0
Karara Dry Tailings
Storage Facility

Christian Trulsson - Business Development Manager MH
Brisbane, 5 June 2013

The info...
Karara Dry Tailings Storage Facility
- Agenda







Project Background
Mobile Conveyor System Basics
System compone...
FLSmidth
- Who are we?


FLSmidth supplies everything from single machines to complete minerals and cement
flow sheets in...
Karara Iron Ore Project
- Location

The information contained or referenced in this presentation is confidential and propr...
Karara Iron Ore
- Process Flowsheet


Karara Mining is a 50-50 joint venture between Gindalbie Metals
Limited and AnSteel...
Karara Dry Tailings Storage Facility
- The FLSmidth Approach
 Site Visit
 Review conditions
 Receive technical inputs

...
Stacking Technologies

The information contained or referenced in this presentation is confidential and proprietary to FLS...
Stacking Method Economics
TRUCKS (AND DOZERS)
GRASSHOPPER/PORTABLE
CONVEYORS

BOOM SPREADER

OPEX

MOBILE CONVEYOR
- PERMA...
Mobile Conveyors



Satefy
Environment

The information contained or referenced in this presentation is confidential and...
World’s First
Mobile Stacking Conveyor
Client: PP&L – 1975
Capacity: 1000 tph

The information contained or referenced in ...
World’s Largest Tailings Stack




Mantos de Oro La Coipa, Chile
Capacity 1,200tph
Commissioned 1990

The information c...
Applications




Overburden Removal and Stacking
Permanent and Reusable Heap
Leach Pads
Tailings Conveying and Stacking...
Karara Dry Tailings Storage Facility
- Environment


The plant is state of the art technology including significant
impro...
Karara Dry Tailings Storage Facility
- Safety






Site access enhanced.
Equipment and vehicles can move freely arou...
Mobile Conveyor System Basics










Low ground pressure on crawler tracks (15-30psi)
Automatic alignment and ...
Ground Bearing Pressure
- Interesting facts....




20 psi ground pressure over the whole machine.
35 psi when a trippe...
Mobile Stacking Conveyor

The information contained or referenced in this presentation is confidential and proprietary to ...
Mobile Conveyor Basics
- Single Belt








No transfer points
No spillage
No wear
No dust
Less noise
Single drive...
Alignment Control
(critical for belt tracking)

Retreat stacking copper ore onto leach pad
– Note straightness of stacking...
Alignment Control
(critical for belt tracking)

The information contained or referenced in this presentation is confidenti...
Mobile Conveyor Basics
- Tripper

The information contained or referenced in this presentation is confidential and proprie...
Mobile Conveyor Basics
- Track Leveling

The information contained or referenced in this presentation is confidential and ...
Mobile Conveyor Basics
- Track Leveling

The information contained or referenced in this presentation is confidential and ...
Mobile Conveyor Basics
- Joints Between Frames

The information contained or referenced in this presentation is confidenti...
Operating on Irregular Terrain

The information contained or referenced in this presentation is confidential and proprieta...
Mobile Conveyor Basics
- Ramp Construction

The information contained or referenced in this presentation is confidential a...
Mobile Conveyor Basics
- Term Definitions

Advance Stacking

Retreat
Stacking

The information contained or referenced in ...
Definition of Terms
Retreat Stack

The information contained or referenced in this presentation is confidential and propri...
Definition of Terms
Advance Stack

The information contained or referenced in this presentation is confidential and propri...
Karara Dry Tailings Storage Facility
- Operating Principle

The information contained or referenced in this presentation i...
Simple Stacking Plan

The information contained or referenced in this presentation is confidential and proprietary to FLSm...
Complex Stacking Plan

The information contained or referenced in this presentation is confidential and proprietary to FLS...
Karara Dry Tailings Storage Facility
- System Components
Equipment #

Description

RADIAL STACKER

Secondary System Radial...
Karara Dry Tailings Storage Facility
- Secondary System Radial Stacker

The information contained or referenced in this pr...
Karara Dry Tailings Storage Facility
- CV-108 Reclaim Hopper Feeder

The information contained or referenced in this prese...
Karara Dry Tailings Storage Facility
- CV101-Ramp Conveyor

The information contained or referenced in this presentation i...
Karara Dry Tailings Storage Facility
- CV-104 Mobile Stacking Conveyor

The information contained or referenced in this pr...
Karara Dry Tailings Storage Facility
- CV-105 MSC Tripper Cross Conveyor

The information contained or referenced in this ...
Karara Dry Tailings Storage Facility
- CV-106 Spreading Conveyor

The information contained or referenced in this presenta...
Karara Dry Tailings Storage Facility
- Automation and Control
The system is state of the art technology.
 High level of a...
Karara Dry Tailings Storage Facility
- Conclusion Mobile Conveyors


Equipment and systems are proven



Equipment desig...
Karara Dry Tailings Storage Facility
- Summary




Mobile tailings stacking system – 2850tph – 3.3km conveying
The tech...
Questions?

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and i...
Thank You!

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and i...
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Christian Trulsson, FLSmidth Australia - Mobile Dry Stack Conveyor System for Tailings Management at the Karara Iron Ore Project

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Christian Trulsson, Business Development Manager, FLSmidth Australia delivered this presentation at the 10th Annual Bulk Materials Handling conference 2013. This conference is an expert led forum on the engineering behind the latest expansions and upgrades of bulk materials facilities. It also evaluates the latest engineering feats that are creating record levels of throughput whilst minimising downtime.

For more information on this conference, please vist http://www.informa.com.au/bmh2014

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Transcript of "Christian Trulsson, FLSmidth Australia - Mobile Dry Stack Conveyor System for Tailings Management at the Karara Iron Ore Project"

  1. 1. Karara Dry Tailings Storage Facility Christian Trulsson - Business Development Manager MH Brisbane, 5 June 2013 The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  2. 2. Karara Dry Tailings Storage Facility - Agenda       Project Background Mobile Conveyor System Basics System components Operating Principle Summary and Conclusion Questions The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  3. 3. FLSmidth - Who are we?  FLSmidth supplies everything from single machines to complete minerals and cement flow sheets including associated services – One Source  +15,000 employees globally engaged in design, supply, construction, operation & maintenance, and service support to the minerals and cement industries  17+ locations across Australia.  Head Office in Copenhagen/Denmark and listed on Danish Stock Exchange The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  4. 4. Karara Iron Ore Project - Location The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  5. 5. Karara Iron Ore - Process Flowsheet  Karara Mining is a 50-50 joint venture between Gindalbie Metals Limited and AnSteel, one of China’s biggest steel makers and iron ore miners. Courtesy of Gindalbie Melats Ltd The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  6. 6. Karara Dry Tailings Storage Facility - The FLSmidth Approach  Site Visit  Review conditions  Receive technical inputs  Conceptual material handling solutions  +/- 30%-50% accuracy CAPEX  Detailed Study  +/- 15%-25% CAPEX/OPEX  Final Engineering  Fabrication/Erection  We offer turnkey systems or assistance with installation, training and commissioning in addition to post commissioning support. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  7. 7. Stacking Technologies The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  8. 8. Stacking Method Economics TRUCKS (AND DOZERS) GRASSHOPPER/PORTABLE CONVEYORS BOOM SPREADER OPEX MOBILE CONVEYOR - PERMANENT - REUSABLE CAPEX The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  9. 9. Mobile Conveyors   Satefy Environment The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  10. 10. World’s First Mobile Stacking Conveyor Client: PP&L – 1975 Capacity: 1000 tph The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  11. 11. World’s Largest Tailings Stack    Mantos de Oro La Coipa, Chile Capacity 1,200tph Commissioned 1990 The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  12. 12. Applications    Overburden Removal and Stacking Permanent and Reusable Heap Leach Pads Tailings Conveying and Stacking The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  13. 13. Karara Dry Tailings Storage Facility - Environment  The plant is state of the art technology including significant improvements on environmental impact of the waste and the facility.  Ideal for:         Dry climates Wet climates Cold climates Substantially reduced water requirements Elimination of water loss through evaporation Groundwater contamination eliminated Vast reduction in environmental footprint => less CAPEX Rehabilitation plan established including the use of native flora to maintain The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  14. 14. Karara Dry Tailings Storage Facility - Safety      Site access enhanced. Equipment and vehicles can move freely around the storage site. Truck traffic eliminated. The risk of tailings overflow or run-out due to catastrophic failures of storage pond walls is eliminated. Can be established in high seismic regions. Ajka Bauxite, Hungary 2010 Rio Pomba, Brazil 2007 The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  15. 15. Mobile Conveyor System Basics          Low ground pressure on crawler tracks (15-30psi) Automatic alignment and leveling Highly accurate positioning through GPS control Robust systems with high availability (typically 90+%) Low operational cost Improved safety Environmental benefits Higher the capacity the greater the operational savings Current capacities 500-12,000 tph. Up to 800m long The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  16. 16. Ground Bearing Pressure - Interesting facts....    20 psi ground pressure over the whole machine. 35 psi when a tripper is directly over a given track Can reach as low as 15 psi  Reference  D11 dozer is 19 psi  large haul truck is 70 psi.  A human wearing work boots is 3-4 psi. The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  17. 17. Mobile Stacking Conveyor The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  18. 18. Mobile Conveyor Basics - Single Belt        No transfer points No spillage No wear No dust Less noise Single drive Etc The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  19. 19. Alignment Control (critical for belt tracking) Retreat stacking copper ore onto leach pad – Note straightness of stacking face The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  20. 20. Alignment Control (critical for belt tracking) The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  21. 21. Mobile Conveyor Basics - Tripper The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  22. 22. Mobile Conveyor Basics - Track Leveling The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  23. 23. Mobile Conveyor Basics - Track Leveling The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  24. 24. Mobile Conveyor Basics - Joints Between Frames The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  25. 25. Operating on Irregular Terrain The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  26. 26. Mobile Conveyor Basics - Ramp Construction The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  27. 27. Mobile Conveyor Basics - Term Definitions Advance Stacking Retreat Stacking The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  28. 28. Definition of Terms Retreat Stack The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  29. 29. Definition of Terms Advance Stack The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  30. 30. Karara Dry Tailings Storage Facility - Operating Principle The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  31. 31. Simple Stacking Plan The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  32. 32. Complex Stacking Plan The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  33. 33. Karara Dry Tailings Storage Facility - System Components Equipment # Description RADIAL STACKER Secondary System Radial Stacker CV-101 Ramp Conveyor CV-104 Mobile Stacking Conveyor (MSC) CV-105 MSCT Cross Conveyor CV-106 Spreading Conveyor CV-108 Reclaim Hopper Feeder CV-103* Extendable Moveable Conveyor MOT-101* Mobile Overland Tripper (for CV-103) CV-102* Extendable Feed Conveyor *CV-102 , CV-103 and MOT-101 are not needed on day 1 for operation. => Total of ~3.3km conveying The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  34. 34. Karara Dry Tailings Storage Facility - Secondary System Radial Stacker The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  35. 35. Karara Dry Tailings Storage Facility - CV-108 Reclaim Hopper Feeder The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  36. 36. Karara Dry Tailings Storage Facility - CV101-Ramp Conveyor The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  37. 37. Karara Dry Tailings Storage Facility - CV-104 Mobile Stacking Conveyor The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  38. 38. Karara Dry Tailings Storage Facility - CV-105 MSC Tripper Cross Conveyor The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  39. 39. Karara Dry Tailings Storage Facility - CV-106 Spreading Conveyor The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  40. 40. Karara Dry Tailings Storage Facility - Automation and Control The system is state of the art technology.  High level of automation and plant monitoring  Remote monitoring from FLS Perth ICE center  Mobile/email notification  My plan App for iPad and iPhone  Report card  KPI  Maintenance Planning  Remote Support The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 40
  41. 41. Karara Dry Tailings Storage Facility - Conclusion Mobile Conveyors  Equipment and systems are proven  Equipment designed and built to withstand rugged mining operations  Equipment and systems perform at highest availabilities  Lowest operating cost equipment and systems  All solutions are driven by mine plans, topography and material characteristics  As a consequence suppliers need to be systems providers rather than product suppliers The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  42. 42. Karara Dry Tailings Storage Facility - Summary    Mobile tailings stacking system – 2850tph – 3.3km conveying The technology allows for a process that enables dewatered tailings material to be conveyed and stacked rather than pumped. Environmental benefits      Smaller footprint => less CAPEX Decrease environmental exposure Reuse much of the water Improves rehabilitation efficiency Safety benefits  Site access enhanced  Traffic eliminated  Risk of pond failures eliminated  Significant reduction in OPEX The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  43. 43. Questions? The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
  44. 44. Thank You! The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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