Application of Surface Miner today and future development

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Marjorie Lauren Mathews
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1 Application of Surface Miner today and future development Heiko Teuber BAUMA 2010 Munich forum

2 TAKRAF systems for open cast mining 2

3 TAKRAF systems for open cast mining 3

4 application of Surface Miner niche technology COAL Surface Miner India World (2004) ~ 40 Mio t 373 Mio t 4,629 Mio t share of production 13 % 2.2 % (open cast) IRON ORE Surface Miner Australia World (2009) ~ 38 Mio t 370 Mio t 2,300 Mio t share of production 10 % 1.6 % sources: WCI,USGS, IMME, market research 4

5 application of Surface Miner current limits performance is closely linked to compressive strength and rock structure of the material with a disproportional decline of the cutting capacity in competent material cutting tools available do not provide sufficient wear life in highly abrasive material causing loss of production due to down time for tool change few mine/ pit layouts have been designed for the use of Surface Miners and the machine has to adapt to existing operation methods limiting its performance 5

6 application of Surface Miner - advantages Eliminating blasting - less environmental impact, increased safety, release of blocked reserves Extracting valuable minerals in a selectively - less dilution, higher efficiency in the down stream process Extracting ROM product in one step - primary/secondary crushing are dispensable, lower CAPEX 6

7 application of Surface Miner - assessment product fines content lump size limit selective extracting cutting capacity material compressive strength joint structure mine block layout loading transport (crushing) effective capacity production & costs 7

8 operation method: direct loading 8

9 operation method: stock pile 9

10 operation method: stock pile first cut final cut 10

11 operation method: windrow 11

12 operation methods: comparison 12

13 operation methods: comparison 13

when total equipment operation hours are compared What loading

14 operation methods: comparison low utilisation of loader and trucks if they cannot be used other wise separate loader questionable, when total equipment operation hours are compared What loading option is better, has to be assessed for each application individually. 14

15 TAKRAF Surface Miner TSM

16 TAKRAF Surface Miner TSM 300 crawlers run on even ground (pictured from the rear) rear crawler front crawler 16

17 cutting capacity and product size passing [%] sample 1 sample 2 sample 3 sample particle size [mm]

18 TAKRAF TSM 300 in iron ore cutting depth up to 800 mm loading height up to 7 m travel speed 20 m/min turning radius 8 m engine CAT C32 ACERT tank capacity min l Service weight 125 t 18

19 TAKRAF Surface Miner TSM 500e first Surface Miner with electric cutting drum drive 19

construction machinery and mining equipment proven expertise in the development and manufacture of complete drive

20 partners for the development one of the leading suppliers of continuous mining systems world wide proven design of surface miners with direct twin drive ranging from 560 kw to 1000kW one of the world s leading manufacturers of construction machinery and mining equipment proven expertise in the development and manufacture of complete drive systems for these applications including hydraulic and electric motors, planetary gearboxes and control technology 20

21 TAKRAF Surface Miner TSM 500e first Surface Miner with electric cutting drum drive 21

22 electric drive system for surface miner compact unit for cutting drum drive directly integrated in the drum extreme low wear and tear because there are no moving parts out side the encapsulated drive unit. cutting drum driveline efficiency of 84% engine control for partial load conditions reduced fuel consumption 22

23 TAKRAF Surface Miner TSM 500e cutting depth cutting width design capacity loading height travel speed turning radius engine tank capacity service weight features up to ,400 up to min mm mm m³/h m m/min m kw liters t high fuel efficiency emission certified engine large operator cabin ROPS/ FOPS central lubrication service station near ground dust suppression machine monitoring and auto control and more 23

24 TAKRAF Surface Miner System Surface Miner blast free extracting selective mining with high accuracy small sized, belt ready product Surface Miner System less man power less vehicles single energy source - electric power reduced carbon emission In-pit conveying 24

25 Conclusions Surface Miner is niche technology although it can improve product quality, release blocked reserve and reduce CAPEX Key for overall performance is the loading and transport method TAKRAF TSM500e with electric drive for high volume applications continuous system for soft to semi hard commodities becomes an alternative 25

26 THANK YOU FOR YOUR ATTENTION TAKRAF GmbH Torgauer Str Leipzig Germany BAUMA 2010 HALL C2 stand 227/324

Tenova TAKRAF Expertise in Open Cast Mining Technology

Tenova TAKRAF Expertise in Open Cast Mining Technology Nils Scharfenberg TAKRAF GmbH Ulaanbaatar, 7 th of September 2011 SchRs 100.5/0,5.0 Schallmauer Opencast Mine, Rhineland/Germany Capacity 180 m3/h;