The Asia Miner

JAN-FEB 2017

The ASIA Miner - Reporting Important Issues to Mining Companies in the Asia Pacific Region

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Page 66 of 103

VDMA 65 2017 • VDMA MINING SUPPLEMENT services for the whole lifecycle of a plant, and at the same time, to ex- pand our local proprietary business. The service business unit will in- clude service centers, spare parts business, upgrade refurbishments and asset management." The Mining Technologies business unit has three different op- erating units: mineral processing (crushing, grinding and pyro pro- cessing), materials handling (stockyards and port handling systems) and mining systems (continuous mining including the large crawler mounted machines and heavy-duty conveying including overland conveying systems). "Each operating unit has global responsibility for its projects and products," Jabs said. "In the future, our performance will be solely evaluated by the combined global success of the proj- ect." This is a new concept within thyssenkrupp Industrial Solutions and they are eager to prove it will work. They recently submitted a proposal for two large conveyor systems for two different customers in Asia, most likely using gearless drive technology. New Approaches to Crushing Last year, thyssenkrupp unveiled the huge 63-130 gyratory crusher, first at bauma and then at MINExpo and the first two machines have been ordered. The crushers will be supplied as part of semimobile crushing plants for a copper ore mine. "The tendency with crushing installation investments is to focus on operating expenses," said Frank Drescher, head of product division crushing technology, thys- senkrupp. "We are currently working on several in-pit crushing and conveying (IPCC) projects, and this new gyratory crusher, which is lower in weight and higher in capacity, represents a new path forward for us." One of those major projects that combines conveying systems and crushing plants is the Cuajone project in Peru. "At this installa- tion, a gearless conveyor serves one of the largest semimobile crush- ing installations in the world," Drescher said. When thyssenkrupp began development on the 63-130, they were expecting positive feedback because it opens new possibilities for plant design. "We can place in those modular plants a choice of crushers from the 75 to the 130," Drescher said. "That gives us a great deal of flexibility to respond quickly to requests." Many of the competitive mining-class gyratory crushers on the market today are being used for installations with concrete founda- tions. Other manufacturers were not as much concerned with out- of-balance forces, but thyssenkrupp had a keen understanding of them because they were using gyratory crushers to large extending semimobile steel structures. "That's where we have a tremendous advantage," Drescher said. "The extremely efficient operation of the gyratory crusher prolongs the lives of these semimobile installations. With the 130, we have been focused not just to make the equipment bigger and more pow- erful, but managed also to reduce the forces substantially," Drescher explained. The semimobile installation avoids the concrete work to a great extent and allows for pre-assembly of large modules, which reduces the initial cost. "Further, these systems provide the option to relocate the crushing plant within the mine following the excavation and to reduce the truck fleet and cost involved thereof," Drescher said. "This could be the deciding factor for many projects." In the last 10 years, the majority of thyssenkrupp's underground crushing installations have been designed with gyratory crushers mounted in a stationary system, many of them with thyssenkrupp's split shell design to reduce component dimensions and weight for transportation. Most are complete systems that include conveyors and the company only sees that number growing. "More and more mines today prefer the packaged crushing plant based on the raw feed capacity and feed required by the processing plant," Drescher said. "That approach puts us in more of an OEM system supplier position." Maintaining a certain level of technology, thyssenkrupp has managed to optimize pricing to a point where they can com- pete in the standard machine business. "We are working directly with local markets and dealers and that's a fundamentally differ- ent view from the 'tailor-made' mining business. It's a different approach to engineering as well as keeping equipment in stock," Drescher said. Jabs explained that the tailor-made solutions for mining are part of the company's DNA. "That's how we roll," Jabs said. "But now thyssenkrupp is trying to transfer that DNA also to the mass mining market. Some of these smaller cone crushers and other items are sold as a commodity." The custom-made mindset has prevented the company from competing for the business in these markets in the past. "We have dedicated teams serving this market now," Drescher said. "Local business units have adopted this very quickly and it's a driving element to be closer to the customer and to provide those services quickly." Bridging Gaps With Grinding Technology Using the expertise within the business area, thyssenkrupp can en- gineer systems to mine and transport phosphate and fertilizers from pit to port. "Working with our colleagues in Dortmund, who design fertilizer plants, thyssenkrupp can design the entire beneficiation pro- cess as well as the ship-loading process," said Uwe Schuh, head of department grinding technology mineral processing, thyssenkrupp. "We are currently looking at several projects in North Africa." Phosphate can be exported as ore (phosrock) or a liquid (phos- phoric acid). India imports a lot of phosrock; other destinations, such as Brazil, would rather receive phosphoric acid. thyssenkrupp has been looking at fine grinding as a way to re- duce water and energy consumption (See Minerals Processing, p. 32). Using the experience gained with phosphate grinding in dry re- gions, the company believes it can parlay that into savings for other metal recovery plants. They recently received an order from Ma'aden in Saudi Arabia to install crushing and dry grinding equipment with- in a fertilizer plant in a very dry region. "This will be the first HPGR application for phosphate ore," Schuh said. "They have limited water resources and this installation will come online during the first quarter of 2017." Developments with grinding have helped bridge the gap with thyssenkrupp as it relates to its service initiatives. "Our service center in Chile was developed to support HPGR refurbishments," Jabs said. "Today, however, it is acting as an equipment rebuild facility. We recently had a shovel undercarriage in for a rebuild. There is no limit to the services that we can provide." The company could also say that about their service centers, located near Perth and Johannesburg. Reducing or Eliminating Trucks The Mining Technologies business unit within thyssenkrupp contin- ues to develop solutions to eliminate or reduce the use of trucks. "When we discuss new projects with mining clients, the first thing they want to evaluate is whether it is possible to mine and transport ore without trucks — that is a significant change in thinking from just a few years ago," Jabs said. "Even customers in the oil sands have started to investigate new mine developments without trucks. Whether they

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