Gary James, A Calibre Global Company - Outlining a Case Study of a 20,000t Stockpile and 400t Bin Design for Sticky Bauxite Ore


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Gary James, Principal, MINERVA Engineers, A Calibre Global Company 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

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Gary James, A Calibre Global Company - Outlining a Case Study of a 20,000t Stockpile and 400t Bin Design for Sticky Bauxite Ore

  1. 1. Case Study - 20,000 stockpile and 400t Bin Sticky Ore “ Details, Details, Details ” Bauxite Project WA. Gary James. Calibre Minerva IIR Materials Handling Week. Brisbane June 2013
  2. 2. Bauxite Project WA • • • • Its all in the details. Think strategically. KISS. Keep the flow sheet simple. Bauxite companies have been dealing with the issue for many years. Iron ore “below water table” no different. • Designers reluctant to throw out easy handling dry ore standards for chutes, bins etc.
  3. 3. Bauxite Project WA • Some prefer to be optimistic. They shouldn’t be. • Good data is hard to get. • Do not trust the data. If below water table ore data looks OK, don’t believe it. • Use companies TUNRA, BME/UOW, J & J to test, model and audit the final design. • The claim “ designed to TUNRA etc” often false.
  4. 4. Typical Bauxite Behaviour Photos from another project. Cemented lumps fall free, causing blockages and damage. HDPE on steep walls Stainless
  5. 5. ROM and Primary Sizing
  6. 6. ROM and Primary Sizing
  7. 7. ROM and Primary Sizing
  8. 8. ROM and Primary Sizing Very steep side walls means narrow back wall. Hence trucks dump over the side. 82º back 72º sides HDPE Chute longer to take corners out of play
  9. 9. ROM and Primary Sizing 2100mm slow belt stops spillage
  10. 10. ROM and Primary Sizing
  11. 11. ROM and Primary Sizing Dust Collection Dust collectors roll out. No ducting on dirty side
  12. 12. Overland Conveyor Feed Details Direct loading of overland conveyor from sizer. Curved plates, reduce risk of build-up & lower belt impact. Curved plates cause ore collision and loss of energy
  13. 13. Overland Conveyor Feed Details Ductless dust collection Chute longer than sizer. This takes the corners out of play.
  14. 14. Overland Conveyor Discharge & Drive Area Return idlers/pulleys are under the truss with 18m pitch. Carry back falls in easy access locations Skid loader access under take-up, & tunnel under drives etc
  15. 15. Overland Conveyor Discharge Belt washing & several scrapers and rollers No back wall in chute Walk way along elevated loading point, allows unobstructed cleanup. Ductless dust collection
  16. 16. Overland Conveyor Discharge
  17. 17. UOW/BME chute modelling ( Iron ore project) Small impact zone introduced for primary crushed ore. Smaller ore can be designed with direct feed. Design the belt for direct feed.
  18. 18. Sticky Ore Detailing No back wall in chute under pulley HDPE Receiving belt is designed for direct feed, so if sticky ore becomes a problem, the cross bars can be removed. Removable side wall module allows reconfiguration or deletion Walk in doors 22m3 live capacity
  19. 19. Conveyor Drive Area Drive through tunnel under drive zone for clean-up
  20. 20. 1000 t bin, Screening & Sec Crushing •Steep xxx walls, round corners Ductless dust collection Steep walls & no end walls equals no valleys Down sloped reversing conveyor for clean out of system
  21. 21. 1000 t bin, Screening & Sec Crushing Sloping floor Drain to ground
  22. 22. 1000 t bin, Screening & Sec Crushing
  23. 23. Stockpile
  24. 24. Stockpile
  25. 25. Stockpile With Big Outlet • 20,000 t live. • 23m long offset outlet to reduce height of the rat hole.
  26. 26. Stockpile With Big Outlet
  27. 27. Stockpile Outlets Wider outlet Wider outlet Even drawdown Steeper wall Two apron feeders back to back, each under a double hopper
  28. 28. Stockpile Outlets Conical hopper. Can also be used on the end walls of a wedge shaped hopper.
  29. 29. Stockpile Outlets A wedge means vertical end walls. ( Can relax the rule to use the conical angle on the end walls.) Wedge means outlet has a ratio between 3 & 5 to 1 Add inserts when ratio 6 to 1 & above
  30. 30. Stockpile Outlets No flat areas Round corners 26m outlet Ductless dust collection Back to back apron feeders sharing common take-up rails
  31. 31. Stockpile Outlets With Round Corners
  32. 32. 400t OBC Feed Bin Conveyor/feeder extended to increase belt life
  33. 33. 400t OBC Feed Bin
  34. 34. 400t OBC Feed Bin Vertical scrapings chute to feeder below
  35. 35. 400t OBC Feed Bin
  36. 36. 400t OBC Feed Bin
  37. 37. 400t OBC Feed Bin Outlet of 400t bin fits into the shape set by the 5 roll 60 degree conveyor idlers No skirts
  38. 38. The End