Case Study - 20,000 stockpile
and 400t Bin Sticky Ore
“ Details, Details, Details ”

Bauxite Project WA.

Gary James.
Cali...
Bauxite Project WA
•
•
•
•

Its all in the details.
Think strategically.
KISS. Keep the flow sheet simple.
Bauxite compani...
Bauxite Project WA
• Some prefer to be optimistic. They
shouldn’t be.
• Good data is hard to get.
• Do not trust the data....
Typical Bauxite Behaviour
Photos from another
project. Cemented lumps
fall free, causing blockages
and damage.
HDPE on ste...
ROM and Primary Sizing
ROM and Primary Sizing
ROM and Primary Sizing
ROM and Primary Sizing
Very steep side
walls means narrow
back wall. Hence
trucks dump over
the side.

82º back

72º sides...
ROM and Primary Sizing

2100mm slow belt
stops spillage
ROM and Primary Sizing
ROM and Primary Sizing Dust Collection

Dust collectors roll
out. No ducting on
dirty side
Overland Conveyor Feed Details
Direct loading of
overland conveyor from
sizer. Curved plates,
reduce risk of build-up
& lo...
Overland Conveyor Feed Details

Ductless dust
collection

Chute longer than
sizer. This takes the
corners out of play.
Overland Conveyor Discharge & Drive Area

Return
idlers/pulleys
are under the
truss with
18m pitch.
Carry back
falls in ea...
Overland Conveyor Discharge
Belt washing & several scrapers and rollers

No back wall in chute
Walk way along elevated
loa...
Overland Conveyor Discharge
UOW/BME chute modelling ( Iron ore project)
Small impact zone introduced for primary crushed ore.
Smaller ore can be desig...
Sticky Ore Detailing
No back wall in
chute under
pulley

HDPE

Receiving belt is designed for direct
feed, so if sticky or...
Conveyor Drive Area
Drive through tunnel
under drive zone for
clean-up
1000 t bin, Screening & Sec Crushing
•Steep
xxx
walls,
round
corners

Ductless
dust
collection

Steep walls & no end
walls...
1000 t bin, Screening & Sec Crushing

Sloping floor
Drain to ground
1000 t bin, Screening & Sec Crushing
Stockpile
Stockpile
Stockpile With Big Outlet
• 20,000 t live.
• 23m long offset outlet to reduce height of the rat hole.
Stockpile With Big Outlet
Stockpile Outlets
Wider outlet

Wider outlet

Even drawdown

Steeper wall

Two apron feeders back to back,
each under a do...
Stockpile Outlets

Conical hopper.
Can also be used
on the end walls of
a wedge shaped
hopper.
Stockpile Outlets
A wedge means
vertical end walls.
( Can relax the
rule to use the
conical angle on
the end walls.)

Wedg...
Stockpile Outlets
No flat areas

Round corners
26m outlet
Ductless dust
collection

Back to back apron feeders
sharing com...
Stockpile Outlets With Round Corners
400t OBC Feed Bin

Conveyor/feeder
extended to increase
belt life
400t OBC Feed Bin
400t OBC Feed Bin

Vertical scrapings
chute to feeder
below
400t OBC Feed Bin
400t OBC Feed Bin
400t OBC Feed Bin

Outlet of 400t bin
fits into the shape
set by the 5 roll 60
degree conveyor
idlers

No skirts
The End
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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

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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 http://www.informa.com.au/bmh2014

Published in: News & Politics
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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
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