JAN-FEB 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

Issue link: https://vdma.epubxp.com/i/951969

Contents of this Issue


Page 33 of 51

VDMA 32 VDMA MINING SUPPLEMENT • 2018 Tenova TAKRAF has recently developed a symbiotic niche in the oil sands industry by giving both new and existing production trains the supercharged boost they need to sustain profitability in a low oil price environment. While boosting production, TAKRAF has also achieved a recovery increase in the downstream extraction process. Critically, this combined success has been proven during the perfor- mance-limiting artic winter months. During 2013, TAKRAF was engaged by one of the principle oil sands producers to solve the winter time stalling of their existing double roll crushers (DRC). The direct effect of the halt, as well as their inability to restart, resulted in significant cumulative annual restrictions on winter production. In 2014, TAKRAF began retrofitting all their primary crushing plants with the New Generation TAKRAF TRC 25.34 double roll crusher. The New Generation DRC increased drivetrain inertia (200%), use- able kinetic energy (185%) and available motor torque (168%). This resulted in peak crushing demand dropping from nearly 600% full load torque (FLT) to a level near 350% FLT. A specially designed motor with a Breakdown Torque (BDT) greater than 430% FLT was then implemented to deliver the full 350% FLT through a larger capacity fluid coupling. These changes represented a paradigm shift in the basic crush- ing principles used for a primary crusher in oil sands. Previously, the technology primarily relied on expending its limited kinetic energy during every major crushing event; however, if the kinetic energy was completely expelled before the feed material was processed, the crusher would stall. Subsequent restart attempts were insufficient and often consumed the available heat capacity of the fluid cou- pling, further suspending the production recovery. The New Genera- tion DRC possesses the ability to process the most difficult materials without primarily relying on consuming any kinetic energy. The iner- tial storage buffer translates directly to production guarantee. This philosophy was then applied to the entire primary crushing plant, two trains of which were put into production in 2016. The robust TAKRAF drive units and an abundance of surplus kinetic energy are already proven to process sustained tonnage rates exceeding 14,000 metric tons per hour (mt/h), while maintaining an impressive 400- x 400-mm maximum product size — even when the feed approaches a 10:1 crushing ratio. At the same time, the TRC 25.37 is able to develop an 11% increase in the surface area of the product, significantly as- sisting the oil recovery process. In the redesign of the primary crush- ing plant, none of the components were ignored in the new generation plant. In addition to functionality and reliability, maintainability and a reduction of downtime were key areas of focus. The net result, according to TAKRAF, is the most effortlessly maintainable, cleanest and pow- erful primary crushing plant, which now fulfills both the immediate and future needs for mining oil sands. The TRC 25.37 is designed for a sustained 17,000-mt/h throughput capacity in all oil sands materials during the most frigid conditions. The two units, which commenced production in 2016, are derated to the contracted 14,000-mt/h capac- ity, but can be fully realized with a simple change to the ratio of the apron feeder. For those mines not immediately requiring the implementation of a complete new crushing plant, the upgrade to the powerful New Generation TAKRAF TRC 25.34 DRC has proven to be an economically effective means to increase production through elimination of stalls and reduced maintenance downtime, as well as increased recovery through achieving a high crushing ratio, even in the most extreme winter conditions. This type of primary crusher upgrade typically requires a shutdown period of 22 to 30 days. Economically, the payback period is less than two winter seasons. Transporting and Charging Explosives With the increasing number of panel-caving operations, where ore is mined by conventional drill-and-blast operations, transporting ex- plosives to the loading locations and scheduling blasts are two very important underground mining issues. Many mines rely on a mixture of ammonium nitrate and fuel oil (ANFO). Production drill holes can be as long as 25 m with a diameter up to 3 inches, which means the typical round requires approximately 3,000 kg of ANFO. By lim- iting the hole-charging time and reducing the transportation costs, mines could achieve a higher level of productivity at a lower cost. Paus has developed an ANFO-charging concept that combines the transportation and charging of ANFO in one machine to extend A New Generation of Extreme Oils Sands Crushers The TAKRAF New Generation DRC increased drivetrain inertia over 200%, useable kinetic energy 185% and available motor torque 168%. This resulted in peak crushing demand dropping from nearly 600% Full Load Torque (FLT) to a level near 350% FLT. The Universa 50 from Paus can be equipped with a full ANFO charging platform.

Articles in this issue

view archives of VDMA - JAN-FEB 2018