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Fully mobile crushers

Surface coal mining is often extremely heavy-duty work carried out with extremely heavy-duty machinery. After the top rock cover is blasted away, giant excavators systematically remove the coal seams. Across the world, ever new and ever larger deposits are being developed. Demand for coal is rising rapidly – in part due to the growing raw materials needs of the emerging economies.

So it’s all the more important that mining techniques become more efficient and saves on resources. The potential for savings is huge: Hundreds of heavy-duty trucks, each carrying up to 350 tons, are in operation every day transporting valuable raw materials and overburden to often distant unloading points, where they are crushed for further processing or stockpiled. For mine operators this is a mammoth logistical exercise. Added to the high fuel costs there are also the costs of wear parts such as the four-meter-diameter tires that have to be replaced every year. One set can cost as much as 300,000 euros.

A current example of innovative engineering from ThyssenKrupp is the development of powerful, fully mobile crushers which allow open pit operators to dispense completely with the use of heavy trucks. To make the process more efficient, the experts from ThyssenKrupp are now taking the crushers directly to the face: There, the fully mobile crawler-mounted machines are loaded with meter-size blocks of material by an excavator. The crushed raw material is then transported away on a shiftable conveyor belt system. Now, instead of hundreds of truck drivers, only three to four specialists are needed to operate the electrically powered crusher/belt system. This reduces operating costs enormously and cuts CO2 emissions by up to 350,000 tons per year. And instead of keeping stocks of many different truck spares, operators can rely on low-cost, standardized spare parts for the crusher/belt system.

In China, a fully mobile crusher with conveyor system is replacing up to 26 large mining trucks. These trucks consume around 190 liters of diesel per operating hour. Assuming a constant annual output and taking into consideration the higher availability of the continuous system, savings on diesel fuel amount to 22 million liters per year.

The first of these crusher plants went into operation in the Yimin He surface coal mine in Inner Mongolia in 2007 and has already proved itself under extreme climate conditions: The system operates with a rated capacity of 3,000 tons per hour even at minus 40 degrees. And an order for three further systems was received from China in 2011. The systems have a rated capacity of up to 10,000 tons per hour.

 

 

Fully mobile crushers
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