Tag Archives: sizers

TAKRAF X-TREME sizers go the distance at Guinea bauxite mine

Three TAKRAF X-TREME class sizers supplied to a large bauxite mining operation in Guinea are, the OEM says, fully delivering on their promise of exceptional reliability and wear behaviour.

Commissioned in late 2018, the sizers had, as of the end of February 2021, crushed more than 27 Mt of bauxite ore and were still operating with their original set of wear parts.

The sizers were supplied as part of an important production expansion project at the mine. This project, awarded in late 2016 to TAKRAF as an EPC contract, encompassed a comprehensive wagon unloading, crushing and conveying system.

The TAKRAF sizers included within the overall system comprised one 3,600 t/h primary TCS-X 14.35 located in the pit beneath the wagon tippler; and two 1,800 t/h secondary TCS-X 08.30 located in the crushing building.

Both the primary and the secondary sizers are from TAKRAF’s X-TREME class sizer range. This range was developed to provide extended reliability and availability through a heavy-duty drivetrain, robust shaft and bearing assemblies, and the use of advanced wear resistant materials.

Ease of maintenance is another advantage of the TAKRAF sizer, with the primary sizer installed on site featuring a bolted tooth system to enable easy and quick replacement when sufficient wear has been experienced, the company says.

Conor Mitchell, TAKRAF Product Manager – Roll Crushers, said: “The combination of high reliability and long lifetime of wear parts means significantly higher machine uptime and that ends up translating into increased productivity for this bauxite operation. These performance levels reinforce that our X-TREME class sizer line provides maximum reliability and availability in difficult conditions, which is something the market has been calling for quite some time.”

McLanahan readies second DDC-Sizer for Queensland coal mine

McLanahan says it has won a second DDC-Sizer order from a coal mine in Queensland, Australia, less than a year after commissioning the first.

With the duplication of the crushing circuit, the site now boasts three McLanahan Feeder-Breakers and four McLanahan DDC-Sizers, the company said.

The mine will be processing a maximum of 715 t/h of raw coal through the new McLanahan DDC-Sizers. The secondary sizer will receive minus 250 mm raw coal from the McLanahan run-of-mine (ROM) coal feeder-breaker, with the final washable product size from the tertiary sizer being a nominal 50 mm. This involves no screening between stages, the company said.

Brad Anstess, Coal Specialist for McLanahan, said: “Not only will the customer increase their production, but they will run the equipment in a parallel configuration; that is, having two three-stage crushing modules – ensuring consistency of supply and meeting annual production goals.”

The process will see ROM coal delivered into each ROM receival hopper. Below these receival hoppers, a McLanahan Feeder-Breaker is installed where it will receive a grizzly-controlled top size of approximately 600 mm x 600 mm x 1,000 mm. The feeder-breaker will metre the feed of these large lumps and break them to a nominal 220 mm x 220 mm x 300 mm size, the company said. These nominal 220 mm lumps of rock and coal from the feeder-breaker are then processed by the secondary sizer to a nominal 110 mm and then to a tertiary sizer for a nominal 50 mm product ready for washing in the coal handling preparation plant.

The sizer assemblies were finalised in April this year and each machine was then prepared for the customer who was invited to the McLanahan Workshop located in Cameron Park, New South Wales, the company said.

Each sizer underwent three-and-a-half hours of factory acceptance testing, with vibration and temperature monitored across a range of components including the bearings, motor couplings and gearboxes. “Both the secondary and tertiary sizers ran as expected by the customer, with some minor adjustments made upon test completion,” the company said.

McLanahan Project Manager and Mechanical Engineer, Chris Raines, monitored both sizers for the duration of the factory acceptance tests, and made relevant adjustments to optimise performance on each machine, the company said.

“The McLanahan workshop team took additional care to focus on ensuring roll centre adjustment was accurate as this was important to the client,” Raines said. “The customer is very happy with the finished product. Particularly with the design improvements we’ve made over previous machines.”

The sizers are awaiting shipment from the McLanahan workshop and are due to be commissioned before the June quarter of 2020.

TAKRAF helps CBG’s bauxite expansion project hit first ore goal

TAKRAF has reported on the recent start-up of Compagnie des Bauxites de Guinée (CBG)’s Bauxite Production Expansion project in Kamsar, Guinea.

The first ore milestone at the project, which sought to increase production from 13.5 to 18.5 Mt/y, was reached on schedule, on budget and, most importantly, safely, at the end of last year.

TAKRAF, in late 2016, was awarded an engineering, procurement and construction contract worth around €100 million ($113 million) for a greenfield railcar unloading and primary crushing station, as well as a secondary crushing station and a brownfield conveyor system. The railcar unloading system was designed in collaboration with Ashton Bulk.

The scope of supply included three TAKRAF sizers, with a primary sizer in the pit beneath the tippler and two secondary sizers. These sizers, as well as the apron feeders, were designed and fabricated at Tenova TAKRAF’s Lauchhammer fabrication facility in Germany.

An important safety milestone of 1.5 million lost-time-injury-free hours was achieved on site in December 2018, according to TAKRAF.

Frank Hubrich, TAKRAF CEO, said: “We are extremely proud to be a part of this important project and of our milestone achievements. These only serve to underline the competence and commitment to our clients of our global TAKRAF organisation.

“Whether it be a greenfield or an existing brownfield operation, we work with our clients to ensure that their requirements are met on time, within budget and most importantly, safely.”

Fluor Corp acted as the engineering, procurement and construction management (EPCM) services contractor on the project, responsible for the expansion of the mine infrastructure, rail system, port facility and processing plant infrastructure and utilities.

NRW Holdings signs A$10 million deal to buy RCR’s Mining and Heat Treatment businesses

NRW Holdings has entered into an agreement to acquire RCR Tomlinson’s Mining and Heat Treatment businesses for A$10 million ($7.3 million) in cash.

The agreement was signed with RCR’s administrators, which have been offloading various RCR subsidiaries since shortly after the company declared total liabilities of A$581.3 million alongside cash and equivalents of A$89.9 million in its 2018 financial year.

The purchase consideration will be funded from NRW’s existing cash reserves, with the deal expected to complete within the next two weeks, NRW said.

RCR Mining and Heat Treatment form part of the original RCR Tomlinson business established over 100 years ago.

RCR Mining includes the Mining Technologies business, which owns significant intellectual property across a range of products and processes and is recognised as a market leader by global resources clients, according to NRW.

“The Mining Technologies business is a leading national and international original equipment manufacturer and innovative materials handling designer with an extensive product range including apron and belt feeders, high capacity conveyors, slide gates, stackers, spreaders, fully track-mounted in-pit mining units (an example pictured above), sizers, scrubbers and screening plants,” NRW said.

One of RCR’s recent mining technology innovations is a 5 km relocatable conveyor, which includes a semi-mobile primary crushing station and feeds directly into Fortescue Metals’ Cloudbreak iron ore processing facility in the Pilbara of Western Australia.

Both the Mining Technologies and Heat treatment businesses have a high proportion of activity in equipment product support and maintenance (both on site and off site), NRW said, adding that the Heat Treatment business has facilities that include the largest stress relieving furnace in Australia.

Mining Technologies and Heat Treatment generated around A$110 million of revenue in the 2018 financial year and have a track record of delivering positive earnings, NRW noted, explaining the acquisition would be earnings per share accretive on a full-year basis, excluding integration and other one-off costs.

Jules Pemberton, NRW’s Managing Director and Chief Executive Officer, said the acquisition would allow NRW to provide incremental services, in line with its strategic objectives, to several core clients common to both NRW and the RCR businesses.

“In addition, the annuity style income from the maintenance activities of Mining Technologies and Heat Treatment will provide a platform to continue to build a broader service offering across an expanded resources and oil and gas client base.”