PIT T O PLANT

CURRENT TRENDS

A l l a n D. F e r n i e Wright E n g i n e e r s L i m i t e d Vancouver, B . C . , Canada

For p r e s e n t a t i o n a t t h e SNE-AIME F a l l X e e t i n g and E x h i b i t S a l t Lake C i t y , Utah - October 19-21, 1 9 8 3

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Abstract. Growing i n t e r e s t i n p i t c r u s h i n g and conveying i s e v i d e n t from t h e m y a r t i c l e s , t e c h n i c a l p a p e r s , and new equipment development r e c e n t l y presented. A p p l i c a t i o n o f a p i t c n u h i n g and conveying system is complex, as many f a c t o r s puch as mine d e s i g n , p r o d u c t i o n s c h e d u l i n g as w e l l as i n i t i a l and ongoing capitel. and o p e r a t i n g c o s t s must be thoroughly and r e a l i s t i c a l l y examined. T h i s paper w i l l a d d r e s s t h e fundamentals t o b e considered and review s e v e r a l approaches t o developing a t o t a l system f o r a new and e x i s t i n g mine s i t u a t i o n . The p l a n n i n g f u n c t i o n w i l l be o u t l i n e d and o p e r a t i n g and d e s i g n c r i t e r i a d e f i n e d t o i n t e r f a c e t h e mining opera t i o n and t h e p i t c r u s h l n g conveying system. Introduction I n - p i t c r u s h i n g and- conveying (ICC) is n o t t h e u n i v e r s a l panacea f o r r e d u c i n g t h e opera t i n g c o s t s o f open p i t mining o p e r a t i o n s ; however, economic f o r c e s have caused a move towards ICC due t o t h e r a p i d i n c r e a s e i n l a b o u r , f u e l and maintenance c o s t s . As a l l open p i t mines a r e d i f f e r e n t , and s i n c e p l a n n i n g a multi-system method o f o r e and waste e x t r a c t i o n i s far more complex t h a n f o l l o w i n g t h e t r a d i t i o n a l t r u c k / s h o v e l method w i t h i t s b u i l t i n f l e x i b i l i t y , a n independent e v a l u a t i o n o f s e v e r a l mining schemes i s required to select t h e most economical operation. Hine P l a n n i n g There a r e two p l a n n i n g s c e n a r i o s f o r ICC t o c o n s i d e r i n t o d a y ' s changing mining scene, The first i s f o r a new mine and i n v o l v e s d e v e l o p i n g b a s i c c o n c e p t s and l o n g r a n g e p l a n s ; t h e o t h e r i s f o r an o p e r a t i n g mine, and i n v o l v e s developing c o n c e p t s which can be worked i n t o t h e e x i s t i n g p i t w i t h o u t i n t e r f e r e n c e w i t h d a i l y production. Both planning functions may require e v o l v i n g s e v e r a l d i f f e r e n t schemes t o f i n d t h e most p r a c t i c a l and c o s t e f f e c t i v e method o f t r a n s p o r t i n g t h e o r e from p i t t o p l a n t . There a r e a number o f b a s i c fundamentals which must be a d d r e s s e d i n t h e development o f a n I C C system, whether i t i s planned f o r a new mine o r an e x i s t i n g o p e r a t i o n . For example: can a permanent h i g h w a l l b e e s t a b l i s h e d , is i t mandatory t h a t t h e p i t develop a s a cone no f i x e d wall, can t h e p i t be mined w i t h push backs, a l t e r n a t i n g from s i d e t o s i d e , c a n a permanent ramp be e s t a b l i s h e d p a r t o f t h e way i n t o t h e p i t , o r t o t h e p i t bottom, is t h e s u r f a c e topography and p l a n t s i t e o r w a s t e dump such t h a t a system o f o r e p a s s e s and a conveyor ramp t o an a d i t would be practical. I n p l a n n i n g t h e p i t i t must be remembered t h a t a c c e s s o r Bervice ramps need n o t be a s wide a 3 h a u l a g e ramps and do n o t have t o t o l l o w o r e production. The p i t ramp e x i t i s n o t a s c r i t i c a l f o r a s e r v i c e ramp a s f o r a haulage road b u t should provide ready a c c e s s t o t h o p i t shop.

I n d w e l o p i n g a n ICC s y s t e a , c o n s i d e r a b l y more d e t a i l e d long-term p l a n n i n g is r e q u i r e d . It i s p o s s i b l e t h a t more i n i t i a l d r i l l i n g might have t o b e done i n o r d e r t o e s t a b l i s h confidence i n being a b l e t o reach t h e ore with a conveyor system and moveable c r u s h e r , s a y 20 t o 30 y e a r s hence. Tbis does n o t mean l o s s of f l e x i b i l i t y , it i s t o prove t h a t i t is possible. It i s p o s s i b l e t h a t phased developnent w i l l become p w t o f t h e o v e r a l l scheme. iUso f o r a new mine, i t i s q u i t e l i k e l y t h a t a p i t r i m c r u s h e r ( f i x e d o r moveable) w i l l be r e q u i r e d f o r a p e r i o d of t i m e , a s t h e economics of I C C hinge on r e p l a c i n g t h e h i g h l i f t and long t r u c k h a u l a g e ramp. I n o r d e r t o e s t a b l i s h a f l x e d ranp f o r sone l e n g t h i n t o t h e p i t , it nay be n e c e s s a r y t o remove a d d i t i o n a l waste d u r i n g pre-production o r d u r i n g t h e first few y e a r s o f mining. T h i s a d d i t i o n a l c o s t may be o f f s e t i n l a t e r y e a r s by p r o v i d i n g extended p i t l i f e w i t h mineable o r e a t d e p t h by t h e u s e o f ICC. One n o t a b l e d i f f e r e n c e i n ore/waste haulage by conveyor v e r s u s t r u c k i s t h e much narrower conveyor ramp a t 20-25s s l o p e r a t h e r than t h e 7-81 limit placed on t r u c k ramps. This r e s u l t s i n a much s h o r t e r o v e r a l l d i s t a n c e from t h e s h o v e l a t t h e f a c e t o t h e p i t r i m . I n some c a s e s t h e s e r v i c e ramp f o r p i t equipment a c c e s s and conveyor ramps t o g e t h e r a r e t h e same c o s t a s t h e much wider main h a u l a g e ramp. An i m p o r t a n t p a r t of t h e concept planning process i s t h e application of financial a n a l y s e s f o r t h e v a r i o u s schemes p r o j e c t e d f o r a minimum o f 20 y e a r s . Comparative system and f i n a n c i a l a n a l y s e s w l l l i n d i c a t e t h e concept most s u i t e d t o t h e mine. Further detailed p l a n n i n g on t h e s e l e c t e d scheme can then be done t o prove t h e f e a s i b i l i t y and v i a b i l i t y through t h e v a r i o u s phases of t h e o p e r a t i o n . h e o f t h e more s e n s i t i v e economic f a c t o r s i n the f i n a n c i a l projections r e l a t e s t o petroleum f u e l c o s t compared t o e l e c t r i c power cost. The h i g h e r t h e p r i c e of e l e c t r i c i t y , This t h e l e s s c o s t advantage t h e r e i s t o I C C . can i n f l u e n c e a d e c i s i o n i f o r when t o proceed w i t h a system. Taking t h e complexity o f t h e p l a n n i n g f u n c t i o n o f I C C i n t o a c c o u n t , i t is n o t p r a c t i c a l t o develop a p i t and then t r y t o f i t a n I C C i n t o i t . The planning must be an i n t e g r a t e d process. H a t e r i a l s Handling Large volume movement o f ore/waste by t r u c k from a n open p i t i s u s u a l l y c l a s s i f i e d a s c y c l i c o r non-continuous a s compared t o c o n t i nuous systems such a s a bucket wheel e x c a v a t o r combined w i t h moveable conveyors. The combination o f a t r u c k / s h o v e l o p e r a t i o n w i t h ICC b r i n g s t h e m a t e r i a l s h a n d l i n & system v e r y c l o s e t o continuous. The e l i m i n a t i o n of long up-hill h a u l d i s t a n c e s , t r a v e l time, d e l a y s on t h e ramp, t r u c k queuing a t t h e c r u s h e r and s h o v e l , means t h a t with s h o r t h a u l , f a s t - c y c l e t r u c k haulage, and a f e e d e r ahead o f t h e c r u s h e r , c o n t i n u o u s movement of m n t e r i a l from t h e p i t c a n be achieved.

Design c r i t e r i a f o r a mining materials ~t is acknowledged t h a t t h e i n - p i t c ~ ~ s h e r handling system !Dust be c l e a r l y defined in can have 20-302 g r e a t e r u t i l i z a t i o n than t h e o r d e r t o c o r r e c t l y s e l e c t , s i z e and determine , surface crusher, thus achieving g r e a t e r a l l t h e components which i n f l u e n c e c a p i t a l and tonnage v i t h a s m a l l e r u n i t (54" m r a t o r y operating costs. T h i s paper does not atteapt i n s t e a d o f 60"). t o g i v e a complete design c r i t e r i a o u t l i n e but Conveyors do not run o u t of f u e l , develop d e a l s more s p e c i f i c a l l y v i t h f a c t o r s *ich ' f l a t t i r e s , g e t s t u c k with a box t h a t w i l l n o t i n f l u e n c e i n - p i t c r u s h e r s and l a r g e capacity l i f t , have t o wait f o r t h e snow plow and s o high t e n s i o n conveyors. on. Conveyors have a h i s t o r y of high a v a i l M n y o f t h e f a c t o r s s e t o u t a basis a b i l i t y when operated and maintained a s a f o r equipment tender documents and , t r a n s p o r t a t i o n system. This means p r o v i s i o n construction/installation c o n t r a c t s . of a weekly scheduled p r e v e n t a t i v e m i n t e n a n c e program d i l i g e n t l y followed and p r e f e r a b l y General computer monitored. Location of I C C equipment from benches 0 Geographic l o c a t i o n , e l e v a t i o n , topography being b l a s t e d is of concern. Today's b l a s t i n g o Access, t r a n s p o r t a t i o n , r o a d s , r a i l , e t c , equipment and techniques keep f l y rock t o a 0 Climatic c o n d i t i o n s : minimum, therefore allowing mining and temperature range m a t e r i a l s handling t o work c l o s e l y t o g e t h e r . p r e c i p i t a t i o n , r a i n , snow It i s v i s e t o keep t h e main haulage wind v e l o c i t y conveyors more than a s a f e d i s t a n c e from seismic data b l a s t i n g ; however, t h e c r u s h e r and i n - p i t o Operating data: conveyors can be w i t h i n 100-120 metres with r e l a t i v e s a f e t y . me most v u l n e r a b l e p a r t s o f mine o r e h a s t e production t h e crusher and conveyors a r e t h e d r i v e s which system u t i l i z a t i o n i n hours p e r year can be s h i e l d e d t o a degree, thus reducing t h e deducting: r i s k o f being s t r u c k . s t a t u t o r y holidays The q u e s t i o n of system downtime f o r moving unscheduled d e l a y s t h e crusher i s of concern. Most l a r g e open fog, whiteout days p i t o p e r a t i o n s which a r e adding I C C have a t snow days l e a s t one f i x e d crusher on s u r f a c e . It is P.M. S h i f t s o f t e n p o s s i b l e t o f i n d some "make-upn o r e i n equipment moves t h e limbs of t h e p i t whlch can be kept in-hand o p e r a t i n g hours p e r day a c t u a l deducting: and hauled by t r u c k t o t h e s u r f a c e c r u s h e r lunch breaks during t h e p i t c r u s h e r move. Each mine w i l l s h i f t changes b e d i f f e r e n t b u t a way t o keep t h e m i l l going t r a v e l time f o r s e v e r a l days can u s u a l l y be found. system m e c h a n i c a l / e l e c t r i c a l a v a i l a b i l i t y The two most important t h i n g s t o keep i n unscheduled shutdown mind a r e t o minimize t h e number of moves, and system start-up/shutdown if p o s s i b l e t o schedule t h e moves a t a time o Annual production o r e and waste i n t o n s when t h e p l a n t s t o c k p i l e is f u l l and when t h e o Daily production t o meet p l a n t r a t e i n tons m i l l is scheduled f o r a maintenance shutdown. o Average production/hour One of t h e c r i t i c i s m s of I C C i s l o s s o f o Design r a t e +20% over average r a t e , peak f l e x i b i l i t y i n an o r e body with varying t y p e s r a t e ( s h o r t term) +20% over design r a t e and grades. Location of t h e p i t c r u s h e r under these circumstances becomes critical as Material Characteristics blending i n t h e p i t t o one feed p o i n t becomes difficult. I n some c a s e s , i t may be more o Ore t y p e , waste rock t y p e , overburden j economical t o have two p i t c r u s h e r s i n description d i f f e r e n t l o c a t i o n s feeding a main conveyor o S p e c i f i c g r a v i t y of o r e h a s t e haulage system. o Bulk d e n s i t y o f crushed ore/waste An o r e p a s s system w l t h two r a i s e s t o o Run-of-mine lump s i z e separate locations i n t h e p i t is another o C h a r a c t e r i s t i c s of b l a s t e d ore/waste a l t e r n a t i v e f o r d e a l i n g with t h e blending slabs problem. blocks There a r e s e v e r a l b a s i c c o n f i g u r a t i o n s f o r high f i n e s p i t crushing/conveying a l l of which have been o Size analysis of run-of-mine broken s u c c e s s f u l l y applied: orehaste Fig.1 Underground ramp system o S i z e a n a l y s i s of crushed o r e h a s t e Fig.2 ( a ) ( b ) and ( c ) Conveyor ramp system o Moisture c o n d i t i o n s i n p i t influencing Fig.3 Active o r e pass, underground c r u s h e r and orehaste conveyor ramp o Ore/waste hardness, a b r a s i o n Fig.4 Mobile c r u s h e r , c r o s s - p i t conveyor and o Angle of repose crushed o r e / n a s t e highwall bridge conveyor t o p i t r i m . o Angle o f withdrawal, crushed ore/waste From t h e foregoing d e s i g n c r i t e r i a , I C C , Design C r i t e r i a system concepts can be e v o h e d and following a s c r e e n i n g s t u d y , t h e most a c c e p t a b l e scheme A comprehensive design c r i t e r i a i s The next can be chosen f o r f u p t h e r study. u s u a l l y defined a f t e r a p r e - f e a s i b i l i t y study. s t a g e i n v o l v e s s e l e c t i o n o f equipment t o s e t The s t u d y u s u a l l y d e f i n e s t h e production r a t e i n t o t h e concept. based on o r e grades, r e s e r v e s and i n d i c a t e d metallurgical recoveries.

Crushing P l a n t (s Crusher f i x e d , moveable, mobile (walking o r crawler mechanism) o Type jaw, impact, r o l l gyratory o S i z e r e l a t e d t o p i t equipment o S e t t i n g r e l a t e d t o p l a n t requirement o Feed arrangement double t r u c k dump apron o r b e l t f e e d e r o Discharge arrangement feeder "take zway" conveyor

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Conveyors There a r e two major components t o be c a r e f u l l y considered i n t h e design and selection of high tension conveyors, p a r t i c u l a r l y f o r high l i f t , long c e n t r e p i t conveyors. The most c o s t l y p a r t of t h e system f o r both c a p i t a l and o p e r a t i n g a r e t h e b e l t s , t h e second being t h e i n i t i a l c o s t of t h e drives. Horsepower and b e l t t e n s i o n must be optimized t o reduce t h e number of b e l t t e n s i o n r a t i n g s t o one o r two, a s a s p a r e b e l t is a high c o s t inventory item. The use of m u l t i p l e d r i v e s reduces t h e s p a r e s inventory and a l s o allows continued o p e r a t i o n of a conveyor a t reduced tonnage should a d r i v e f a i l . When lengthening o r s h o r t e n i n g conveyors within t h e p i t , d r i v e u n i t s may be added o r reduced accordingly. Conveyor design must address f u l l y , tempera t u r e c r i t e r i a , a s w e l l a s c h a r a c t i s t i c s of t h e m a t e r i a l t o be handled. This paper i s not intended t o t r e a t t h e s u b j e c t of conveyor design but t h e success of an i n - p i t conveyor system hinges on many component, s e l e c t i o n f e a t u r e s which a r e highlighted f o r consideration. Conveyor S e l e c t i o n : B e l t Width To avoid s p i l l a g e from a b e l t c a r r y i n g c o a r s e crushed ore/waste, p a r t i c u l a r a t t e n t i o n must be paid t o t h e load p o i n t s and b e l t edge d i s t a n c e t o t h e load on t h e b e l t . Based on 305 mm, maximum lump s i z e (which could have a long dimension o f 457 mm), a minimum of 203 mm edge d i s t a n c e a t t h e load p o i n t should be allowed. For c o a r s e o r e b e l t s , i t i s d e s i r a b l e t o keep t h e crosss e c t i o n a l load t o l e s s than 80% of t h e Conveyor Equipment Manufacturers Association s t a n d a r d s (CEMA) when c a r r y i n g t h e design tonnage. T h i s means t h a t flowsheet tonnage w i l l be 65-702 of CEMA depending on c o n t r o l o f feed t o t h e conveyor system. Peak tonnage can The crossbe a s high a s 85% of CEMA. s e c t i o n a l load should then be c a l c u l a t e d using a 20 degree surcharge a n g l e using 35 degree A s t h e m a t e r i a l is equal l e n g t h i d l e r r o l l s . conveyed over a long d i s t a n c e , t h e dynamic s e t t l i n g of t h e load can o f t e n reduce t h e surcharge a n g l e t o 15 degrees. This reduces t h e edge d i s t a n c e t o 198 mm which is adequate t o c o n t a i n t h e load. For c o a r s e o r e conveyors 4 t o 5 Speed For overburden conveyors 5 t o 8 m/s. m/s. I n c l i n e k n ~ l e A 25% ramp i s considered maximum f o r maintenance access.

A 202 ramp i s considered Decline Angle maximum f o r containing m a t e r i a l on t h e conveyor under braking conditions. Conveyor Components: Belt Carry s i d e cover t h i c k n e s s 14 mm minimum. Back cover 6 mm minimum. Temperatures below -35 degrees C have a dramatic e f f e c t on rubber f l e x r e s u l t i n g i n high f r i c t i o n f a c t o r s . S a f e t y f a c t o r of t h e b e l t should be 6.7 minimum f o r a l l running conditions. For a c c e l e r a t i o n and braking t h e s a f e t y f a c t o r must n o t go lower than 3.0. Cord p r e s s u r e on p u l l e y s f o r s t e e l c o r d b e l t s can be about 16 kg/cm*. Drives Controlled torque and a c c e l e r a t i o n / b r a k i n g is a must. Pulleys and S h a f t s For high tension conveyors the pulley, hub and shaft combination must be c a r e f u l l y designed a s an i n t e g r a l u n i t t o t r a n s f e r l a r g e dynamic f o r c e s t o and from t h e b e l t . Metallurgy and treatment of steel used for pulleys, p a r t i c u l a r l y i f c a s t end d i s c s a r e used, should be c a r e f u l l y s p e c i f i e d . A l l welds should be s u b j e c t e d t o thorough examination. P u l l e y s should be s t r e s s r e l i e v e d a f t e r welding and machining. Heavy-duty diamond lagging for drive p u l l e y s pays o f f , a s p u l l e y change o u t s f o r r e l a g g i n g a r e c o s t l y i n down time. Non-driving p u l l e y s which a r e i n contact with t h e c a r r y s i d e of t h e b e l t should have p l a i n lagging. A l l p u l l e y s f o r b e l t speeds over 5 m / s should be turned and dynamically balanced. Idlers Very o f t e n b e l t t e n s i o n s a r e s u f f i c i e n t l y high t o permit wide i d l e r spacing with minimum sag. I d l e r s should be checked f o r load c a p a c i t y p a r t i c u l a r l y t h e r e t u r n s a s the high tension belt weight can be significant. I d l e r s should be heavy-duty, high-quality r o l l s with through bored end d i s c s . Minimum t o t a l i n d i c a t e d runout of 0.8 mm should be specified to prolong bearing life, p a r t i c u l a r l y on high speed b e l t s . For b e l t t r a c k i n g , two r o l l V-return i d l e r s have been found d e s i r a b l e with t h e added b e n e f i t of having f o u r bearings t o carr-jt t h e heavy r e t u r n b e l t . S p e c i a l a t t e n t i o n should be paid t o i d l e r spacing and blocking on convex and concave curves. Even though t h e r a d i i appears t o be l a r g e , t h e load imposed on t h e i d l e r s , p a r t i c u l a r l y on convex curves, is s i g n i f i c a n t . Impact i d l e r l i f e can be g r e a t l y extended A t load p o i n t s by using r e s i l i e n t mountings. having high impact, t h e e n t i r e support frame f o r a l l t h e impact i d l e r s can be v i b r a t i o n i s o l a t e d t o t h e b e n e f i t of i d l e r and b e l t life. Structure Conveyor d r i v e heads, t a i l s and take-up modules should have supporting s t e e l designed with allowance f o r f a t i g u e s t r e s s e s r e s u l t i n g from 700,000 load cycles. Control Control of a l a r g e crushing, conveying system and t h e a b i l i t y t o quickly

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a s c e r t a i n t h e cause of and respond t o unscheduled shutdown i s an a r e a which must be adequately considered. The f i r s t a c t i v i t y is t o d e f i n e t h e e x t e n t and l o c a t i o n of c o n t r o l and monitoring by producing an Instrument Control Diagram. From instrument d a t a s h e e t s , loop diagrams can be prepared. The use of video d i s p l a y , programmable logic controllers, combined with a t e l e m e t e r i n g system t o a c e n t r a l c o n t r o l panel allows complete monitoring and c o n t r o l of t h e system. The foregoing d i s c u s s i o n of design c r i t e r i a and component f e a t u r e s covers a s m a l l p a r t of the total. Areas such a s mechanical, s t r u c t u r a l , e l e c t r i c a l , instrumentation, dust control, fire detection and suppression r e q u i r e s complete coverage t o d e f i n e t h e system. Summary I n - p i t crushing and conveying i s i n t h e development; phase. New equipment and design innovabion w i l l come about i n an e f f o r t t o reduce t h e c o s t of mine m a t e r i a l s handling f o r a l l open p i t o p e r a t i o n s . Planning an i n - p i t crushing and conveying system i s a complex procedure and r e q u i r e s confirm its careful consideration to p r a c t i c a b i l i t y and economic b e n e f i t . A s t h e p i t c o n f i g u r a t i o n is i n f l u e n c e d by t h e m a t e r i a l s handling system, mine planning i n c o r p o r a t i n g p i t crushing and conveying must be an i n t e g r a t e d design. The a p p l i c a t i o n o f crushing and conveying t o a p i t r e q u i r e s long term planning and p o s s i b l y more i n i t i a l d r i l l i n g a s i t i s d i f f i c u l t t o change b a s i c concepts a f t e r 10 o r 15 y e a r s of production. I n p i t s with varying o r e t y p e s , scheduling on a weekly b a s i s may be necesary t o determine t h e p r a c t i c a b i l i t y of feeding a blend t o an i n - p i t crusher. T h i s complication combined w i t h grade cut-off and s t r i p r a t i o becomes a vital part of planning crushing plant relocations. The i n - p i t conveyor system must be designed f o r high u t i l i z a t i o n and a v a i l a b i l i t y . To t h i s end p r e p a r a t i o n o f a comprehensive "Design C p i t e r i a n is an a b s o l u t e n e c e s s i t y , a s i t p l a y s an important r o l e i n e s t i m a t i n g c a p i t a l c o s t s , p r o j e c t i n g o p e r a t i n g c o s t s and s u s t a i n i n g c a p i t a l requirements. A l l t h e s e f a c t o r s become p a r t o f t h e t o t a l economic p i c t u r e and determine t h e s u c c e s s of t h e mining o p e r a t i o n i n c o r p o r a t i n g i n - p i t c r u s h i n g and conveying. References Hays, Ronald M., October 1983 Mine plan in^ Considerations f o r I n - p i t Crushing and Conveying, SME-AIME, S a l t Lake C i t y , Utah.