gary james, a calibre global company - outlining a case study of a 20,000t stockpile and 400t bin...
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Case Study - 20,000 stockpile and 400t Bin Sticky Ore
“ Details, Details, Details ”
Bauxite Project WA.
Gary James.
Calibre Minerva
IIR Materials Handling Week. Brisbane June 2013
Bauxite Project WA
• Its all in the details.
• Think strategically.
• KISS. Keep the flow sheet simple.
• Bauxite companies have been dealing with
the issue for many years. Iron ore “below
water table” no different.
• Designers reluctant to throw out easy
handling dry ore standards for chutes, bins
etc.
Bauxite Project WA
• Some prefer to be optimistic. They
shouldn’t be.
• Good data is hard to get.
• Do not trust the data. If below water table
ore data looks OK, don’t believe it.
• Use companies TUNRA, BME/UOW, J & J
to test, model and audit the final design.
• The claim “ designed to TUNRA etc” often
false.
Typical Bauxite Behaviour
Photos from another
project. Cemented lumps
fall free, causing blockages
and damage.
HDPE on steep
walls
Stainless
ROM and Primary Sizing
ROM and Primary Sizing
ROM and Primary Sizing
Very steep side
walls means narrow
back wall. Hence
trucks dump over
the side.
ROM and Primary Sizing
72º sides 82º back
Chute longer to take
corners out of play
HDPE
ROM and Primary Sizing
2100mm slow belt
stops spillage
ROM and Primary Sizing
ROM and Primary Sizing Dust Collection
Dust collectors roll
out. No ducting on
dirty side
Overland Conveyor Feed Details
Direct loading of
overland conveyor from
sizer. Curved plates,
reduce risk of build-up
& lower belt impact.
Curved plates
cause ore collision
and loss of energy
Chute longer than
sizer. This takes the
corners out of play.
Ductless dust
collection
Overland Conveyor Feed Details
Overland Conveyor Discharge & Drive Area
Return
idlers/pulleys
are under the
truss with
18m pitch.
Carry back
falls in easy
access
locations Skid loader access
under take-up, &
tunnel under drives etc
Overland Conveyor Discharge
Belt washing & several scrapers and rollers
Ductless dust collection No back wall in chute
Walk way along elevated
loading point, allows
unobstructed cleanup.
Overland Conveyor Discharge
Small impact zone introduced for primary crushed ore.
Smaller ore can be designed with direct feed. Design the
belt for direct feed.
UOW/BME chute modelling ( Iron ore project)
Sticky Ore Detailing
No back wall in
chute under
pulley
HDPE
Removable side
wall module
allows
reconfiguration
or deletion
Receiving belt is designed for direct
feed, so if sticky ore becomes a
problem, the cross bars can be
removed.
Walk in doors
22m3 live
capacity
Conveyor Drive Area
Drive through tunnel
under drive zone for
clean-up
1000 t bin, Screening & Sec Crushing
• xxx
Steep
walls,
round
corners
Steep walls & no end
walls equals no valleys
Down sloped
reversing conveyor
for clean out of
system
Ductless
dust
collection
Sloping floor
Drain to ground
1000 t bin, Screening & Sec Crushing
1000 t bin, Screening & Sec Crushing
Stockpile
Stockpile
Stockpile With Big Outlet
• 20,000 t live.
• 23m long offset outlet to reduce height of the rat hole.
Stockpile With Big Outlet
Stockpile Outlets
Two apron feeders back to back,
each under a double hopper
Wider outlet
Steeper wall
Even drawdown
Wider outlet
Stockpile Outlets
Conical hopper.
Can also be used
on the end walls of
a wedge shaped
hopper.
Stockpile Outlets
Wedge means
outlet has a ratio
between 3 & 5 to 1
Add inserts when
ratio 6 to 1 &
above
A wedge means
vertical end walls.
( Can relax the
rule to use the
conical angle on
the end walls.)
Stockpile Outlets
Back to back apron feeders
sharing common take-up
rails
26m outlet No flat areas Round corners
Ductless dust
collection
Stockpile Outlets With Round Corners
400t OBC Feed Bin
Conveyor/feeder
extended to increase
belt life
400t OBC Feed Bin
400t OBC Feed Bin
Vertical scrapings
chute to feeder
below
400t OBC Feed Bin
400t OBC Feed Bin
Outlet of 400t bin
fits into the shape
set by the 5 roll 60
degree conveyor
idlers
400t OBC Feed Bin
No skirts
The End
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