Tag Archives: gyratory crusher

AngloGold Ashanti confirms caving plans in Colombia

Automation, Base metals, Bulk handling, Comminution of minerals, Environmental, Explosives and blasting, Mine shafts and equipment, Mineral project development, Mining equipment, Mining events, Mining services, Power supply for mines, Precious metals, Sustainable mining, Water management, , , , , , , , , , , , , , , , ,

The Massmin 2020 crowd got a glimpse of just what will be required to build Colombia’s first underground caving mine during a presentation from AngloGold Ashanti’s Lammie Nienaber this week.

Nienaber, Manager of Geotechnical Engineering for the miner and the presenter of the ‘Building Colombia’s first caving mine’ paper authored by himself, AngloGold Ashanti Australia’s A McCaule and Caveman Consulting’s G Dunstan, went into some detail about how the company would extract the circa-8.7 Moz of gold equivalent from the deposit.

The Nuevo Chaquiro deposit is part of the Minera de Cobre Quebradona (MCQ) project, which is in the southwest of Antioquia, Colombia, around 104 km southwest of Medellin.

A feasibility study on MCQ is expected soon, but the 2019 prefeasibility study outlined a circa-$1 billion sublevel caving (SLC) project able to generate an internal rate of return of 15%. Using the SLC mining method, a production rate of 6.2 Mt/y was estimated, with a forecast life of mine of 23 years.

The MCQ deposit is a large, blind copper-gold-silver porphyry-style deposit with a ground surface elevation of 2,200 metres above sea level (masl, on mountain) and around 400 m of caprock above the economic mineralisation.

Due to the caving constraints of the deposit, the first production level to initiate caving (undercut) is expected to be located around 100 m below the top of the mineralisation at 1,675 masl (circa-525 m below the top of the mountain), with the mining block extended around 550 m in depth (20 production levels at 27.5 m interlevel spacings).

The main ore transfer horizon is located 75 m higher in elevation than the mine access portals at 1,080 masl and the proposed valley infrastructure. The initial mining block will be accessed by twin tunnels developed in parallel for 2 km at which point a single access ramp will branch up towards the undercut; the twin tunnels will continue another 3.7 km to the base of the SLC where the crushing and conveying facilities will be located.

The company is currently weighing up whether to use tunnel boring machines or drill and blast to establish these tunnels.

Nienaber confirmed the 20 level SLC panel cave layout would involve 161 km of lateral development and 14 km of vertical development. There would be six ore pass connections on each level, four of these being ‘primary’ and two acting as backups. The crusher would be located on the 1155 bottom production level.

Due to the ventilation requirements in Colombia the mining fleet selected for Quebradona is predominantly electric, Nienaber said, adding that the units will initially be electric cable loaders powered by 1,000 v infrastructure.

Fourteen tonne LHDs were selected for the production levels based on their speed, bucket size (enables side-to-side loading in the crosscut and identification of oversize material) and cable length, the authors said. On the transfer level, 25 t loaders were specified to accommodate the shorter tramming lengths and limited operating areas (there are a maximum of two loaders per side of the crusher due to the layout).

As battery technology improves in the coming years, the selection of loader sizes may change as additional options become available, according to the authors.

The selection of the present Sandvik fleet was predominantly based on the electric loaders and the OEM’s ability to provide other front-line development and production machines required to undertake SLC mining, the authors said.

This decision also accounted for the use of automation for the majority of production activities, with the use of a common platform seen as the most pragmatic option at this stage.

It has also been proposed that the maintenance of the machines be carried out by Sandvik under a maintenance and repair style contract since there is a heavy reliance on the OEM’s equipment and systems.

An integrated materials handling system for the SLC was designed from the ore pass grizzlies, located on the production levels, to the process plant.

Due to the length of the ore passes (up to 500 m), and the predicted comminution expected by the time the rock appears on the transfer level, larger than industry standard grizzly apertures of 1,500 mm have been selected.

The design criteria for the underground crusher was that it needed to reduce the ore to a size suitable for placement on the conveyor belt and delivery to the surface coarse ore stockpile, after which secondary crushing prior to delivery at the process plant will be undertaken.

Assuming the maximum size reduction ratio for the crusher of circa-6:1 at a throughput rate of 6.2 Mt/y, a 51 in (1,295 mm) gyratory crusher was selected. This crusher is also suitable to support block cave mining should the conversion of mining method occur, according to the authors.

The process plant will include high pressure grinding rolls as the main crushing unit on the surface, supported by a secondary crusher to deal with oversize material. The ore then feeds to a ball mill before being discharged to the flotation circuit.

The gold-enriched copper concentrate will be piped to the filter plant for drying and the removal of water down to a moisture content of 10%, according to the company, while the tailings will be segregated to pyrite and non-pyrite streams before being distributed to one of two filter presses.

Dry stacking of the tailings will be used, with the pyrite-bearing tailings being encapsulated within the larger inert tailings footprint.

With the feasibility study due before the end of the year – and, pending a successful outcome – the proposed site execution works could start in the September quarter of 2021, Nienaber said.

FLSmidth tackles the need for higher power, throughputs with new TSUV Mark 5 gyratory crusher

Comminution of minerals, Equipment maintenance, IoT, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, Sustainable mining, , , , , ,

FLSmidth has launched a new “digitally-enabled” gyratory crusher to, it says, deliver the lowest total cost per tonne of material processed, even when crushing the most challenging ore.

In response to the industry need for higher power crushing and throughputs for lower-grade ores, FLSmidth has developed the TSUV Mark 5 Top Service Gyratory Crusher, the world’s most opex- and capex-efficient gyratory crusher, it said.

FLSmidth’s latest generation gyratory crusher, the TSUV Mark 5, follows the success of the Top Service (TS) and Top Service Ultra Duty (TSU) models.

The unique top-service design prioritises safety, maintenance and efficient crushing performance, FLSmidth says. Unlike other gyratory crushers that require workers to get in underneath the crusher to perform high-risk maintenance, the TS range allows service and maintenance to be carried out from above, increasing speed, safety and simplicity. Additionally, the 100-plus tonne, fully-dressed main-shaft no longer needs to be guided into the eccentric assembly by hand. “Now, the shaft aligns automatically, dramatically reducing risk,” the company says.

All TS gyratory crushers are built for strength, durability and the ability to adapt to the various requirements of mine operators, but the TSUV design adds even more power, capacity and flexibility, to give mine operators a low total cost of ownership, according to FLSmidth.

The improved power handling capabilities of up to 1,500 kW allow miners to process more material as ore yields decline, enabling operations to remain competitive, while the crusher footprint has only nominally increased.

Optimised eccentric speeds ensure maximum throughput without incurring excessive wear rates, the company says. This is a finely balanced equation, based on extensive R&D work, which, together with the new service and operational features, gives operators the lowest possible cost per tonne of material processed, it explained.

“To offer even greater potential to optimise performance, the TSUV Gyratory Crusher is digitally enabled – giving operators more control over operations and availability,” FLSmidth says. “The ability to make fine adjustments to wear compensation, track equipment trends and instantly detect crusher obstructions will enable increased uptime, optimum equipment life and significantly reduce risk of unplanned downtime.”

The TSUV Gyratory Crusher can be connected to FLSmidth’s digital ecosystem, which provides operators with the benefits of both FLSmidth technologies and experience. A range of services is on offer, geared towards maintaining asset health and optimising performance, many of which can be carried out remotely, saving both time and money, the company says.

The TSUV Gyratory Crusher’s advanced control system gives operators a 24/7 view of performance metrics, enabling increased reliability, FLSmidth says. And, with further condition monitoring feedback and controls, maintenance can be more proactive, minimising the risk of unscheduled stops.

“Through a combination of all these features, the TSUV Gyratory Crusher achieves the lowest cost per metric tonne in operation of any crusher on the market and gives you the lowest total cost of ownership,” the company says. “This translates into a reduced environmental impact.”

Chris Reinbold, Head of Global Product Line Management, Senior Vice President, Mining, said: “We remain steadfast in our aim to reduce emissions from mining to zero by 2030. Increasing the sustainability of key equipment, like the gyratory crusher, is part of our core goal to invest in efficiency-focused R&D, to deliver the best available equipment to the minerals industry.”

MACA receives early call up for Red 5’s King of the Hills gold project

Comminution of minerals, Mineral processing, Mineral project development, Mining services, Precious metals, , , , , , , , , ,

Red 5 Ltd says it has taken another key step towards the development of its King of the Hills (KOTH) project in Western Australia, after issuing a notice of award for the engineering, procurement and construction (EPC) contract and the bulk earthworks for the process plant to MACA Interquip.

The EPC contract and bulk earthworks – which encompass the KOTH processing facility, equipping of the bore fields, high voltage power distribution, workshop, warehouse and bulk earthworks – will be undertaken as a fixed‐price contract, Red 5 said.

The KOTH feasibility study outlined a 16-year life of mine plan from open-pit and underground mining, whereby the company would produce 176,000 oz/y of gold over the first six years. The capital cost came in at A$226 million ($158 million) and life of mine all-in sustaining costs were A$1,415/oz.

MACA Interquip, a multi‐disciplined mineral processing provider, has a strong track record of the construction of similar carbon‐in‐leach processing plants to the 4 Mt/y process plant planned at KOTH, Red 5 explained.

Following execution of the EPC contract, commitments to‐date for the KOTH project will total A$143 million, compared with the capital budget of A$155 million for these items – which represent 82% of the total capital budget for processing infrastructure of A$188 million (excluding owners costs and contingency).

Commitments made to date include:

  • Purchase of 240‐bed camp accommodation, water and waste water treatment plants and central facilities;
  • Design and construction contract for a 450‐person village;
  • 6 Mt/y gyratory crusher and 4 Mt/y SAG mill;
  • Early works agreement with APA Group for the gas pipeline lateral; and
  • EPC contract for the process facility and bulk earthworks.

Construction of the village commenced in October 2020 and is on track to be operational in February 2021. The process plant bulk earthworks (for which equipment will be mobilised) are scheduled to commence on December 1, 2020, pending the final remaining permit (currently on schedule).

The EPC contract provides for two phases. The first is limited to A$50 million and Phase 2 is for the remainder of the contract value, which will be released at the discretion of Red 5, based on the status of debt financing.

The notice of award provides for the immediate commencement of the design and procurement activities for the process plant as well as mobilisation of earthmoving equipment to site, Red 5 said. It, however, limits commitments to A$10 million and is an interim measure to allow the plant design and mobilisation for earthworks to commence immediately while the contract is executed.

Once executed, the value of these contracts, together with the purchase of the 6 Mt/y gyratory crusher and 4 Mt/y SAG mill (already awarded to MACA Interquip), is A$129 million.

The purchased long‐lead items of the crusher and mill are currently being transported, in preparation for the planned delivery to Australia late in the June quarter of 2021.

The company is currently calling tenders for both the open pit and underground mining contracts, the independent power producer contract and the supply of gas. These contracts are expected to be finalised in the coming months, it said.

Red 5 Managing Director, Mark Williams, said: “Our decision to award these key contracts and make commitments to significant long‐lead items prior to completing project debt funding reflects our confidence in the robustness of the King of the Hills project.

“Importantly, the commitments made to date are below budget for this stage of the KOTH project, and should give our stakeholders confidence that we are well on track to progress the development of this major project, with production planned to start in June quarter of 2022.”

thyssenkrupp to deliver jaw gyratory crusher to Roy Hill iron ore mine

Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Steel and iron ore, , , , , , ,

thyssenkrupp is to install the first above ground jaw gyratory crusher in Australia at the Roy Hill iron ore mine, in the Pilbara of Western Australia, following an agreement signed with the mining company.

Located 340 km southeast of Port Hedland, Roy Hill has integrated mine, rail and port facilities and produces 55 Mt/y of iron ore, with approval to increase to 60 Mt/y.

The new crusher will be designed for high performance and cost-effective operation, ie low servicing and maintenance costs, according to thyssenkrupp.

Ben Suda, Head of Sales at thyssenkrupp Industrial Solutions (Australia), said: “We are excited and grateful for the opportunity to be supplying Roy Hill with a new primary jaw gyratory crusher. This is the third order for such machine within a short time in Australia. It shows once again the confidence our customers in the country place in crushing equipment from thyssenkrupp.”

The jaw gyratory crusher is characterised by an especially enlarged feed opening, according to thyssenkrupp. It is normally serrated and, together with the upper part of the mantle, forms the initial crushing zone. The coarsely crushed material is then reduced to the desired product size in the crushing chamber below.

Jaw gyratory crushers can handle much bigger chunks of material than comparable gyratory crushers of the same mantle diameter and feature a higher crushing ratio, with less tendency to become clogged in the feed zone as a result of bridging, the company concluded.

FLSmidth to help modernise crushing, grinding circuit at Zijin’s Serbia copper op

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, , , , , , , , , , ,

Zijin Mining Group has chosen an FLSmidth gyratory crusher, SAG mill and ball mill for the Majdanpek mine, part of the Chinese mining company’s majority owned Zijin Bor copper mine, in Serbia.

The delivery of the equipment to Majdanpek, 180 km from Belgrade, is expected to occur between 12 and 18 months from now, with the project estimated to reach completion by the end of 2020. The order has a combined value of around DKK200 million ($30 million), according to FLSmidth, and has been recognised in the order intake for the September quarter.

The order of the new FLSmidth crushing and grinding circuit for the front end of the concentrator comes as Zijin looks to modernise Majdanpek, which will be the largest of its three Serbian copper concentrators, FLSmidth said.

Acquired as part of the majority acquisition of Bor in late 2018, the Majdanpek mine uses open-pit mining and flotation to produce copper concentrates, with a designed mining and processing scale of 10 Mt/y, according to Zijin. The operation is currently at a scale of 6 Mt/y, it said.

In the next six years, the company says it plans to invest more than $1 billion in the upgrading, expansion, or construction of the four mines and smelter at Bor. After the completion of the first phase of the project, it is estimated output will go to 82,000 t/y of copper in concentrates, with the smelter producing 80,000 t/y of copper cathode. After the completion of phase two, this could go to 120,000 t/y of concentrate and 150,000 t/y of cathode.

Manfred Schaffer, President of Mining and Group Executive Vice President at FLSmidth, said: “This extensive order underlines the strong value proposition of FLSmidth to our customers in the copper industry. Our market leading crushers and mills will provide significant improvements for Zijin Mining in terms of productivity and processing efficiency.”

thyssenkrupp wins gyratory crusher order for Julong copper mine in China

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, , , ,

thyssenkrupp Industrial Solutions says it has won an order to supply two sets of gyratory crushers to the Julong copper mine, in China, an operation situated at an altitude of over 5,000 meters above sea level.

“Once again, it shows our solutions and engineering capabilities are able to work under the toughest environmental conditions,” the company said.

thyssenkrupp will support the second phase of the productivity expansion and reconstruction project of the mine, which is operated by Western Mining Group.

The company says it has also recently made progress on two other fronts: First, winning an order to supply two sets of bi-direction drum reclaimers to be used in a “transaction centre” of iron ore in Hebei, China, and, second, witnessing the successful delivery of steel parts for the Hesteel Laoting project.