Tracked Self-Driven Dozer Mining Unit (TDMU)

OVERVIEW

These high throughput dozer traps will dry mine lower head-grade mineral sands resources at much higher throughput, a lower $/t, with higher reliability and availability and lower greenhouse gas emissions than historically employed methods.  Productivity improvements that increase profit to shareholders by many $M’s pa. With the triple grouser 900mm extended tracks being driven by high torque electric servo-motors (no messy, inefficient, fire hazard hydraulics), these mobile modern technology TDMU’s ensure high yields from large / complex mineral resources. Driving more $M to annual profits AND increasing total yield from the ore body by several $10M’s over the life of mine.

Being continuously tethered at up to a 500m working radius provides the flexibility to continuously recover large blocks or narrow tracts of resource, with quick change-over times to start up the next block / section. And they can climb up to 30 degree slopes, to simplify pit transitions. Powered by incoming HV via cable reel, on-board genset, or piggy-backed mobile genset for travel off-grid. All controlled from a fully insulated switch room built to cool-room spec with a marine grade air-conditioner for maximum reliability in hot climates.

A self-levelling low vibration two-mass screen (explanation here), fed full width by a low profile belt-on-slat conveyor, will permit automated dozer cab operated density controlled slurry transport over long distances. A quick-remove hopper is available for FEL or excavator use. The low feeder entry point increases average pushed t/m of dozer travel, resulting in extended pushing distances and less frequent relocations. Trash is easily cleared by a dozer, with no skips required.

Constructed from fully hot dip galvanised structural modules, shop tested major subassemblies can be transported around the globe for rapid assembly and commissioning. Local fabrication and assembly of some modules is available for suitable sites. Galvanised Victaulic pipework fittings, long life ceramic button, bolted panel main feeder linings and UHMWPE chute linings, with auto-lube bearings used throughout to simplify maintenance, and stair and walkway access to all maintenance points.

iPUT Dozer Trap: Hose side, dozer operational configuration, air powered screen access walkway lowered to show this detail
iPUT Dozer Trap: Hose side, dozer operational configuration, air powered screen access walkway lowered to show this detail

These machines have been progressively developed via a dedicated R&D program over several years, in close consultation with highly respected senior mine personnel and leading industry power-houses. “A sublime solution to problems that have beset the industry for decades” says one GM Ops. Well suited to continuous extraction of strandlines and especially helpful to chase fingers. At 3,700t/hr max the largest unit will likely reset the economic case on dredging .vs. dry mining. Click here for an example of a block mine plan.

KEY PERFORMANCE SPECIFICATIONS

Annual Throughput:  14 mtpa (assuming 1 short move every 2 days, 1 dayshift maintenance a month and 5 day annual outage)

Capacity (max/nominal): 2,000 / 1,700 t/hr @1.6 bulk density, 2.6 SG (950 t/hr nom and 3,200 t/hr nom units also available)

Trash handling: Calcite rocks to -500 mm; (Grizzly apertures 44 cm x 117 cm, screen at -3.2 mm (or -2 mm option), to suit resource / application)

Unladen Travel speed (high / low):  2.5 km/hr (on flat) / 0.5 km/hr (on 20+ deg incline)

DN450 interchangeable 10m feed & slurry hoses: up to [email protected] (950m working range from tether skid)

Power supply: 22 kV reeled cable (450m max + plugged extensions) OR 1 MW prime on-board genset (+30hr fuel)

Slurry pump: 16/14, with 1,000 kW 3.3 kV VSD direct drive motor (800 kW for genset configuration)

Unladen mass:  274t (+ 12t hopper+ 2.5t cable)

Avg Ground pressure: <145 kPa (unladen); <60 kPa (max laden, sunk to chassis); <40 kPa (max laden, sunk to optional belly plates)

Feeder drive:  185 kW VSD; bevel helical planetary torque-arm drive; 0.5m/s at max throughput

Feeder bed:  1,700mm wide (2m belt) x 600 mm deep (adjustable to 350 mm to suit weather / local ore characteristics)

Power @ 0.9PF:  1.6 MVA @ 22 kV supply c/w incoming ring main 22kV isolation protection for surge mgt

Sump live volume:  20 m3; at 15 m3 working volume and 2,000 t/hr providing 23 – 34 seconds residence time for operational range of 45% to 55% w/w concentration slurries

Optional FEL / Excavator Hopper:  50 m3 / 80t capacity;  10t mass, 25 mm thick UHMWPE bolted panel lining; chain slings

Ambient de-rating:  >45o/C

iPUT Dozer Trap: FEL Hopper fitted and showing air powered screen access walkway lowered
iPUT Dozer Trap: FEL Hopper fitted and showing air powered screen access walkway lowered

Stockpile Reclaim Dozer Trap

OVERVIEW

Modular skid mounted dozer trap module constructed to modern OHS, operational and maintenance standards, for loading yard conveyors from 2.5m RL. Very robust construction, grizzly protected, with easy access for cleaning, and simplified maintenance requirements. Adjustable bed depth to handle ore variation, automated hydraulic belt tensioning / take-up system, modular bolted UHMWPE chute panels for long life and low wall friction, optionally with ceramic button linings to suit highly abrasive ores, complete with crowned pulleys, s/s primary, secondary and return scrapers, and belt splicing station, make these units very easy to live with. Using fabric belts to suit ores such as bauxite, salt and sand, but well suited to use with iron ore and most heavy / lumpy / rock ores, using a steel cord belt on the conservatively sized pulleys.

The modular structure is fully hot dip galvanised and stainless steel / non-corrosive materials used for all belt contacting components. Configured with a robust headwall for dozer pushing forces, and an integral rilling-style side wing-wall, these units can easily be transported to site as ‘flat-packs’, containerised, or sent fully complete, tested and ready for operation. Quick-remove FEL hopper option available.

Available configured to be fixed to foundations, or fully portable via dozer push points / tow points and rounded infills to minimise pushing / towing forces. When used in combination with tracked portable radial stackers, they make for a very efficient stockpile configuration for rapid ship-loading and flexible storage systems.

iPUT Dozer Trap 1500mm Portable Feeder (Click image to play 360 deg rotating view)

KEY PERFORMANCE SPECIFICATIONS

Capacity: 1,500 t/hr at 0.31 m/s belt speed and 1.25 bulk density;   2,500 t/hr at 0.52 m/s and 1.25 bulk density;   max capacity = 3,500 t/hr at 0.5 m/s belt speed and 1.8 bulk density;   (up to 6,000 t/hr available)

Unladen mass:  53t

Ground pressure:  <39 kPa (unladen)  ;  <55 kPa (laden)

Belt Feeder: 1,500 mm wide PN1250 4ply belt, 11 degree inclined, 830 mm ceramic lagged head pulley, 530 mm ceramic lagged tail pulley, 1.8m face width, @14m centres, via 117cm x 34cm aperture grizzly (2.5m high entry point, 4.8m long feed zone)

Feeder drive:  75 kW VSD (415V 4 pole motor)

Ambient de-rating:  >45o/C

Fluidised Conveying Dozer Trap

OVERVIEW

A DPU (Dozer Pumping Unit) with 20 deg inclined 1.2m wide belt feeder, sump and pump only (no screen) mounted on a single dozer pushed skid. This is the most economical way to convert a truck-shovel operation to a pumped conveying system IF the feed is relatively clean and slurry pipework can be run relatively flat. As may occur in a silica sand mining operation.

Looking a lot like the stockpile discharge feeder above, except inclined at 20 degrees, slightly narrower, and ~2m longer. Discharging over an adjustable vibrating bar divergator grizzly above a sump and pump, both located in the triangular opening below, with trash thrown forward for intermittent clearing by dozer. Same side supply / return lines, complete with water calming sump entry, automated level control, and solenoid activated direct injection startup jets for recovery after a crash stop, or for emergency density reduction.

Adjustable bed depth to handle ore variation, automated hydraulic belt tensioning / take-up system, modular bolted ceramic lined chute panels, complete with crowned, ceramic lagged and conservatively sized pulleys, s/s primary, secondary and return scrapers, and belt splicing station, plus Victaulic pipework fittings, and auto-lubed bearings used throughout to simplify maintenance, making these units very easy to live with.

The modular structure is fully hot dip galvanised and stainless steel / non-corrosive materials used for all belt contacting components. Configured with a robust headwall for dozer pushing forces, and an integral rilling-style side wing-wall, these units can easily be transported to site as ‘flat-packs’, containerised, or sent fully complete, tested and ready for operation. Local fabrication and assembly of some modules is available for suitable sites.

KEY PERFORMANCE SPECIFICATIONS

Capacity (max/nominal):  1,100 / 950 t/hr  @1.6 bulk density, 2.6 SG

Trash handling: Lumps to -300mm; (Grizzly apertures 45cm x 117cm (2.5m high entry point, 4.8m long feed zone), divergator -50mm or less, to suit resource)

Power supply: 415V plugged cable (MV / HV incoming available)

Slurry pump: 14/12, with 450kW soft start motor

Unladen mass:  93t

Ground pressure:  <15kPa (unladen)  ;  <20kPa (laden)

Feeder drive:  75kW VSD; 0.36 m/s at max throughput (optional density control)

Belt Feeder: 1,200 mm wide PN1250 4ply belt, 20 degree inclined, 830 mm ceramic lagged head pulley, 530 mm ceramic lagged tail pulley, 1.5m face width, @16m centres

Power @ 0.9PF:  600 kVA @ 415kV supply

Sump live volume: 6 m3; at 5 m3 working volume and 1,100 t/hr providing 14 – 21 seconds residence time for operational range of 45% to 55% w/w concentration slurries

Ambient de-rating:  >45o/C

Dozer Pushed Mining Unit (DMU)

OVERVIEW

Having all the main performance features of the TDMU, but without the self-driven mobility features, these economical dozer pushed skid mounted dozer traps will dry mine lower head-grade mineral sands resources at higher throughput, a lower $/t, with higher reliability and availability than historically employed configurations.  A two-skid easily aligned configuration, particularly suited to achieve high yields from large strandline mineral resource deposits.

A fixed (illustrated), or optionally self-levelling, low vibration two-mass screen will permit autonomous dozer cab operated density controlled slurry transport over long distances. The low feeder entry point increases average pushed t/m of dozer travel. Trash is easily cleared by a dozer, with no skips required.  Powered by incoming HV via plugged cable or on-board genset.

Constructed from fully hot dip galvanised structural modules, shop tested major subassemblies can be transported around the globe for rapid assembly and commissioning. Local fabrication and assembly of some modules is available for suitable sites. Victaulic pipework fittings, long life ceramic button bolted panel chute linings and auto-lube bearings are used throughout to simplify maintenance, with step and walkway access to all maintenance points.

iPUT DMU Screen Skid: Fixed levelling configuration; showing air powered screen access walkway lowered
iPUT DMU Screen Skid: Fixed levelling configuration; showing air powered screen access walkway lowered

KEY PERFORMANCE SPECIFICATIONS

Annual Throughput:  13.5 mtpa (assuming 1 short move every 2 days, 1 dayshift maintenance a month and 5 day annual outage)

Capacity (max/nominal):  2,000 / 1,700 t/hr  @1.6 bulk density, 2.6 SG (1,100 / 950 t/hr also available)

Trash handling: Calcite rocks to -500mm; (Grizzly apertures 44cm x 117cm, screen -3.2mm or less, to suit resource)

Power supply: 22 kV plugged cable  OR 1 MW prime on-board genset

Slurry pump: 16/14, with 1,000 kW 3.3kV VSD direct drive motor (800 kW for genset configuration)

Unladen mass:  213t

Ground pressure:  <30 kPa (unladen)  ;  <42 kPa (laden)

Feeder drive:  185kW VSD; 0.5m/s at max throughput

Power @ 0.9PF:  1.6 MVA @ 22 kV supply

Sump live volume:  20 m3 ; at 15 m3 working volume and 2,000 t/hr providing 23 – 34 seconds residence time for operational range of 45% to 55% w/w concentration slurries

Ambient de-rating:  >45o/C