Chevron-MegaPipe Conveyor The New IPCC System

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Collin Parks
5 years ago
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(24,4 x 11,0 cm) thyssenkrupp, Siemens and ContiTech:

1 Bitte decken Sie die schraffierte Fläche mit einem Bild ab. Please cover the shaded area with a picture. (24,4 x 11,0 cm) thyssenkrupp, Siemens and ContiTech: Chevron-MegaPipe Conveyor The New IPCC System Christian Dirscherl (Siemens), Branco Lalik (thyssenkrupp)

2 Chevron-MegaPipe Conveyor Agenda Motivation & Objectives Our Approach Tests Conclusion 2

3 Chevron-MegaPipe Conveyor Agenda Motivation & Objectives Our Approach Tests Conclusion 3

4 Motivation & Objectives Why IPCC? - What is the right haulage balance to optimize OPEX? And the right equipment to get the job done the cheapest and safest way? 4

5 Economical, Ecological & Operational Criteria Truck Haulage DIESEL MANPOWER CO 2 EMISSION WATER CONSUMPTION SECONDARY & TERTIARY COSTS SAFETY HAUL ROAD MAINTENANCE 5

6 Motivation & Objectives Comparison of available transportation modes β max < 5 Truck Haulage β max < 20 Troughed Belt Conveyor β max < 45 Chevron-MegaPipe Conveyor 6

7 Chevron-MegaPipe Conveyor Agenda Motivation & Objectives Our Approach Tests Conclusion 7

8 Our Approach Chevron-MegaPipe Conveyor: Based on 30 years experience! thyssenkrupp conventional pipe conveyor in Quatalum, Qatar 2000 t/h, 13 degrees, alumina powder 8

9 Our Approach New Pipe Belt Combined Proven Technologies High-Rated ST-belts Know-How Chevron-MegaPipe MegaPipe Chevron-Belts 900 mm Larger Pipe Diameter 9

10 Our Approach IPCC with Chevron-MegaPipe Conveyor System Stationary pipe conveyor system linked to a crusher station at the bottom of mine. The tail station (tension station) is based at the bottom and the head station (DirectDrive station) is located at the rim of the open-pit Steep angle inclination up to 45 A service cab driven by a rope winch is provided for maintenance and inspection along the structure Crusher station Pipe section Service cab Head station Tail station 10

11 Our Approach Crusher Station & Pipe Feed at Tail Take-up tower Dump truck Crusher station Chevron pattern Material discharge Pipe forming Belt feeder Belt U-forming Material transfer Pipe 11

12 Our Approach Tail Station material discharge belt feeder take-up tower transfer chute counter weight bar sizer door obstacle moveable speed up conv. hood skirtboard Chevron pattern pipe forming 12

13 Our Approach Material Discharge at Direct Drive Head Station Access to service cab Rope winch Crossing Pipe forming Housing of drive pulley Direct drive Spillage conveyor Disc brake 13

14 Our Approach Gearless Conveyor Reference Antapaccay Prosper Haniel Las Bambas Escondida OGP1 Cuajone P install 2 x 3,800 kw 2 x 3,200 kw 4 x 4,400 kw 5 x 5,000kW 2 x 6,000kW year nominal torque 576kNm 631kNm 637kNm 774kNm 1042kNm nominal speed 63rpm 47rpm 66rpm 62,5rpm 55rpm mass 43,6t 45,5t 52,5t 58t 80t 14

15 Our Approach Head Station with Siemens Direct Drive Direct drive main components: Rotor Stator Base plate with anchoring material Slip rings Brush holder with tachometer Air / Water cooler Terminal box 15

16 Chevron-MegaPipe Conveyor Agenda Motivation & Objectives Our Approach Tests Conclusion 16

17 Tests Test program Pilot plant for determination of the max. dynamical inclination angle Testing of Wear and Impact Strength of Chevron-Cleats Ø 800 mm diabase 250 mm 17

18 Tests Max. dynamic inclination angle - Standard MegaPipe MegaPipe 18

19 Tests Max. dynamic inclination angle - Standard MegaPipe MegaPipe Material starts to move 19

20 Tests Max. dynamic inclination angle - Chevron MegaPipe Chevron- MegaPipe 20

21 Tests Max. dynamic inclination angle - Chevron MegaPipe Chevron- MegaPipe Material starts to move 21

Tests Max. dynamic inclination angle: Results 42 31 53 45!

22 Tests Max. dynamic inclination angle: Results ! Standard MegaPipe 0 Chevron 50mm 0 Non critical Temporal limited movement of single particles caused by the change of inclination Critical: majority of particles start to slide down opposite to the conveying direction 22

study design of Chevron-MegaPipe Conveyor

23 Tests Wear tests on chevrons in a transfer chute of the Limestone Plant Oettelshofen Estimated LIFETIME of chevrons for selected in feasibility study design of Chevron-MegaPipe Conveyor (C-C 1026m, v=4.19 m/s) and feeding point up to 10 years! F 23

24 Chevron-MegaPipe Conveyor Agenda Motivation & Objectives Our Approach Tests Conclusion 24

Conclusion Key facts: Technical Information: Conveying over mine slopes with inclinations up to 45 Mine depths of up to 700 m and Mass flows of up to 6000 t/h

mm Impact- and wear-optimized design of chevron ribs Conveyor belts with Steel Cord- and Fabric-Carcasses Cost- and Energy Efficient Siemens DirectDrives

25 Conclusion Key facts: Technical Information: Conveying over mine slopes with inclinations up to 45 Mine depths of up to 700 m and Mass flows of up to 6000 t/h Nominal belt breaking strength of up to 9500 N/mm Outer pipe diameter of up to 900 mm (belt width 3200mm) Primary crushed material with lump sizes up to 400 mm Impact- and wear-optimized design of chevron ribs Conveyor belts with Steel Cord- and Fabric-Carcasses Cost- and Energy Efficient Siemens DirectDrives Benefits & Features: Rapid return of investment Significantly reduced mining truck fleet and CO 2 -Footprint Closed-trough transport environment friendly & safe! 25

26 Thank you! 26

Continental SportContact 6 Workshop: Performance via Mold Technologies Pattern Layout Precision

Bitte decken Sie die schraffierte Fläche mit einem Bild ab. Please cover the shaded area with a picture. (24,4 x 7,6 cm) Continental SportContact 6 Workshop: Performance via Mold Technologies Pattern Layout