant improve it.
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Joy Global Mine Planning Tools
Joy global has 4D Modeling capability
3D Topography with 3D Equipment with Time
Allows mine planners more flexibility to integrate movement of IPCC System with rest of overall mine plan
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Joy Global IPCC 3D Modeling Capabilities
Concept to Reality
Ability to optimize production consistently
Validate
Update
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Total Cost of Ownership (TCO)
Detail evaluation on a side-by-side TCO sensitivity or what if analysis, which allows one to quickly understand the quantified
reasoning with respect to a comparative analysis and the resulting
optimal equipment selection
Capital acquisition that disregards equipment reliability and performance can pose a significant overall financial risk regarding
the viability of a given mining application
Total Cost of Ownership analysis is advantageous over using just capital justification because product price is one of the most un-
predictable cash flow components
Conventional Net Present Value (NPV) based analysis requires a full system or complete mine-site study in order to understand the revenue
associated with a particular mining application.
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Target key factors in Total Cost of Ownership
Reliability and Productivity have the greatest impact on TCO ($/ton)
Reliability= Availability + Component Life + Support
(Maintenance) (Design Quality) (PT P&H MinePro)
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Joy Global Partners on Total Cost of Ownership (TCO) Analysis
Partner in development of detailed TCO sensitivity or what if analysis, which allows quick understanding of the quantified reasoning with
respect to a comparative analysis and the resulting optimal equipment
selection
Work together to analyze capital acquisition with equipment reliability and performance to analyze overall financial risk regarding the viability
of an IPCC System application
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Joy Global IPCC System The TCO Advantage:
EASE OF MAINTENANCE
PreVail Remote Health Monitoring for data analysis and diagnostics
Maintenance is performed as a complete integrated system and not as individual components operating in series
PRODUCTIVITY
System components linked for continuous optimized production
SUPPORT
One stop after market Joy Global Smart Services support for entire System
SAFETY
Remote operation technology for complete system
Fewer operators and support equipment