Sandvik has applied an innovative 3D methodology to conduct design work on a new crushing plant at Randgold Resources’ Gounkoto mine in Mali. The project entails the crushing of the primary ROM gold ore and transporting it to a secondary crushing station to be stacked by a slewing stacker. Sandvik Mining Systems was awarded the contract in January 2011 and the scope of work included civil, electrical, mechanical and structural design, procurement, fabrication and ex-works delivery of the plant, as well as commissioning assistance. Time Mining erected and commissioned the plant in December 2011.

“One of the keys to the success of this contract was the fact that we harnessed proven Sandvik crushing equipment and technology in the design,” Marnus Fick of Sandvik Mining states. “When it comes to design, the traditional 2D approach with detailed construction drawings is invariably associated with fabrication errors and mechanical equipment not fitting well onto the structural components. On this project we effectively removed a lot of this uncertainty by creating a 3D representation in a data managed environment, using a product called Teamcenter that controls the various revisions the design went through. The critical factor is that all revisions to the 3D design were carried out in a managed environment. This means that we completely captured all associated design data, including vendor data sheets and 2D designs, to reduce errors. In the end we were able to supply Time Mining with a very easily interpretable representation of the plant that made the construction drawings so much easier to understand. It also greatly facilitated the identification of the steel members that arrived on site, effectively shortening the time to project completion.”

He adds: “Combining the 3D design with the data management system also allowed us to compile a bill of quantities and manage it through the various lifecycle stages, from concept through fabrication into logistics control and construction. Taking this approach allowed us to significantly reduce the likelihood of errors and boost the ability to do materials control on site, ultimately increasing the speed of construction.” HAZOPS (hazards and operability studies) were incorporated into the design to ensure safe and efficient operations of the plant. Sandvik also set up a local supply of critical spares through its office in Mali and will continue to support the life of plant via this office.

Gounkoto is a recent greenfields discovery which is located 25 km south of Randgold Resources’ Loulo gold mine. Sandvik’s scope of supply commenced from the top of the tip bin, designed to suit a Caterpillar 777 dump truck. Ore is withdrawn from a 100 t bin via a 1.8 m wide by 7 m long apron feeder, which will deposit the ore straight into a CJ815 Jawmaster primary crusher at a rate of 800 t/h. The crushed -350 mm ore from the primary crusher is deposited via a chute onto a 1,200 m wide transfer conveyor which in turn transfers the ore to the secondary crushing station. The -100 mm product is stockpiled using a 1,200 m wide slewing conveyor capable of creating a plus 20,000 t stockpile. The discharge chutes from the primary sizers are lined with 16 mm VRN400 liners to reduce maintenance downtime in this high wear area. The scope included the total steel support structure of the CS660 secondary crusher, including the structures required to support a 25 t electric overhead crane.

Sandvik Mining Systems is a product area of Sandvik Mining, created in the wake of the recent restructuring of the Sandvik Group’s global operations. The new product area became fully operational in early 2012 and specialises in bulk materials handling solutions. From continuous opencast mining systems and in-pit crushing and conveying (IPCC) to integrated stacking, reclaiming and conveying systems for mines, stockyards, mills and port facilities, Sandvik Mining Systems offers total solutions and turnkey installations including a wide range of individual equipment like crushing plants, reclaimers, stackers, bucket wheel excavators, spreaders and shiploaders.