Excellence In Technology

Open Pit Mining Systems
And Equipment
www.thyssenkrupprobins.com
Phone: 303-770-0808
Fax: 303-770-4522
E-mail: [email protected]
A company
Of ThyssenKrupp
Technologies
ThyssenKrupp Robins
TK
ThyssenKrupp Robins Inc.
7730 East Belleview Ave. Suite 404
Greenwood Village, Colorado
80111-5820 U.S.A.
8009-TKRI OPEN PIT MINING / 072009el / DEPT. 2300
Excellence
in Technology
Excellence in Technology
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Mining technology from ThyssenKrupp
ThyssenKrupp Robins
The most economical solution for modern
open pit mines.
Who we are
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ThyssenKrupp mining equipment and systems offer
an efficient, reliable and economical solution to mining
operations. Some of the applications are:
earthmoving for land reclamation, removal of
overburden in new open pit mines, mining of raw
materials such as lignite, limestone, oil sand,
phosphate, bituminous coal, hard rock and ore.
More than 120 years experience, comprehensive
know-how and high quality standards allow
ThyssenKrupp to hold the top position throughout the
world in the field of open pit mining equipment and
technology.
Systems and equipment Capabilities
ThyssenKrupp Robins, Inc., (TKRI), is a member of the
ThyssenKrupp Fördertechnik GmbH Group.
Headquartered in Denver, Colorado, TKRI stands ready to
furnish a wide range of Bulk Material Handling and Mining
equipment including:
• Overland Conveyors
• Pipe Conveyors
• Customized In-plant Conveyor systems to fit in
existing plants
• Semi-Mobile and Fully Mobile Crushing Plants
• Stockpiling, Reclaiming and Blending Machinery
• Belt Feeders, Plow Feeders and Apron Feeders
• Customized DEM Transfer Chutes
Our clients are:
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Marine Terminals
Open Pit Mines
Power Stations
Cement Plants
Refineries
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Steel Mills
Recycling Facilities
Paper Mills
Aggregate Mines
These systems are capable of handling various materials
including:
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Coal
Petroleum Coke
Sulfur
Lignite
Limestone
Iron Ore
Copper Ore
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Earth/Rock
Bauxite
Phosphate Ore
Woodchips
Cement
Fertilizer
Grain and Others
TKRI’s dedication to maintaining the most advanced
technical capabilities in conveyor system design is
evidenced by its computer-based conveyor calculation
programs which afford a detailed comparison of alternate
conveyor selections. Its extensive list of references
includes innovative, low-cost and highly efficient material
handling and mining equipment.
Furthermore, TKRI can execute turnkey projects from
preliminary estimates or feasibility studies, to design
engineering, material procurement, construction,
supervision and system start-up. TKRI can offer total
project responsibility, planning, engineering, quality
assurance, manufacturing, and construction management.
Please check us out at www.thyssenkrupprobins.com
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Service and Spare Parts
Every plant and every system can only perform as
well as maintenance and service allow. You can rely
on ThyssenKrupp’s after sales service. We provide
experienced specialists to assist the customers in a
variety of tasks, from the planning phase through
design to site management, construction
supervision and personnel training.
ThyssenKrupp’s after sales service department
provides assistance in modernizing and inspection
of existing plants and ensures the timely supply of
spare parts.
Early detection of wear and minor damage provide
the necessary information for preventative
maintenance planning. For this reason
ThyssenKrupp offers inspections at customers’
requests, in particular of precision parts, such as
ball races, slew bearings and gear reducers.
Above: Replacing a Bucketwheel gear reducer
on a large Bucketwheel excavator.
Far left: Assembly of the telescopic conveyor
bridge of a Bucketwheel excavator.
Center left: Re-installation of balls in an open ball
race bearing after inspection.
Below: A completely assembled compact
Bucketwheel excavator being loaded onto a ship.
One decisive feature insures our success: the ability to
define key mining problems, prepare adequate
solutions and to develop advanced mining equipment
and technologies.
ThyssenKrupp offers leading edge mining technology
in optimizing existing mining systems, especially in
planning and building of turnkey systems tailored to
the specific requirements of the customers.
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Planning, consulting, engineering, manufacture
and service
Comprehensive know-how, specialization in many
fields and superior engineering knowledge combined
with innovative developments make ThyssenKrupp a
competent partner in all phases of project planning,
design and construction of mining equipment and
systems.
A wide range of mining equipment for open pit mining
enables us to provide customized solutions for all
mining requirements. Alternative solutions can be
studied and neutrally developed based on requirement, economy and efficiency.
Manufacturing
Whether manufactured at our own works (as
shown) or by our local partners, high quality
remains the number one priority.
Highly qualified ThyssenKrupp fabrication
supervisors ensure the high quality standards of
fabrication in our own works and at other
fabrication facilities worldwide.
Left: Fabrication of a ring girder for a large
Bucketwheel excavator.
ThyssenKrupp stands for comprehensive know-how
and engineering experience, combined with modern
technology and the most advanced solutions.
Modern computer technology (CAE, CAD, FEM, CIM
and PPS) permits us to economically design
components and machines, guarantees rapid and
precise access to calculations concerning loads and
deformation, and enables ThyssenKrupp to make
check calculations for proposed design variants under
the aspect of optimum design criteria.
These widely used computer based techniques lead to
more efficiency in project planning, assist in contract
and construction management and control of plants.
Certification according to the requirements of DIN/ISO
9001 and EN 29001 by Lloyd’s Register Quality
Assurance and Germanischer Lloyd also document the
high quality standards of ThyssenKrupp open pit
mining equipment and systems.
Above: Pre-assembly of a compact Bucketwheel
excavator.
Left: A pre-assembled travelling mechanism of a
large Bucketwheel excavator.
Below: Precision gear reducer parts for a Bucketwheel drive.
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Mining
Components
Large Bucketwheel Excavators
With a wide range of components ThyssenKrupp
provides the basis for optimum processing and
recovery of raw materials. Emphasis is placed in the
design and manufacturing of these components as
well as on high efficiency and reliability at a low
operating and maintenance cost.
ThyssenKrupp supplies rail shifting heads for the
relocation of shiftable conveyors (right). The shifting
heads are utilized with a properly fitted dozer to move
the conveyor system.
Left, twin briquetting press for binderfree briquetting
of peat, lignite and fibrous materials.
Above, a travelling plow feeder in a
German power station with a 3 m
discharge wheel diameter and 250 -1,000
t/h reclaim capacity. Plow feeders are
available with diameters up to 4.2 m and
reclaim capacities up to 3,000 t/h. The
units are very reliable and environmentally friendly.
Center, a magnetic separator for removal of tramp
iron from bulk materials.
Right, Blendomat discharge units with a diameter of
6.5 m, are specifically suited to overcome the
problems associated with reclaiming poorly flowing,
sticky bulk materials with a tendency to bridge. They
are used in power stations and in the cement and
chemical industries.
In the world of technical giants, ThyssenKrupp
provides some of the largest mining equipment on
earth.
Continuously operating Bucketwheel excavators,
spreaders and high capacity conveyor systems are
employed in the mining of huge quantities of raw
materials. Several million cubic meters of
overburden have to be removed to expose the raw
material seams, subsequently backfilled for
reclamation of the land, e.g. using XPS® cross pit
spreader systems from ThyssenKrupp.
The product line of mining equipment mainly
comprises large Bucketwheel excavators for open pit
mines with very high production rates, as well as
standard and compact Bucketwheel excavators for
earthmoving projects and open pit mines with small
and medium production rates.
Shown above, the largest Bucketwheel excavator in
the world with a daily capacity of 240,000 m3 (bank),
commissioned in 1978. Its place of operation is the
German Hambach open pit mine of Rheinbraun AG.
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More Examples of large Bucketwheel
Excavators
Hopper Cars, cable reel cars, inspection
cars
Large Bucketwheel excavator systems from
ThyssenKrupp are custom designed and built for
the specific operating conditions and the
production rates for each open pit mine.
Currently attained production rates are up to
240,000 m3 (bank) per day, digging heights of as
much as 100 m and service weights of 13,500
tons.
Above is another large Bucketwheel excavator at
the German Garzweiler open pit mine (previously
Hambach) operating in low cut. (Capacity:
200,000 m3 per day.)
Right is a Bucketwheel excavator in the Polish
Belchatow open pit mine operating at a daily
capacity of 130,000 m3 (bank).
Below is a large Bucketwheel excavator in the
Greek Amynteion open pit mine with a daily
capacity of 100,000 m3 (bank).
Depending on the mine plan, ThyssenKrupp
Bucketwheel excavators are supplied as a
complete system with a connecting conveyor
bridge and loading unit or as a single
Bucketwheel excavator with a discharge boom.
If the latter option is selected, a mobile transfer
conveyor is usually employed between the
Bucketwheel excavator and the belt conveyor to
reduce the frequency of shifting the bench
conveyor.
As a supplier of turnkey mining systems, the
ThyssenKrupp product line includes a variety of auxiliary
equipment.
Above, a combined feed hopper and cable reel car
travelling on rails. The electrical power supply to the
mobile transfer conveyor and the Bucketwheel excavator
is provided via the cable reel.
Right, a travelling cable reel car on crawlers with power
and control cable reels.
Below, a travelling inspection car for monitoring and
repair work on overland conveyors.
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Transport Crawlers
ThyssenKrupp transport crawlers are the result
of vast experience in moving large and heavy
mining equipment, such a conveyor drive
stations or crushing plants. The transport
crawlers are designed to travel over steep uphill
and downhill slopes and to cope with uneven
terrain. Their carrying loads range from 150 to
1,200 tons. Heavy mining equipment, such as
semi-mobile crushing plants and conveyor drive
stations, have to be relocated as mining
progresses.
ThyssenKrupp has developed transport crawlers
capable of relocating such equipment in a short
period of time easily and economically.
Left, a transport crawler carrying an 850 ton load
while moving a semi-mobile crushing plant in
South Africa.
Below is a transport crawler moving a heavy
conveyor drive station weighing 700 tons.
Above left, one of six Bucketwheel excavators in
the Elbistan open pit mine in Turkey operating at
a daily capacity of 60,000 m3.
Above right, two trench reclaimers with telescopic Bucketwheel boom for the storage and
homogenizing bunkers of a German lignite open
pit mine. Capacity: 120,000 t/d. Track gauge:
64.2 m.
The Bucketwheel excavator to the right operates
in the Goonyella lignite open pit mine in Bowen
Basin, Queensland, Australia, and is used to
remove overburden. Capacity: 50,000 m3/d.
Below, a Bucketwheel excavator system of
60,000 m3/d capacity working in an Australian
open pit mine.
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Mining
Various equipment
Standard and compact Bucketwheel
excavators
Mobile transfer conveyors
Standard and compact Bucketwheel excavators
are especially economical for many applications
where the material to be mined is soft or mediumhard, but they can also be used for special tasks,
such as mining of hard materials like limestone.
Mobile transfer conveyors are utilized in continuous
mining and conveying systems as a link between
the mining equipment and the bench conveyor.
They overcome the variation in distance and height
between the mining equipment and the bench
conveyor, lengthening the intervals between
conveyor shifts and thus reducing downtime.
Short booms, low-positioned counter-weight,
ease of maintenance and operation as well as
high reliability in operation are further advantages
of these BWE’s.
ThyssenKrupp mobile transfer conveyors are
available in various configurations, such as:
The standard and compact excavator series were
developed to suit the requirements of open pit
mining and earthmoving operations with small
and medium production rates. Standardization of
components and extensive preassembly of the
equipment have significantly reduced the cost of
these machines. The systematic development of
the design and fabrication techniques of this
product line have resulted in optimum adaptation
of the equipment to the specific working
conditions while reducing the delivery time and
the capital investment.
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Mobile transfer conveyors with single
conveyor.
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Mobile transfer conveyors with two
veyors.
con-
ThyssenKrupp mobile transfer conveyors are
designed and built to meet the specific operating
requirements of each mining application.
Above, a Bucketwheel excavator with mobile transfer
conveyor operating in an oil sand mine in Northern
Canada. Capacity: 6,000 m3 /hour.
ThyssenKrupp compact systems consist of a
family of correlated equipment, such as
Bucketwheel excavators, mobile transfer
conveyors, belt conveyors, tripper cars and
spreaders. The effective capacity of the compact
systems range from 4,000 to 65,000 m3 /day.
Left, a mobile transfer conveyor with a single
conveyor in operation in the Mae Moh open pit mine
in Thailand. Capacity: 4,500 m3 /hour.
These compact systems are complemented by
direct dumping systems.
Top: The smallest BWE, the versatile S 100, can
be used for a variety of tasks such as for mining
chalk or as an excavator for special short term
applications. It can be transported on a low bed
trailer. The S 100 series is designed for capacities ranging from 450 to 2,000 m3 /hour.
Center: BWE with a specially designed wheel with
removable buckets fro cutting hard materials.
Left: compact BWE in the Mae Moh open pit mine
in Thailand, removing “gray shale” overburden to
expose the lignite seams. Capacity: 4,100 m3 /
hour.
Below, a mobile transfer conveyor with two
conveyors transporting ferruginous sand in Waikato,
New Zealand. Length: 50 m. Capacity: 1,800 m3 /
hour.
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Tripper cars
ThyssenKrupp provides tripper cars traveling
on rails or on crawlers. For bench conveyors
of 2,000 mm width or more, tripper cars on
crawlers are utilized. Depending on the
operation, the tripper cars have either a
slewable discharge boom to transfer the material to the spreader, or the receiving conveyor bridge of the spreader is directly supported below the
discharge pulley of the
tripper car. All tripper cars can be equipped
with or without the take-up system for the
bench conveyor and with or without the
conveyor drive for the bench
conveyor.
The compact Bucketwheel excavator series is
designed to suit a wide range of operating
conditions. Modern computer aided design
methods wree employed to simplify the operation
of the machine, increase the reliability and
availability, reduce maintenance requirement and
increase the lifetime of the components.
The excavator capacities have been selected to
match the capacities of standard width bench
conveyors. This ensures optimal technical and
economical utilization of the entire mining and
conveying system.
Top: Tripper car on rails with slewable discharge
booom transporting coal.
Center: Tripper car on rails. Capacity: 5,500
m3 / hour.
Bottom: Tripper car on crawlers. Capacity
27,500 m3 / hour.
Above is a standard BWE, type S 400/250
operating in a limestone mine in northern Germany
The wheel with the integrated buckets is
shaped like a milling tool. Capacity: 1,200 m3 /
hour.
Top right, a compact BWE mining hard lignite in
Indonesia. The coal is partly covered by hard
claystone as well as by tough, plastic clay. The
excavator mines the various materials with the
same Bucketwheel. Special shaped teeth are
used to mine the particularly hard layers.
Capacity: 3,100 m3 / hour.
Below, a compact BWE in a greek lignite mine.
Capacity: 2,800 m3 / hour.
Bottom right, a compact BWE operating in a North
American bituminous coal mine. Capacity: 6,600
m3 / hour.
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Spreading and dumping
Bucket chain excavators
Spreaders
The spreader is the last member in the chain of
equipment for continuous removal of overburden.
ThyssenKrupp has built spreaders for all
capacities throughout the world. The service
weight of the equipment ranges from 70 to 5,400
tons.
Above: Spreader for 3-bench operation in a German open pit mine.
Bucket chain excavators find their application
particularly in areas where the material has to be
dug below the excavator operation level. That is
required in cases when the digging face is below
water level or when the ground at the toe level of
the face has insufficient bearing capacity for the
excavator.
As far as operation mode and excavator design
are concerned differentiation is made between
two types: bucket chain excavators moving on
crawlers and those traveling on rails.
Bucket chain excavators on crawlers are
frequently equipped with a slewing mechanism
for the superstructure. They are able to work in
high and low cuts. They mainly work to the block
mining method. In some cases the face
operation method is also employed.
Bucket chain excavators on rails mainly work in
the low-cut mode.
Top right: Giant spreader for dumping overburden
in a German lignite mine. Capacity: up to
300,000 m3 /day.
Center right: C-frame type spreader for continuous dumping of overburden. Capacity: 4,850 m3 /
hour.
Top left: Bucket chain excavators are employed in
applications where the material has to be well
blended during the digging process. This bucket
chain excavator works to the parallel digging
mode in a German open pit mine and is equipped
with a rail shifting device. Capacity: 810 m3 /
hour.
Top right: Low-cut bucket chain excavator working
in the slewing mode in a Southern-European
lignite mine. Capacity: 1,800 m3 /h
Bottom right: Spreader combination in a North
American open pit mine. Capacity: 3.500 m3 /
hour.
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XPS® Cross Pit Spreader systems
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Transportation
Overland conveyor systems
Belt conveyor systems planned and designed,
manufactured and installed by experienced
ThyssenKrupp specialists, prove their high
reliability even under extreme operating
conditions. Special design features ensure high
availability of these systems, for example, idlers
could be designed and supplied to permit their
replacement while the conveyor continues to run.
Integrated monitoring systems insure the early
reporting of components malfunction to prevent
any serious damage to the equipment.
ThyssenKrupp design places conveyor drives
supplying the driving power to the conveyor at the
most favorable location in terms of space and in
order to permit optimum belt tension.
Our design of regenerative downhill conveyors
allows the utilization of the generated energy.
This applies to both straight-line and horizontally
curved conveyors.
Top : Direct dumping system operating in the
USA. Two BWEs with a capacity of 3,000 m3 /
hour each transfer the total capacity of 6,000 m3/
hour to the XPS® spreader. The discharge boom
length is 207m.
Above left: Standard S 400 BWE with conveying
bridge and spreader in a diamond mine in Namibia.
Center right: A standard S 160 BWE for excavating gravel and sand in a direct dumping system,
including a screening plant.
Bottom right: Spreader with 80 m long discharge
boom, operatin in a direct dumping mode in a
phosphate mine in Togo. The complete system of
BWE, MTC and spreader has an overall reach of
180 m. Capacity: 1,800 m3 /hour.
Valuable ore is frequently covered with hardrock,
with is again sometimes covered by soft to
medium-hard material. Under such
circumstances the most economical mining
procedure is to combine discontinuous and
continuous open pit mining equipment.
The hardrock is blasted and excavated by shovels
or draglines, the softer overburden is removed by
Bucketwheel excavators and conveyed to a cross
pit spreader for placing onto the overburden
dump.
Mobile belt conveyor system are tailored to their
specific application whether for mobile crushing
plants or for use in hardrock open pit mines.
Above: Three overland curved belt conveyor
systems, connecting the open pit mine and the
power station, so-called “contour conveying” with
horizontal, concave and convex vertical curves.
One conveyor of 8.55 km and two conveyors of
5.5 km each. Capacity: 1,000 t/h each.
Left: This Pipe Conveyor in the USA, was built by
ThyssenKrupp Robins for the (now closed)
Homestake Mine. The two kilometers from the
mine to the crushing plant were managed with ten
horizontal curves. Capacity: 350 t/h.
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Top: A 19.3 km long single flight, horizontal
curve conveyor carrying lignite.
Center left: Curved overland conveyor, over 5 km
long, at Bayswater Power Station, Australia.
Capacity; 1,000 t/h coal.
Bottom left: 100 km long overland conveyor
system through the North African desert. Capacity: 2,000 t/h phosphate.
Bottom right: A 1.9 km overland reversible belt
conveyor in the US dropping 274 m from the
mine area to the storage area through
mountainous terrain. Capacity: 907 t/h sand and stone
Above: An overland conveyor of 4.6 km length
transports the overburden to a spreader with 60 m
long discharge boom. The spreader discharges the
material to the overburden dump. The overburden is
crushed to size suitable for belt conveyor transport and
is carried out of the pit by inclined belt conveyors.
Center left: Mobile crushing plant on tires in a US
cement plant. Mobile crushing plant on tires with roll
crusher.
Bottom left: Semi-mobile crushing plant with gyratory
crusher, relocatable with transport crawler in USA.
Capacity: 4,500 t/h copper ore.
Below: Semi-mobile crushing plant being relocated
with a transport crawler in a South African cement
plant.
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Hardrock open pit mining
In-pit crushing
Top left: A pipe conveyor in the western US
connecting the mouth of a coal mine with a train
loadout facility at the bottom of a mountain, a
distance of 3.4 km. Capacity: 1270 t/h.
Center left: A 10.8 km long overland conveyor in
the Canadian north. Capacity: 700 t/h coal.
Bottom left: A 6.1 km long curved overland
conveyor in South Africa.
Bottom right: A high altitude overland conveyor
system carrying copper ore over mountainous
terrain. The first two conveyors climb a total of
275 m from the pit bottom and along the pit edge
and create a 19,000 ton intermediate stockpile.
The third conveyor runs from the stockpile area
down to the concentrator, dropping 257 m over a
distance of 5,253 m.
ThyssenKrupp engineers made an important
contribution to one of the most significant
improvements in hardrock open pit mining, the
conversion from discontinuous, cost-intensive
material transportation by mining trucks to
continuous, more economical transportation by
belt conveyor systems.
Utilizing several decades of crushing technology,
ThyssenKrupp is today one of the most
experienced and successful manufacturers of the
new “in-pit curshing” systems with mobile and
semi-mobile crushing plants, mobile transfer
conveyors, belt conveyor systems and spreaders
with tripper cars.
The product line includes state our latest design
crushers, screens, drill hammers and hydraulic
hammers.
Above is an overall view of an in-pit crusher with
conveyor and spreader system.
Below: The world’s largest semi-moblile crushing
plant is located in a Chilean copper ore mine.
This in-pit crushing plant has a capacity of approximately 10,000 t/h of overburden.
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High capacity conveyor systems and
transfer stations
Top left: Conveyor collecting and distribution point
with upstream and downstream belt conveyors in
a lignite open pit mine, Germany.
Center left: Another conveyor distribution point.
Center right: Two cross-saddle train-loading
stations with slewing conveyor and traveling
saddles in a German lignite mine, loading
120,000 m3/day overburden or 120,000 t/d coal
into railroad cars, continuously passing under the
station on two adjacent rail tracks.
Bottom right: High-capacity train-unloading
station for lignite in a large German mine. Direct
material transfer from the train to a 6,400 mm
wide conveyor. Capacity: 17,000 t/h.
ThyssenKrupp high capacity conveyor systems
transport the materials mined by large
Bucketwheel excavators. High capacity conveyor
systems for open pit mines are available in
stationary, shiftable and relocatable designs.
Conveyor systems with belt widths ranging form
1,000 to 3,000 mm and maximum capacity of
25,000 m3 per hour are supplied. The product
line also offers head and tail stations, shuttle
head stations and take-up stations.
Above: Relocatable conveyor head station in a
lignite mine. Capacity: 21,500 m3 /hour.
Bottom Left: A special solution 6,400 mm wide
conveyor belt positioned under a railroad car
unloading station at a German min. Capacity:
17,000 t/h coal.
Bottom center: “Round the Pit” conveyor system
in a North American coal mine.
Below right: Shiftable conveyor in South Africa.
Capacity: 1,920 m3 / hour.
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High capacity conveyor systems and
transfer stations
Top left: Conveyor collecting and distribution point
with upstream and downstream belt conveyors in
a lignite open pit mine, Germany.
Center left: Another conveyor distribution point.
Center right: Two cross-saddle train-loading
stations with slewing conveyor and traveling
saddles in a German lignite mine, loading
120,000 m3/day overburden or 120,000 t/d coal
into railroad cars, continuously passing under the
station on two adjacent rail tracks.
Bottom right: High-capacity train-unloading
station for lignite in a large German mine. Direct
material transfer from the train to a 6,400 mm
wide conveyor. Capacity: 17,000 t/h.
ThyssenKrupp high capacity conveyor systems
transport the materials mined by large
Bucketwheel excavators. High capacity conveyor
systems for open pit mines are available in
stationary, shiftable and relocatable designs.
Conveyor systems with belt widths ranging form
1,000 to 3,000 mm and maximum capacity of
25,000 m3 per hour are supplied. The product
line also offers head and tail stations, shuttle
head stations and take-up stations.
Above: Relocatable conveyor head station in a
lignite mine. Capacity: 21,500 m3 /hour.
Bottom Left: A special solution 6,400 mm wide
conveyor belt positioned under a railroad car
unloading station at a German min. Capacity:
17,000 t/h coal.
Bottom center: “Round the Pit” conveyor system
in a North American coal mine.
Below right: Shiftable conveyor in South Africa.
Capacity: 1,920 m3 / hour.
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Hardrock open pit mining
In-pit crushing
Top left: A pipe conveyor in the western US
connecting the mouth of a coal mine with a train
loadout facility at the bottom of a mountain, a
distance of 3.4 km. Capacity: 1270 t/h.
Center left: A 10.8 km long overland conveyor in
the Canadian north. Capacity: 700 t/h coal.
Bottom left: A 6.1 km long curved overland
conveyor in South Africa.
Bottom right: A high altitude overland conveyor
system carrying copper ore over mountainous
terrain. The first two conveyors climb a total of
275 m from the pit bottom and along the pit edge
and create a 19,000 ton intermediate stockpile.
The third conveyor runs from the stockpile area
down to the concentrator, dropping 257 m over a
distance of 5,253 m.
ThyssenKrupp engineers made an important
contribution to one of the most significant
improvements in hardrock open pit mining, the
conversion from discontinuous, cost-intensive
material transportation by mining trucks to
continuous, more economical transportation by
belt conveyor systems.
Utilizing several decades of crushing technology,
ThyssenKrupp is today one of the most
experienced and successful manufacturers of the
new “in-pit curshing” systems with mobile and
semi-mobile crushing plants, mobile transfer
conveyors, belt conveyor systems and spreaders
with tripper cars.
The product line includes our latest design in
crushers, screens, drill hammers and hydraulic
hammers.
Above is an overall view of an in-pit crusher with
conveyor and spreader system.
Below: The world’s largest semi-moblile crushing
plant is located in a Chilean copper ore mine.
This in-pit crushing plant has a capacity of approximately 10,000 t/h of overburden.
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11
Top: A 19.3 km long single flight, horizontal
curve conveyor carrying lignite.
Center left: Curved overland conveyor, over 5 km
long, at Bayswater Power Station, Australia.
Capacity; 1,000 t/h coal.
Bottom left: 100 km long overland conveyor
system through the North African desert. Capacity: 2,000 t/h phosphate.
Bottom right: A 1.9 km overland reversible belt
conveyor in the US dropping 274 m from the
mine area to the storage area through
mountainous terrain. Capacity: 907 t/h sand and
Above: An overland conveyor of 4.6 km length
transports the overburden to a spreader with 60 m
long discharge boom. The spreader discharges the
material to the overburden dump. The overburden is
crushed to size suitable for belt conveyor transport and
is carried out of the pit by inclined belt conveyors.
Center left: Mobile crushing plant on tires in a US
cement plant. Mobile crushing plant on tires with roll
crusher.
Bottom left: Semi-mobile crushing plant with gyratory
crusher, relocatable with transport crawler in USA.
Capacity: 4,500 t/h copper ore.
Below: Semi-mobile crushing plant being relocated
with a transport crawler in a South African cement
plant.
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XPS® Cross Pit Spreader systems
10
Transportation
Overland conveyor systems
Belt conveyor systems planned and designed,
manufactured and installed by experienced
ThyssenKrupp specialists, prove their high
reliability even under extreme operating
conditions. Special design features ensure high
availability of these systems, for example, idlers
could be designed and supplied to permit their
replacement while the conveyor continues to run.
Integrated monitoring systems insure the early
reporting of components malfunction to prevent
any serious damage to the equipment.
ThyssenKrupp design places conveyor drives
supplying the driving power to the conveyor at the
most favorable location in terms of space and in
order to permit optimum belt tension.
Our design of regenerative downhill conveyors
allows the utilization of the generated energy.
This applies to both straight-line and horizontally
curved conveyors.
Top : Direct dumping system operating in the
USA. Two BWEs with a capacity of 3,000 m3 /
hour each transfer the total capacity of 6,000 m3/
hour to the XPS® spreader. The discharge boom
length is 207m.
Above left: Standard S 400 BWE with conveying
bridge and spreader in a diamond mine in Namibia.
Center right: A standard S 160 BWE for excavating gravel and sand in a direct dumping system,
including a screening plant.
Bottom right: Spreader with 80 m long discharge
boom, operatin in a direct dumping mode in a
phosphate mine in Togo. The complete system of
BWE, MTC and spreader has an overall reach of
180 m. Capacity: 1,800 m3 /hour.
Valuable ore is frequently covered with hardrock,
with is again sometimes covered by soft to
medium-hard material. Under such
circumstances the most economical mining
procedure is to combine discontinuous and
continuous open pit mining equipment.
The hardrock is blasted and excavated by shovels
or draglines, the softer overburden is removed by
Bucketwheel excavators and conveyed to a cross
pit spreader for placing onto the overburden
dump.
Mobile belt conveyor system are tailored to their
specific application whether for mobile crushing
plants or for use in hardrock open pit mines.
Above: Three overland curved belt conveyor
systems, connecting the open pit mine and the
power station, so-called “contour conveying” with
horizontal, concave and convex vertical curves.
One conveyor of 8.55 km and two conveyors of
5.5 km each. Capacity: 1,000 t/h each.
Left: This Pipe Conveyor in the USA, was built by
ThyssenKrupp Robins for the (now closed)
Homestake Mine. The two kilometers from the
mine to the crushing plant were managed with ten
horizontal curves. Capacity: 350 t/h.
9
18
Spreading and dumping
Bucket chain excavators
Spreaders
The spreader is the last member in the chain of
equipment for continuous removal of overburden.
ThyssenKrupp has built spreaders for all
capacities throughout the world. The service
weight of the equipment ranges from 70 to 5,400
tons.
Above: Spreader for 3-bench operation in a
German open pit mine.
Bucket chain excavators find their application
particularly in areas where the material has to be
dug below the excavator operation level. That is
required in cases when the digging face is below
water level or when the ground at the toe level of
the face has insufficient bearing capacity for the
excavator.
As far as operation mode and excavator design
are concerned differentiation is made between
two types: bucket chain excavators moving on
crawlers and those traveling on rails.
Bucket chain excavators on crawlers are
frequently equipped with a slewing mechanism
for the superstructure. They are able to work in
high and low cuts. They mainly work to the block
mining method. In some cases the face
operation method is also employed.
Bucket chain excavators on rails mainly work in
the low-cut mode.
Top right: Giant spreader for dumping overburden
in a German lignite mine. Capacity: up to
300,000 m3 /day.
Center right: C-frame type spreader for continuous
dumping of overburden. Capacity: 4,850 m3 /
hour.
Top left: Bucket chain excavators are employed in
applications where the material has to be well
blended during the digging process. This bucket
chain excavator works to the parallel digging
mode in a German open pit mine and is equipped
with a rail shifting device. Capacity: 810 m3 /
hour.
Top right: Low-cut bucket chain excavator working in the slewing mode in a Southern-European
lignite mine. Capacity: 1,800 /
Bottom right: Spreader combination in a North
American open pit mine. Capacity: 3.500 m3 /
hour.
8
19
Tripper cars
ThyssenKrupp provides tripper cars traveling
on rails or on crawlers. For bench conveyors
of 2,000 mm width or more, tripper cars on
crawlers are utilized. Depending on the
operation, the tripper cars have either a
slewable discharge boom to transfer the
material to the spreader, or the receiving conveyor bridge of the spreader is directly
supported below the discharge pulley of the
tripper car. All tripper cars can be equipped
with or without the take-up system for the
bench conveyor and with or without the
conveyor drive for the bench conveyor.
The compact Bucketwheel excavator series is
designed to suit a wide range of operating
conditions. Modern computer aided design
methods wree employed to simplify the operation
of the machine, increase the reliability and
availability, reduce maintenance requirement and
increase the lifetime of the components.
The excavator capacities have been selected to
match the capacities of standard width bench
conveyors. This ensures optimal technical and
economical utilization of the entire mining and
conveying system.
Top: Tripper car on rails with slewable discharge
booom transporting coal.
Center: Tripper car on rails. Capacity: 5,500
m3 / hour.
Bottom: Tripper car on crawlers. Capacity
27,500 m3 / hour.
Above is a standard BWE, type S 400/250
operating in a limestone mine in northern Germany. The wheel with the integrated buckets is
shaped like a milling tool. Capacity: 1,200 m3 /
hour.
Top right, a compact BWE mining hard lignite in
Indonesia. The coal is partly covered by hard
claystone as well as by tough, plastic clay. The
excavator mines the various materials with the
same Bucketwheel. Special shaped teeth are
used to mine the particularly hard layers.
Capacity: 3,100 m3 / hour.
Below, a compact BWE in a greek lignite mine.
Capacity: 2,800 m3 / hour.
Bottom right, a compact BWE operating in a North
American bituminous coal mine. Capacity: 6,600
m3 / hour.
7
20
Mining
Various equipment
Standard and compact Bucketwheel
excavators
Mobile transfer conveyors
Standard and compact Bucketwheel excavators
are especially economical for many applications
where the material to be mined is soft or mediumhard, but they can also be used for special tasks,
such as mining of hard materials like limestone.
Mobile transfer conveyors are utilized in continuous
mining and conveying systems as a link between
the mining equipment and the bench conveyor.
They overcome the variation in distance and height
between the mining equipment and the bench
conveyor, lengthening the intervals between
conveyor shifts and thus reducing downtime.
Short booms, low-positioned counter-weight,
ease of maintenance and operation as well as
high reliability in operation are further advantages
of these BWE’s.
ThyssenKrupp mobile transfer conveyors are
available in various configurations, such as:
The standard and compact excavator series were
developed to suit the requirements of open pit
mining and earthmoving operations with small
and medium production rates. Standardization of
components and extensive preassembly of the
equipment have significantly reduced the cost of
these machines. The systematic development of
the design and fabrication techniques of this
product line have resulted in optimum adaptation
of the equipment to the specific working
conditions while reducing the delivery time and
the capital investment.
•
Mobile transfer conveyors with single
conveyor.
•
Mobile transfer conveyors with two
conveyors.
ThyssenKrupp mobile transfer conveyors are
designed and built to meet the specific operating
requirements of each mining application.
Above, a Bucketwheel excavator with mobile transfer
conveyor operating in an oil sand mine in Northern
Canada. Capacity: 6,000 m3 /hour.
ThyssenKrupp compact systems consist of a
family of correlated equipment, such as
Bucketwheel excavators, mobile transfer
conveyors, belt conveyors, tripper cars and
spreaders. The effective capacity of the compact
systems range from 4,000 to 65,000 m3 /day.
Left, a mobile transfer conveyor with a single
conveyor in operation in the Mae Moh open pit mine
in Thailand. Capacity: 4,500 m3 /hour.
These compact systems are complemented by
direct dumping systems.
Top: The smallest BWE, the versatile S 100, can
be used for a variety of tasks such as for mining
chalk or as an excavator for special short term
applications. It can be transported on a low bed
trailer. The S 100 series is designed for capacities ranging from 450 to 2,000 m3 /hour.
Center: BWE with a specially designed wheel with
removable buckets fro cutting hard materials.
Left: compact BWE in the Mae Moh open pit mine
in Thailand, removing “gray shale” overburden to
expose the lignite seams. Capacity: 4,100 m3 /
hour.
Below, a mobile transfer conveyor with two
conveyors transporting ferruginous sand in Waikato,
New Zealand. Length: 50 m. Capacity: 1,800 m3 /
hour.
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21
Transport Crawlers
ThyssenKrupp transport crawlers are the result
of vast experience in moving large and heavy
mining equipment, such a conveyor drive
stations or crushing plants. The transport
crawlers are designed to travel over steep uphill
and downhill slopes and to cope with uneven
terrain. Their carrying loads range from 150 to
1,200 tons. Heavy mining equipment, such as
semi-mobile crushing plants and conveyor drive
stations, have to be relocated as mining
progresses.
ThyssenKrupp has developed transport crawlers
capable of relocating such equipment in a short
period of time easily and economically.
Left, a transport crawler carrying an 850 ton load
while moving a semi-mobile crushing plant in
South Africa.
Below is a transport crawler moving a heavy
conveyor drive station weighing 700 tons.
Above left, one of six Bucketwheel excavators in
the Elbistan open pit mine in Turkey operating at
a daily capacity of 60,000 m3.
Above right,, two trench reclaimers with telescopic Bucketwheel boom for the storage and
homogenizing bunkers of a German lignite open
pit mine. Capacity: 120,000 t/d. Track gaukge:
64.2 m.
The Bucketwheel excavator to the right operates
in the Goonyella lignite open pit mine in Bowen
Basin, Queensland, Australia, and is used to
remove overburden. Capacity: 50,000 m3/d.
Below, a Bucketwheel excavator system of
60,000 m3/d capacity working in an Australian
open pit mine.
22
5
More Examples of large Bucketwheel
Excavators
Hopper Cars, cable reel cars, inspection
cars
Large Bucketwheel excavator systems from
ThyssenKrupp are custom designed and built for
the specific operating conditions and the
production rates for each open pit mine.
Currently attained production rates are up to
240,000 m3 (bank) per day, digging heights of as
much as 100 m and service weights of 13,500
tons.
Above is another large Bucketwheel excavator at
the German Garzweiler open pit mine (previously
Hambach) operating in low cut. (Capacity:
200,000 m3 per day.)
Right is a Bucketwheel excavator in the Polish
Belchatow open pit mine operating at a daily
capacity of 130,000 m3 (bank).
Below is a large Bucketwheel excavator in the
Greek Amynteion open pit mine with a daily
capacity of 100,000 m3 (bank).
Depending on the mine plan, ThyssenKrupp
Bucketwheel excavators are supplied as a
complete system with a connecting conveyor
bridge and loading unit or as a single
Bucketwheel excavator with a discharge boom.
If the latter option is selected, a mobile transfer
conveyor is usually employed between the
Bucketwheel excavator and the belt conveyor to
reduce the frequency of shifting the bench
conveyor.
As a supplier of turnkey mining systems, the
ThyssenKrupp product line includes a variety of auxiliary
equipment.
Above, a combined feed hopper and cable reel car
travelling on rails. The electrical power supply to the
mobile transfer conveyor and the Bucketwheel excavator
is provided via the cable reel.
Right, a travelling cable reel car on crawlers with power
and control cable reels.
Below, a travelling inspection car for monitoring and
repair work on overland conveyors.
23
4
Mining
Components
Large Bucketwheel Excavators
With a wide range of components ThyssenKrupp
provides the basis for optimum processing and
recovery of raw materials. Emphasis is placed in the
design and manufacturing of these components as
well as on high efficiency and reliability at a low
operating and maintenance cost.
ThyssenKrupp supplies rail shifting heads for the
relocation of shiftable conveyors (right). The shifting
heads are utilized with a properly fitted dozer to move
the conveyor system.
Left, twin briquetting press for binderfree briquetting
of peat, lignite and fibrous materials.
Above, a travelling plow feeder in a
German power station with a 3 m
discharge wheel diameter and 250 -1,000
t/h reclaim capacity. Plow feeders are
available with diameters up to 4.2 m and
reclaim capacities up to 3,000 t/h. The
units are very reliable and environmentally friendly.
Center, a magnetic separator for removal of tramp
iron from bulk materials.
Right, Blendomat discharge units with a diameter of
6.5 m, are specifically suited to overcome the
problems associated with reclaiming poorly flowing,
sticky bulk materials with a tendency to bridge. They
are used in power stations and in the cement and
chemical industries.
In the world of technical giants, ThyssenKrupp
provides some of the largest mining equipment on
earth.
Continuously operating Bucketwheel excavators,
spreaders and high capacity conveyor systems are
employed in the mining of huge quantities of raw
materials. Several million cubic meters of
overburden have to be removed to expose the raw
material seams, subsequently backfilled for
reclamation of the land, e.g. using XPS® cross pit
spreader systems from ThyssenKrupp.
The product line of mining equipment mainly
comprises large Bucketwheel excavators for open pit
mines with very high production rates, as well as
standard and compact Bucketwheel excavators for
earthmoving projects and open pie mines with small
and medium production rates.
Shown above, the largest Bucketwheel excavator in
the world with a daily capacity of 240,000 m3 (bank),
commissioned in 1978. Its place of operation is the
German Hambach open pit mine of Rheinbraun AG.
24
3
Planning, consulting, engineering, manufacture and service
Comprehensive know-how, specialization in many
fields and superior engineering knowledge combined
with innovative developments make ThyssenKrupp a
competent partner in all phases of project planning,
design and construction of mining equipment and
systems.
A wide range of mining equipment for open pit mining
enables us to provide customized solutions for all
mining requirements. Alternative solutions can be
studied and neutrally developed based on requirement, economy and efficiency.
Manufacturing
Whether manufactured at our own works (as
shown) or by our local partners, high quality
remains the number one priority.
Highly qualified ThyssenKrupp fabrication
supervisors ensure the high quality standards of
fabrication in our own works and at other
fabrication facilities worldwide.
Left: Fabrication of a ring girder for a large
Bucketwheel excavator.
ThyssenKrupp stands for comprehensive know-how
and engineering experience, combined with modern
technology and the most advanced solutions.
Modern computer technology (CAE, CAD, FEM, CIM
and PPS) permits us to economically design
components and machines, guarantees rapid and
precise access to calculations concerning loads and
deformation, and enables ThyssenKrupp to make
check calculations for proposed design variants under
the aspect of optimum design criteria.
These widely used computer based techniques lead to
more efficiency in project planning, assist in contract
and construction management and control of plants.
Certification according to the requirements of DIN/ISO
9001 and EN 29001 by Lloyd’s Register Quality
Assurance and Germanischer Lloyd also document the
high quality standards of ThyssenKrupp open pit
mining equipment and systems.
Above: Pre-assembly of a compact Bucketwheel
excavator.
Left: A pre-assembled travelling mechanism of a
large Bucketwheel excavator.
Below: Precision gear reducer parts for a Bucketwheel drive.
25
2
Service and Spare Parts
Every plant and every system can only perform as
well as maintenance and service allow. You can rely
on ThyssenKrupp’s after sales service. We provide
experienced specialists to assist the customers in a
variety of tasks, from the planning phase through
design to site management, construction
supervision and personnel training.
ThyssenKrupp’s after sales service department
provides assistance in modernizing and inspection
of existing plants and ensures the timely supply of
spare parts.
Early detection of wear and minor damage provide
the necessary information for preventative
maintenance planning. For this reason
ThyssenKrupp offers inspections at customers’
requests, in particular of precision parts, such as
ball races, slew bearings and gear reducers.
Above: Replacing a Bucketwheel gear reducer
on a large Bucketwheel excavator.
Far left: Assembly of the telescopic conveyor
bridge of a Bucketwheel excavator.
Center left: Re-installation of balls in an open ball
race bearing after inspection.
Below: A completely assembled compact
Bucketwheel excavator being loaded onto a ship.
One decisive feature insures our success: the ability to
define key mining problems, prepare adequate
solutions and to develop advanced mining equipment
and technologies.
ThyssenKrupp offers leading edge mining technology
in optimizing existing mining systems, especially in
planning and building of turnkey systems tailored to
the specific requirements of the customers.
1
Mining technology from ThyssenKrupp
ThyssenKrupp Robins
The most economical solution for modern
open pit mines.
Who we are
26
ThyssenKrupp mining equipment and systems offer
an efficient, reliable and economical solution to mining
operations. Some of the applications are:
earthmoving for land reclamation, removal of
overburden in new open pit mines, mining of raw
materials such as lignite, limestone, oil sand,
phosphate, bituminous coal, hard rock and ore.
More than 120 years experience, comprehensive
know-how and high quality standards allow
ThyssenKrupp to hold the top position throughout the
world in the field of open pit mining equipment and
technology.
Systems and equipment Capabilities
ThyssenKrupp Robins, Inc., (TKRI), is a member of the
ThyssenKrupp Fördertechnik GmbH Group.
Headquartered in Denver, Colorado, TKRI stands ready to
furnish a wide range of Bulk Material Handling and Mining
equipment including:
• Overland Conveyors
• Pipe Conveyors
• Customized In-plant Conveyor systems to fit in
existing plants
• Semi-Mobile and Fully Mobile Crushing Plants
• Stockpiling, Reclaiming and Blending Machinery
• Belt Feeders, Plow Feeders and Apron Feeders
• Customized DEM Transfer Chutes
Our clients are:
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Marine Terminals
Open Pit Mines
Power Stations
Cement Plants
Refineries
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Steel Mills
Recycling Facilities
Paper Mills
Aggregate Mines
These systems are capable of handling various materials
including:
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Coal
Petroleum Coke
Sulfur
Lignite
Limestone
Iron Ore
Copper Ore
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Earth/Rock
Bauxite
Phosphate Ore
Woodchips
Cement
Fertilizer
Grain and Others
TKRI’s dedication to maintaining the most advanced
technical capabilities in conveyor system design is
evidenced by its computer-based conveyor calculation
programs which afford a detailed comparison of alternate
conveyor selections. Its extensive list of references
includes innovative, low-cost and highly efficient material
handling and mining equipment.
Furthermore, TKRI can execute turnkey projects from
preliminary estimates or feasibility studies, to design
engineering, material procurement, construction,
supervision and system start-up. TKRI can offer total
project responsibility, planning, engineering, quality
assurance, manufacturing, and construction management.
Please check us out at www.thyssenkrupprobins.com
Open Pit Mining Systems
And Equipment
www.thyssenkrupprobins.com
Phone: 303-770-0808
Fax: 303-770-8233
E-mail: [email protected]
A company
Of ThyssenKrupp
Technologies
ThyssenKrupp Robins
TK
ThyssenKrupp Robins Inc.
7730 East Belleview Ave. Suite 404
Greenwood Village, Colorado
80111-5820 U.S.A.
8009-TKRI OPEN PIT MINING / 072009el / DEPT. 2300
Excellence
in Technology
Excellence in Technology