EXPOMIN 2012, Santiago, Chile
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1 Caterpillar Global Mining Product Line Hard Rock CAT Rock Flow System Markus Frenzel EXPOMIN 2012, Santiago, Chile
2 CAT Rock Flow System System Products CAT Rock Flow System Hard Rock Haulage System CAT Rock Feeder: RF300 Dozer Feeder CAT Rock Mover: RM900 Hard Rock Production Conveyor 2 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
3 CAT Rock Flow System Feeder and Mover : Extraction : Haulage CAT Rock Feeder Service drift Production drift CAT Rock Mover 3 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
4 Rock Feeder and Rock Mover in a Continuous Haulage System Video 4 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
5 CAT Rock Flow System in comparison to conventional Block Caving Video 5 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
6 CAT Rock Feeder RF300 I Video Pushing Cylinder Pushing Device quantity: 2 stroke: 1,000mm pressure total : 5147kN Weight total : 13.0 t Moving Dozer Plate 6 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
7 CAT Rock Feeder RF300 II Dozer Plate Cylinder quantity: 4 stroke: 1350mm cycle time: sec. pressure total : 4,021kN 2000 mm 1050 mm 4300 mm Maintenance: Dozer Feeder can be removed from draw point at any time for service and hang up removal. And can be repositioned in drawpoint at any time after work completion. 7 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
8 CAT Rock Mover RM900 I Chain Conveyor Performance: 900 t/h Chain speed: 0.15 m/s Drive power: 2 x 90 KW Pan width: 1,800 mm Pan length: 3,000 mm Conveyor length: 77 m Chain length: m Flight bar: 268 (distance=4) Chain size: 42 x 146 mm Wear elements can be changed easily 8 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
9 Hydraulic Concept Hydraulic System Central Hydraulic Supply System Individual Supply System (Oil) WATER HYDRAULICS (HFA) INDUSTRIAL HYDRAULICS (Oil) Trial No.3 9 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
10 CAT Rock Flow System: Primary Crusher Primary Crusher Impact Roll Crusher Sizer CAT Rock Feeder CAT Rock Flow Feeder compact construction; installation on top of RM900 no foundation and dedicated chambers required applicable for low medium abrasive rock applicable for higher abrasiveness 10 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
11 CAT Rock Flow System: Automation I Specifications Electronic control at each single Dozer Feeder: - providing automated operation - recording of operational characteristics (pressures, strokes, ) Server that links all Dozer Feeders with a central control room Control room PC: - remote control and remote changing of sequences of the Dozer Feeders - Visualization of the operational data from each Dozer Feeder - Draw control: Steering and recording the amount of ore taken from each draw point CAT Rock Feeder CAT Rock Flow Feeder 11 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
12 CAT Rock Flow System: Automation II Specifications Control System - One data world (EIP) - Control and visualization of other subsystem - Load depended conveyor control Draw Control - Selective extraction - Flexible sequence / Mix of qualities - Easy Hang-up detection Subsystem - Communication with pumps, conveyor and monitoring of chain tension Data Base - Data storage in SQL database - Real time data logging State of the Art Automation due to highest level of Functionality and Flexibility Remote control Draw Control Integration of Subsystems Data Storage 12 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
13 Reference List of Components Rock Flow Mover broad range of expertise based on nearly 100 years of experience in underground mining Hard Rock Modifications: adapted to use in abrasive hard rock Rock Flow Feeder established system due to substitution in former Westfalia Lünen bunker discharge conveyor systems Hard Rock Innovation: Pushing Device Rock Flow Automation actually operating in several CAT systems (longwall) Hard Rock Modifications: customized software for Rock Flow System 13 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
14 CAT Rock Flow System - Review Technical & Financial Values Technical HSE Aspects Financial Multiplied production when compared to conventional technology (LHD) Continuous operation continuous haulage Less staff, ventilation, air conditioning, energy and infrastructure Mobile feeder (RF300) can be removed from and reinserted into the drawpoint at any time for maintenance or hang-up removal High level of safety High grade of automation in mining process Manless production process No diesel fumes & heat Environmentally friendly Reduced face costs Increase of productivity and equipment utilization Reduction of TOC Reduced number of active drawpoints reduction of infrastructural efforts and staff Block Caving Mines can improve their production by generating a continuous haulage stream from the draw points by using the CAT Rock Flow System 14 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
15 CAT Rock Flow System Trial No. 2 CAT Rock Flow System Hard Rock Haulage System Trial No.2 - Functionality Test - 15 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
16 CAT Rock Flow System Trial No. 2 Location Codelco El Salvador mine Geology Porphyritic Copper deposit copper content: Ø 0.6% deposit: Andesite & Quartz-Andesite surrounding rock: Felspar, Bornite, Chalcopyrite Molybdenum, Gypsum & Quartz σ C = MPa (Ø 140 Mpa), ρ Ore = 2.7 t/m³ System Components 1 Chain Conveyor (75m) 4 Rock Feeder (one-sided) Impact Roll Crusher Central Hydraulic Station Specification Chain Conveyor *CC capacity rated. : 900 t/h CC capacity mean : 700 t/h CC capacity max. : >1000 t/h engine performance: 2 x 75 kw velocity of CC: 0,15m/s Test Results volume extracted total : 122,120 t extraction rate mean : t/h (each RF300) extraction rate max. : t/h (each RF300) *CC= chain conveyor 16 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
17 CAT Rock Flow System Test Assembly for Trial No.2, Lünen, Germany, / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
18 CAT Rock Flow System Codelco- El Salvador Mine -trial No. 2, / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
19 CAT Rock Flow System Video Codelco- El Salvador Mine -trial No. 2, / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
20 CAT Rock Flow System Trial No. 3 CAT Rock Flow System Hard Rock Haulage System Trial No.3 - First Industrial Application - 20 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
21 CAT Rock Flow System Industrial Application Trial No.3 System ~ Setup System Details 4 Chain Conveyor à 75m 8 Rock Flow Feeder per Production Drift (32 in total) 16 Hydraulic Stations Technical Data RM900 Capacity: 900t/h Engine Performance: 2 x 90 kw Velocity of Chain Conveyor: 0.15m/s Production Target Volume of 5,000 tpd Production Target Start of Trial: 2013-July Period: 18 Month 21 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
22 CAT Rock Flow System Industrial Application Conveyor footprint RF300 Sizer 22 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
23 Thank you for your attention & Glückauf 23 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING
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