H3 MOBILE ROLLER SCREEN SYSTEM

Transcription

1 H3 MOBILE ROLLER SCREEN SYSTEM

2 FOTO MOS is an independent Italian company founded with the aim of developing a new generation of mining machines. We have a long tradition as designers and manufacturers of mobile gantry cranes and material handling systems. After 40 years in the heavy transportation market and hundreds of machines delivered, we are still able to grant innovative solutions and create efficient and reliable machines that are custom made. Most of our employees are engineers and we focus our work on the material handling in opencast mines. MOS activity is based on a new innovative patent that assures a more efficient hauling system and higher production screening process

3 MOS H3 SERIES: 3000 ton/hour When it comes to sizing and loading the ore material onto the extraction point of the open pit mines, the MOS H3 Mobile Roller Screen System is particularly impressive thanks to its exceptional performance. Equipped with an efficient roller screen, the MOS H3 series ensures mobility (3 km/h), high productivity (3000 ton/h) and efficiency in a rugged machine even in difficult working conditions. Designed and patented by MOS, this screening and loading technology is the ideal choice for cutting mining processing costs and offers a flexible range of applications in the open pit mines. The intuitive nature of the H3 series makes it easy to use while also ensuring quick and trouble free positioning at the extraction point

4 SIZING AND LOADING THE ORE MATERIAL DIRECTLY IN THE MINING EXTRACTION LOCATION GENERATOR SERVICE CRANE/BREAKER BOOM ROLLERS SCREEN LOADING BUCKET Extraction loading ore material on MOS H3 Screening onsite loading automatically on dump truck A NEW STANDARD With its unique features, the innovative MOS H3 series overcomes the disadvantages of the conventional mining material hauling and processing systems. Bringing the roller screen to the extraction location, waste and oversized stones will not loaded on trucks anymore. MOS H3 series is able to screen 3000 tons of ore material per hour and load it on the trucks. We set up a new standard in the market but other benefits are: High production rate, sizing the ore material at the extraction location and loading automatically on trucks Total mobility on every surface and up to 8% slope to stay close to the extraction equipment DUMPING CHUTE High efficiency to load on trucks only neat material, removing stones and impurities Cutting mining processing costs, reducing the number of necessary trucks, their maintenance and most of the standard equipment used nowadays CONTROL CABIN STEERING WHEELS 06 07

5 MINE OF SOLUTIONS HIGH LOADING CAPACITY EXTRAORDINARY MOBILITY Being a mobile gantry, the MOS H3 series can travel within the mine pit and from site to site with extraordinary agility and easy maneuverability. The equipment is designed to follow the mining loading activity front and travelling on the hauling roads. It can also travel on asphalt, concrete or uneven and inclined roads up to 8% maximum slope. The MOS H3 series can steer at 90, carousel, front or rear side in order to stay as close as possible to the loading equipment or to the loading platform area, minimizing the movements of the extraction equipment. Compared to what currently exists in the market of mining in-pit screening equipment, MOS H3 series has a higher production rate, reaching 3000 metric ton per hour and combining a high capacity mobile screen to a wheel loader/shovel, but still maintaining the mobility of a standard dump truck. The machine also isolates the hard unwanted impurities like oversized rocks and loads the dump truck with only valuable fine mineral ore. The use of rolling shafts with constant gap between discs and the use of scraper tools beneath each roller to remove caked material ensure a high rate and quick scalping operation. The productivity is related to the width of the internal roller shafts (see product details) and the capacity of the used loading machines available on the extraction site. HAULING ONLY PURE MATERIAL The MOS H3 series screens the ore material onsite, ensuring the load of only pure material on the trucks. Where waste and oversized stones are up to 40% of the extracted material (like phosphate ore), the MOS H3 series can increase significantly the efficiency and the productivity of the whole mine. Instead of transporting waste or unprocessed ore to the screening site, it is now possible to haul more uniform and clean material, increasing the daily production rate using the same fleet of dump trucks. Or it is possible to reduce the number of mobilized dump truck to fit the daily production rate so all the fleet CAPEX and OPEX expenses (equipment price, drivers, fuel, tires, grease, amortization, insurance, etc.) will be significantly reduced

6 CUTTING MORE PROCESSING COSTS With a MOS H3 series working in-pit, the customer will not need to install and operate other equipment at the feeding hopper installation. Rock breaker booms, rollers screen and rock crusher are no longer necessary. For existing conventional feeding hopper: the installed rock breaker boom, roller screen and rock crusher can be switched off. The dumped material is sent directly from the apron feeder to the installed vibrating screen. All the OPEX expenses for these machines (electrical energy, operators, maintenance and so on) will be economized. It is even possible to sell these machines as second hand equipment for other mining activities. Since the oversized waste material is already removed in-pit, the OPEX for the waste disposal system will be cut. Moreover the feeding hopper will produce less noise and less vibrations, extending its operating life. ENVIRONMENTALLY FRIENDLY Manufacturing and maintaining all mining equipment has a relevant carbon footprint. Improving the productivity of the hauling process leads to less dump trucks roaming the mine and a reduced annual fuel consumption. To reduce our carbon footprint, we design each generation of our products to be as energy efficient as possible. When products can be used longer, fewer resources need to be extracted from the earth to make new ones. For installation of a new feeding hopper: with the MOS H3 series working in-pit, the related CAPEX expenses will be optimized and significantly reduced. Rock breaker booms, rollers screen and rock crusher are no longer necessary. Also the reduction of the waste size material results in less disposal equipment. VERSATILITY & CUSTOMIZABLE FEATURES The MOS H3 series can be manufactured as per the customer needs. It also can be designed to fit within the customer s existing loading/hauling equipment. With different gaps between roller shafts configurations, several mining material can be processed granting high productivity. MOS H3 series can be used either for scaling out the fines from the loaded material (by placing the dump truck under the roller screen) or for providing feed of the oversized material (by placing the dump truck on the dumping chute). It can be used to accomplish loading and scalping for industries such as phosphates, bauxite, coal, granite, salt, gypsum, limestone, coke, quartz, salt, aggregates and other mineral processing applications

7 MOBILE ROLLER SCREEN ton/h The MOS H3 mobile roller screen series is engineered for high production mining and developed for moving the ore material at low cost per ton and saving energy Contents page Loading buckets.... pag. 14 Dimensions pag. 16 Upper trolley with rollers screen... pag. 18 Structure and tire groups pag. 20 Power train / hydraulic transmission pag. 22 Operator s cabin pag. 26 Standard equipment... pag

8 H3 SERIES LOADING BUCKET The H3 family: H3/L for loader H3/S for shovel MOS H3/L for wheel loader MOS H3/L with rotated bucket MOS H3/S for shovel MOS H3/S for shovel with rotated bucket H3/L: BUCKET FOR WHEEL LOADER H3/S: BUCKET FOR SHOVEL Capacity m 3 Flow ore control hydraulically assisted Capacity 32.5 m 3 Rotating cylinders 2 units Rated payload ton Rotating cylinders 2 units Rated payload 36 ton Cylinders stroke mm Bucket width mm Cylinders stroke mm Bucket width mm (can be adjusted) Max working pressure 260 Bar Min. bucket height mm Max working pressure 260 Bar Min. bucket height mm Weight kg Complete cycle time 24 seconds Weight kg Complete cycle time 14 seconds For both configuration Floor sheet 12 mm Side sheet 10 mm Front sheet 10 mm Canopy sheet 5 mm 14 15

9 DIMENSIONS MAIN DIMENSIONS (on request dimensions can be modified) 1. Internal width mm MOS H3 SERIES IS DESIGNED TO WORK WITH ALL AVAILABLE LOADING AND HAULING EQUIPMENT IN THE MARKET OR WITH NON-STANDARD MACHINES Track Min. height under beam Outside wheel mm mm mm 5. Max. height under beam mm Outside chute and bucket Outside closed chute mm mm FRONT VIEW MINIMUM HEIGHT FRONT VIEW MAXIMUM HEIGHT WITH BUCKET FOR LOADER 8. Max. outside rollers mm 9. Min. bucket level mm 10. Max. bucket height mm 11. Max. outside protection mm 12. Wheelbase mm 13. Max. length mm 14. Min. width with shovel bucket mm 15. Min. shovel bucket height mm Max. shovel bucket height Max. outside shovel bucket mm mm FRONT VIEW MAXIMUM HEIGHT WITH BUCKET FOR SHOVEL LATERAL VIEW 18. Max. height under dumping chute mm Dumping chute width mm THE ABOVE MENTIONED DIMENSIONS ARE GIVEN FOR INFORMATION PURPOSE ONLY AND ARE APPLICABLE FOR DUMP TRUCK WITH THE FOLLOWING DIMENSIONS: L=12.5M, H=7M, W= 8M. 17

10 UPPER TROLLEY WITH ROLLER SCREEN MOS H3 series is designed to support rollers screen that size the ore material and dump the coarse fraction to the ground. Operating Rollers The rollers screen is composed by two set of rotating rollers break the ore material and move it along. Fine grains smaller than the effective separating size drop down between the rollers and fall into the dump truck. Coarse grains bigger than the separating size are pushed forward and dumped through the chute. Rollers Design Robust housing for supporting heavy coarse grains impact Rollers positioned in parallel with convenient slope Individually controlled rollers Number of roller shafts : 2 x 14 = 28 Side supports and bearings with automatic greasing for each roller set Each roller is powered by an electric motor with speed control; a flexible coupling is positioned between gear and shaft Installed electric power for each roller motor : 7.5 kw 10hp Total installed rollers power : 28 x7.5= 210 Kw hp Total power consumption : 28 x 4.71 =132 kw 179 hp Net inner width of each rollers: mm Total inner width of the assembly for two rollers : mm Upper side width for ore containing : mm Dumping chute of coarse ore L = mm from side centre with wearing plates Rotating dumping chute for width dimension reducing during machine translation from site to site Scraper tools under roller shaft to remove caked material Vertical flaps to direct the fine ore inside the truck Upper Trolley Frame The upper trolley, with its frame, supports all the rollers and the bucket and it is equipped with translation wheel bogies. Two hydraulic cylinders move the trolley for a better transversal distribution of sized ore material on truck body. This translation can be done in automatic or manually using the controls in the operator s cabin; the translation movement is done during bucket rotation for minimizing the cycle time. All the process is controlled by cameras and visualized in the monitors inside the operator s cab. Trolley translation made by Cylinders stroke Hydraulic cylinders 2500 mm Max. working pressure Average translation speed 260 Bar 0:15 m/min variable 18 19

11 STRUCTURE AND TIRE GROUPS The 4 shock absorbers allow the mobile rollers machine to: Run on heavy uneven ground 2.8 Km/h Lift the frame till mm when necessary for the transit of the dump truck underneath Other shock absorber characteristic: Cylinder with safety valve Included Lifting frame speed Effective cylinder 280 mm Control of the height extension Tire groups transmission and steering 0-5 m/min - variable The H3 series has the shape of a mobile gantry for receiving underneath the dump trucks and it is provided with steering tires for moving in the mine at 2.8 km/h, following the loader and distributing the ore mineral on the dump trucks. The frame of MOS H3 series is designed with box section for a better torsion and bending strength. Mild steel used throughout provides flexibility, durability and resistance to impact loads, even in cold climates. The frame and its parts are bolted and can be stored and shipped inside containers. The frame sits on four twin tire groups provided each one with a special shock absorber. N of tire groups N of tires each group Standard tire number and type Driving gears Planetary type Motor type Surmontable slope Translation pump Translation speed total R35 E3 8 compact planetary type 715B3 Bonfiglioli A2FE Rexroth 8% A4VG Rexroth 0-46 m/min variable Km/h variable 20 Parking brakes N of steering groups Steering mode Min. steering radius Steering device wet multiple disk brakes spring loaded and hydraulically released 4 Ackermann, carousel, 90, diagonal, front, rear 4 m gear driven slew drive 21

12 HYDRAULIC - ELECTRIC POWER TRAIN TRANSMISSION MOS H3 series has a CAT C27 Acert turbocharged, after cooled diesel engine that delivers high power and reliability. The hydraulic power train transmission provides operating efficiency to the translation motors and to the cylinders for bucket rotation. Diesel engine Model Total rated net power ISO 3046/1 Number of cylinders Bore Stroke Displacement Type Aspiration Emission Alternators Fuel tank capacity Hydraulically driven radiator fan Microprocessed engine management Heavy duty air filter Two stage fuel filter including water separation Auxiliary System voltage Batteries in series/parallel installation Battery isolation relays and switches Emergency stop switches accessible from ground level in engine module 1 x Cat C27Acert U.S. Tier 4 Interim 709 KW rpm/min 950 hp mm mm 27 l Water cooled Turbo charged and aftercooled U.S. EPA Tier4 Interim 2x150 A l 24 V 2 x 120 Ah-12V Ah 24V 22 23

13 Hydraulic system with pump managing system Translation pump Max. oil flow Max. working pressure Buckets cylinders pumps 262 L /min 370 Bar 2 x variable displacement piston pumps Rexroth ELECTRIC SYSTEM DIESEL POWER PACK FOR ROLLER SCREEN DRIVING Installed power Alternator 300 KVA 400 V 50 Hz Buckets cylinders pumps Max. oil flow L/min Filters Translation pump filter 10 micron Diesel brand Fuel tank Cummins L Max working pressure 350 Bar Bucket cylinder pumps filter 10 micron Auxiliary services 2 x gear pumps Pressure filters for gear pumps 40 micron Hydraulic tank capacity L Full flow filter for the return circuit 10 micron Pump managing system Electronic load limit control Proportional control for the translation depending on joystick position Load sensing control for rollers pumps Reduced oil flow of main pumps at high hydraulic oil temperature Pressure cut-off for main pumps Hydraulic oil coolers Oil flow of cooling pumps Diameter of fans 2 x 250 L/min 2 x mm Gear - type cooling pumps supplying high volume, low pressure oil to fans Fan speed and flow oil to the coolers are termostatically controlled 24 25

14 OPERATOR S CAB Designed for operator s comfort, superior control and high productivity. Internal dimension cab Operator s eye level: approximately 7000 mm Length 2150 mm Width 1600 mm Height 2150 mm Switch in seat cushion to automatically neutralize the hydraulic controls when operator leaves the seat Pneumatically cushioned and multi-adjustable comfort seat, safety belt, head and armrests Joystick controls integrated in independently adjustable seat consoles Fold-away auxiliary seat with safety belt FOPS (rock guard; approved according to DIN ISO 3449) All-round safety glass, armored windshield and sliding side window Windshield with parallel intermittent wiper/washer Robust instrument panel including large colored BCS screen Board Control System (BCS) electronic monitoring and data Logging system for vital signs and service data of engines and hydraulic Stairways for access Roller blinds 26 27

15 STANDARD EQUIPMENT Standard equipment may vary. Consult MOS technical office for details. Air conditioner Air cleaner with precleaner Alarm Alternator (105 Amp) Batteries, 100 Ah 12 V (2) Brake release manual pump for towing Oil into the gears, brakes, engine ROPS (Rollover Protection Structure) Diagnostic connector Entertainment radio ready Horn Heater - Defroster Camera for rollers control Camera for body dumper truck control Camera for side bucket control Light, courtesy dome Hydraulic oil temperature Fuel level Seat with air suspension Passenger seat Steering mode panel Windshiel and washer Storage compartment Electric system 24 V Fast - fill fuel system, Wiggins or similar Battery disconnect Engine shutdown VIMS dataport Rotalarms (3) Headlights, LED type Oil change system Service crane 28 29

16 H3 MOBILE ROLLER SCREEN SYSTEM

17 MOS srl Via StrA 3/B Galliera Veneta - PD - Italy info@moscreener.com /