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ThyssenKrupp Robins A company Of ThyssenKrupp

Technologies

ThyssenKrupp Robins Inc. 7730 East Belleview Ave. Suite 404 Greenwood Village, Colorado 80111-5820 U.S.A. www.thyssenkrupprobins.com Phone: 303-770-0808 Fax: 303-770-4522 E-mail: sales.tkri@thyssenkrupp.com 80

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Open Pit Mining Systems And Equipment

Excellence in Technology Excellence in Technology

1 26 Mining technology from ThyssenKrupp

The most economical solution for modern open pit mines.

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.

ThyssenKrupp Robins

Who we are

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

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:

• Marine Terminals • Open Pit Mines • Power Stations • Cement Plants • Refineries

• Steel Mills • Recycling Facilities • Paper Mills • Aggregate Mines

• Coal • Petroleum Coke • Sulfur • Lignite • Limestone • Iron Ore • Copper Ore

• Earth/Rock • Bauxite • Phosphate Ore • Woodchips • Cement • Fertilizer • Grain and Others

These systems are capable of handling various materials including:

25 2

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.

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.

Service and Spare Parts

3 24

Planning, consulting, engineering, manufactureand 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 require-ment, economy and efficiency. 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.

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.

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 Bucket-wheel drive.

23 4 Mining

Large Bucketwheel Excavators

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.

Components

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.

5 22

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. 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. 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).

More Examples of large Bucketwheel Excavators

Hopper Cars, cable reel cars, inspection cars

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.

21 6

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 tele-scopic 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.

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.

7 20 Mining

Standard and compact Bucketwheel excavators

Standard and compact Bucketwheel excavators are especially economical for many applications where the material to be mined is soft or medium-hard, but they can also be used for special tasks, such as mining of hard materials like limestone. 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. 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. 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.

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 capaci-

ties 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.

Various equipment

Mobile transfer conveyors

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. ThyssenKrupp mobile transfer conveyors are available in various configurations, such as:

• Mobile transfer conveyors with single

conveyor.

• Mobile transfer conveyors with two con-

veyors. 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.

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.

Below, a mobile transfer conveyor with two conveyors transporting ferruginous sand in Waikato,

New Zealand. Length: 50 m. Capacity: 1,800 m3 /

hour.

19 8

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.

Above is a standard BWE, type S 400/250 operating in a limestone mine in northern GermanyThe 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.

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 ma-terial to the spreader, or the receiving con-veyor bridge of the spreader is directly sup-ported 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.

Tripper cars

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.

9 18

Bucket chain excavators

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 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

Spreading and dumping

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 Ger-man open pit mine. 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 continu-

ous dumping of overburden. Capacity: 4,850 m3 /

hour. Bottom right: Spreader combination in a North

American open pit mine. Capacity: 3.500 m3 /

hour.

17 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. 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.

XPS® Cross Pit Spreader systems

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.

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 Na-mibia. Center right: A standard S 160 BWE for excavat-ing 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.

11 16

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. Capac-ity: 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.

15 12

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.

Hardrock open pit mining

In-pit crushing

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 ap-proximately 10,000 t/h of overburden.

13 14

High capacity conveyor systems and transfer stations

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.

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.

13 14

High capacity conveyor systems and transfer stations

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.

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.

15 12

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.

Hardrock open pit mining

In-pit crushing

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 incrushers, 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 ap-proximately 10,000 t/h of overburden.

11 16

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. Capac-ity: 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.

17 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. 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.

XPS® Cross Pit Spreader systems

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.

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 Na-mibia. Center right: A standard S 160 BWE for excavat-ing 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.

9 18

Bucket chain excavators

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 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 work-ing in the slewing mode in a Southern-European lignite mine. Capacity: 1,800 /

Spreading and dumping

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 aGerman open pit mine. 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. Bottom right: Spreader combination in a North

American open pit mine. Capacity: 3.500 m3 /

hour.

19 8

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.

Above is a standard BWE, type S 400/250 operating in a limestone mine in northern Ger-many. 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.

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 con-veyor 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.

Tripper cars

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.

7 20 Mining

Standard and compact Bucketwheel excavators

Standard and compact Bucketwheel excavators are especially economical for many applications where the material to be mined is soft or medium-hard, but they can also be used for special tasks, such as mining of hard materials like limestone. 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. 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. 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.

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 capaci-

ties 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.

Various equipment

Mobile transfer conveyors

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. ThyssenKrupp mobile transfer conveyors are available in various configurations, such as:

• 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.

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.

Below, a mobile transfer conveyor with two conveyors transporting ferruginous sand in Waikato,

New Zealand. Length: 50 m. Capacity: 1,800 m3 /

hour.

21 6

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 tele-scopic 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.

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.

5 22

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. 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. 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).

More Examples of large Bucketwheel Excavators

Hopper Cars, cable reel cars, inspection cars

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

Large Bucketwheel Excavators

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.

Components

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.

3 24

Planning, consulting, engineering, manu-facture 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 require-ment, economy and efficiency. 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.

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.

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 Bucket-wheel drive.

25 2

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.

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.

Service and Spare Parts

1 26 Mining technology from ThyssenKrupp

The most economical solution for modern open pit mines.

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.

ThyssenKrupp Robins

Who we are

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

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:

• Marine Terminals • Open Pit Mines • Power Stations • Cement Plants • Refineries

• Steel Mills • Recycling Facilities • Paper Mills • Aggregate Mines

• Coal • Petroleum Coke • Sulfur • Lignite • Limestone • Iron Ore • Copper Ore

• Earth/Rock • Bauxite • Phosphate Ore • Woodchips • Cement • Fertilizer • Grain and Others

These systems are capable of handling various materials including:

TK

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ThyssenKrupp Robins A company Of ThyssenKrupp

Technologies

ThyssenKrupp Robins Inc. 7730 East Belleview Ave. Suite 404 Greenwood Village, Colorado 80111-5820 U.S.A. www.thyssenkrupprobins.com Phone: 303-770-0808 Fax: 303-770-8233E-mail: sales.tkri@thyssenkrupp.com 80

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Open Pit Mining Systems And Equipment

Excellence in Technology Excellence in Technology