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03
2009
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03
2009
EDUCATION
Methods for Exploratory Drilling of Deposits of Mineral Commodities
TRANSFER OF TECHNOLOGY
Impact of financial crisis on the German & global commodity market and the mining
industry
Tudeshki, H. ; Hertel, H.
Surface Mining and International Mining |
Clausthal University of Technology | Germany
Kellner, M.
Geotechnique, Mining, Petroleum Engineering | Surface
Mining and International Mining | Clausthal University of
Technology | Germany
Round Table at Hannover Messe 2009: Climate-Friendly and Energy-Efficient Raw Material ContiTech Conveyor Technology
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ThyssenKrupp Fördertechnik (conveyor technique): Fully Mobile Crawler-Mounted
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Volvo Fleet Under Ground - All Good Things Come From Above
Volvo Construction Equipment
Methods of Boulder Crushing in raw materials production
Tudeshki, H. ; Xu, T.
Essen | Germany
Germany
Surface Mining and International Mining | Clausthal University
of Technology | Germany
Development of the Oil-shale-project El Lajjun in Jordan
von der Linden, E.
The most intelligent chapter in mining history was written by German Engineering
Debriv; Tudeshki, H.
Linden Advisory | Dreieich | Germany
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EDUCATION
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Issue 03 | 2009
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EDUCATION
Methods for Exploratory Drilling of Deposits of Mineral
Commodities
Overall
by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki ; Dipl.-Ing. Heiko Hertel
Surface Mining and International Mining | TU Clausthal | Germany
The drilling technique had established itself as a key technology for the search and exploration of mineral resource
deposits. However, along with the advancement of mining of raw material deposits which outcrop immediately at the
surface or are only slightly covered, we now face the task of finding and opening up deposits that are located deeper
under the surface.
Introduction
The forming of accessible exploration-excavations at
economically and technically meaningful expenses is
limited to a depth of 30 to 50 m. The unknown geological
characteristics and rock properties entail a multitude
of technical, economical and safety-relevant risks for
underground mining operations. This includes the high
expenses for keeping the underground cavities and making
them again usable, in case nothing is found. For exploration
of extensive deposits that are present immediately at the
surface and deposits with highly irregularly distributed
resource contents in compact, and in none and low
water-bearing formations, mining exploration methods
(prospecting trenches or shafts) are preferred. Furthermore,
technically simple exploration excavations can be
constructed in very remote and hard to reach exploration
areas. A tendency to explore deposits in increasing depths
can be expected for future prospection and exploration
activities, so that the exploration by excavations will
further loose importance. The increasingly lower target
horizons of exploration activities go hand in hand with the
progress of raw material extraction in deposits near the
surface, as well as with the increasing performance and
efficiency of modern mining technologies. If nowadays the
usual exploration horizons are located 200 to 300 m under
the surface, in future years the average target depths will
reach over 1000 m. Even today these depths are sometimes
significantly exceeded by single raw material projects (e.g.
Gold mining in South Africa).
Through drilling direct access to the deposit can be
achieved, with a range from a few meters under the ground
level up to several thousand meters, and qualitative and
appropriate information on the overburden and the deposit
can be obtained. With a multitude of drilling methods a
large variety of rock mass properties can be controllable.
In contrast to exploration shafts and trenches, drillings
are not accessible by man, so that geological address and
determination of rock mechanical, as well as hydrological
parameters is done by means of the extracted sample
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material and its analysis in the laboratory. The rock mass
properties can be derived from the rock properties of the
sample material or can be determined direct from the bore
hole with special auxiliary tools in special procedures. In
the interpretation of the samples derived from drillings,
the degree of disturbance of the samples both by the
mechanically and partly hydraulically supported loosening
process of the material out of the rock and the consecutive
transport from the bore hole bottom to the sampling point
above ground, has to be considered. The quality of the
samples is significantly determined by the characteristics
of the formation to be investigated, as well as by the applied
drilling method. Here the general rule is that the specific
costs for one meter drilled increase with increasing
quality of the samples. In principle the success of a drilling
campaign is to be measured with the following factors:
quality and quantity of the samples to be extracted, as well
as the economical costs of drilling. The gross costs for
drilling are composed of specific cost for one meter drilled
and the drilling length in total. The drilling length is again
dependant on the number of drillings and their final depth.
This planning approach, which often initiates the
drilling planning, only refers to the process of drilling and
the sampling. The degree of requirements for this drilling
planning in the true sense is increased with:
•The required information from the sample material
•The increasing drilling length
•An irregular quality distribution in the deposit
•Stratigraphic and tectonic interfering factors in the deposit
and the overburden
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EDUCATION
During planning of the overall project, a multitude
of external factors, e.g. climatic conditions, location
of the drilling site, infrastructure, etc, have to be taken
into consideration. These factors can possibly limit the
application of optimum technical means and considerably
increase the costs for their application, respectively.
Drilling is used for various tasks in research, civil
engineering, as well as in mining projects, both for nearsurface, as well as deep underground exploration. Apart
from the search for and exploration of solid mineral
deposits, some important examples for exploration drilling
are:
•Exploring the deep underground
•Search and exploration of groundwater levels
•Exploration of fluid and gaseous hydrocarbons
•Ground exploration for foundations
Differences for the needed information on the rock and
rock mass characteristics, as well as on the economical,
technical and operational conditions have to be derived
from the individual and specific project definitions.
Due to the fact that, based on the application area of the
drillings, different rock parameters have to be explored, an
increasing specialization of methods, tools and equipment
components has taken place. Three standard drilling
methods were established for exploration drilling for mineral
deposits. In the following report some special drilling
methods for special applications are introduced. Before
the description of the method, significant requirements
and background for the selection of the drilling method are
explained.
Background and Requirements of the
Exploratory Drilling Technique
The primary goal of exploratory drilling is to obtain
reliable sampling material in an adequate amount, so that a
precise and resilient modeling of the deposit can be made.
The quality of a sample can be determined by the following
characteristics:
•Degree of preservation of the natural rock formation
•Specific volume (subject to the bore diameter) of the sample
•Completeness of the sample material
•Separation of cuttings/material from overlying formations
and avoiding mixing of sample material
•Orientation the sample according to their location (in hard
rock)
•Sampling according to depth, or clear assignment of location
of sampling
One of the most important quality criterions of drilling
samples is the degree of conservation of the natural rock
formation, as well as the pore volume and the filling of
the interfaces. The degree of disturbances in sampling
material is mainly subject to:
•The drilling method
•The drilled rock (loose or hard rock)
•The professional execution of drillings
•The diligence in sampling
•The transport and (intermediate) storage of sample material
With special procedures it is possible to obtain (almost)
undisturbed samples with mechanical and partly with
hydraulic processing during the loosening and extraction
process. However, impairment of the sampling material to
different degrees cannot be avoided in all standard drilling
methods, including in the common methods of exploration
of mineral deposits. This is due to economically driven
aspects of the drilling progress. As for the procedurally
conditioned disturbance of the natural rock formation, this
can be stated as a planned and previously known reduction
of the sampling quality. Depending on the applied drilling
methods, the achievable quality of the samples is explained
in different norms and regulations. Within the context of
procedural mechanical and hydraulic application of drilling
forces, rock characteristics also have to be observed. In
principle, for drilling and collection of undisturbed samples
of rocks without or with low granulation (non-cohesive
loose rocks), higher demands have to be met, compared
to compact hard rocks. The following general statement
can be derived from the connection between granular
binding, extraction force and interference of the sampling
material:
•Low granulation a low extraction forces, high interference
•High granulation force a high extraction force, low interference of the sample
The quality category that is supported by the drilling
method needs to correspond to the exploration goal.
However, based on the goal of the exploration, it is possible
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EDUCATION
that even samples with a high degree of disturbance
are adequate. In bigger exploration projects meaningful
combinations of various drilling methods lead to a costefficient and at the same time reliable results.
In addition to the technical quality criteria, and criteria
aspects that are planable prior to the drilling campaign,
certain influencing factors such as qualification of the
drilling personnel also need to be heist red. The resulting
disturbances can appear throughout the entire sampling or
randomly in individual areas. The reliability of the obtained
information can be ensured by professional and diligent
execution of the drillings, the sampling, as well as their
storage and documentation. The risk of disturbances by
the sampling and storing of samples is reduced through
special sampling containers (e.g. Liner).
The area of direct information out of a drill hole
(information window) is limited by its final depth and its
bore diameter. The bore diameter in particular, significantly
influences the information content and the reliability of the
samples. In principle a drill hole only opens a very small
window in the rock mass. Therefore it is possible that erratic
changes in the rock mass, e.g. tectonic disturbances or a
strongly irregular mineral distribution can be missed by
the obtained borehole area. A multitude of erratic changes
can be determined with geophysical methods, which often
are used complementary to exploratory drilling under
difficult rock conditions. However, these do not allow
for a precise determination of the resource content. The
expected distribution of mineralization can be derived with
a high probability from the genesis and the evolved type
of deposit and needs to be taken into consideration in the
dimensioning of the borehole diameter and the needed
specific sample volume.
The highest informative value of a sample is achieved
by an end-to-end and complete sampling over the
entire borehole length. In certain exploration goals
the composition of the rock mass is mostly known or of
secondary importance for the planned extraction of the
raw material. In such cases complete sampling is not
necessary and sectional samples are derived in regular
distances along the drilling path. These distances range
usually between 60 cm and 130 cm. With this method, the
secured amount of available data is reduced to the spot
(random) samples obtained along the bore hole axis. A
distinction has to be made between the incompleteness of
the sampling material, which is due to the type of sampling,
and the incompleteness which is due to procedural losses
and losses related to the drilling technique. It is possible that
due to the technical effects on the rock by drilling forces,
individual elements are destroyed or lastingly changed, so
that they are not suitable or cannot be identified any more.
In case these impairments are not recognized during the
interpretation of the samples, they can cause considerable
Issue 03 | 2009
deviations from the actual rock mass composition and
condition.
The requirements for stabilizing the bore hole wall in
the exploratory drilling technique go beyond the role of
keeping the operating safety. The extracted material from
the bore hole bottom has to be kept free of rocks from the
already penetrated formations. In drillholes without casing,
it is possible that material loosen from the open bore hole
wall – the so-called caving material – and mix with the
sampling material. In obviously stable hard rock formations
it is possible to generally drill without a casing installation.
However, in the case of instable rock formations are
encountered (e.g. areas that are loosened by tectonic
influences or cleft areas that are filled with loose material),
it is possible that the stability of the bore hole wall is highly
altered. Smaller instable zones are usually not detected, so
that the drilling is done according to plan. During further
drilling it is possible that rocks may fall out of these zones
and sink to the bore hole bottom or get into the mud flow. In
completely obtained samples with high quality the caving
material can easily be recognized and be separated from
the actual sampling material. However, in highly disturbed
and incomplete samples it is almost impossible to do this
separation, so that altered material is addressed. With the
mechanical stabilization of the bore hole wall the bore
hole is shut off from the intersected formations, which
ensures an optimal protection from caving. However, the
advantages of a bore hole wall secured by a casing are
faced by considerable economic and technical expenses
through:
•Costs of the casing installation
•The needed hook load of the drilling rig for casing handling
•The additional work and expenses
•The bigger bore diameter for casing sections
•The logistic expenses of establishing the drilling site
Alternatively to casing installation it is possible to
stabilize weak areas which tend to caving or which
impede the stability of the bore hole wall, either through
cementation or through wash over. A possible falsification
through caving needs to be investigated during sampling
and the first geological evaluation on-site.
Interfaces can be addressed in (almost) undisturbed
samples. While interpreting these samples the direction of
strike and dip is of interest. For this reason it makes sense
to obtain oriented samples. In an additional working step,
a mark is placed on the bore hole bottom for orientation
of the position (Northern direction) before coring the next
section. This allows alignment of the samples according to
their original position, which is the base for modeling strike
and dip of the interface structures.
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EDUCATION
The quality and thus the secured information content of
the drilling samples are mainly determined by the abovementioned quality criteria. However, it is only possible to
reliably process the information with a clear assignment of
the sampling position. Furthermore it should be noted that
sampling according to position and depth is often taken
for granted and inadequately observed. An unrecognized
deviation of the drill hole from its given axis always leads to
a difference between the recorded sampling position and
the real one. The influence of these deviations increases
with the inhomogenity of the rock mass. Therefore it can
be said that the controlled course of the borehole and
as such the exact determination of the sampling position
is less a quality characteristic than an indispensable
prerequisite for secure and reliable exploration results.
The measurement of the drilling direction can be done
either after reaching the final depth or already in the drilling
process. The measurement of the borehole measurement
can be done either as a separate work step in given stages
or immediately in the drilling process. Both possibilities
allow control of the bore hole path and thus ensure to
reach the given target.
In the classification of drilling samples, different
technical regulations deal with the relation between
the degree of conservation of the natural rock formation
and the completeness of samples. The sampling
according to depth and location, the extraction in
adequate volumes, as well as the prevention of caving
are more of basic minimum requirements than quality
criteria. In accordance with the German DIN 4021,
the following classifications can be mentioned for
exploratory drillings of mineral raw material:
•Complete extraction of undisturbed samples
•Complete extraction of disturbed samples
•Incomplete extraction of disturbed samples
Pic. 1: Completely extracted and (almost) undisturbed samples
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EDUCATION
1. Core Drilling
2. RC-Drilling (Reverse Circulation Drilling)
or CSR-Drilling (Center Sample Recovery Drilling)
3. Rotary- or Hammer-Drilling
Pic. 2: Incompletely extracted and disturbed samples
In picture 1, completely extracted and almost undisturbed
samples (core samples) are shown. The samples shown
in picture 2 are incomplete and highly disturbed. These
samples can only be used for quantitative assessment
of the drilled formations and the determination of the
resource contents.
The informative value of the samples is completed
through the documentation of drilling parameters, as well
as through the observations of a qualified drilling team.
An adequate logging can provide valuable information
on completeness, as well as on a possible falsification
through contamination of the samples by caving, so that
sufficiently accurate interpretation can even be derived
from disturbed samples.
Standard Drilling Techniques
Deposits of mineral commodities are mainly to be
found in hard rock formations except for placer deposits
and accumulations through substitution processes. The
framework of requirements for suitable drilling methods,
drilling tools and equipment can be derived from geological
and geo-mechanical rock characteristics, from the
required quality criteria of the sample, based on the goal of
the exploration project, as well as from the prognosed size,
form and position of the deposit. Although in detail each
drilling project has its own and special conditions, but with
the high performance and universally applicable equipment
of the modern exploratory drilling technique, they can all
basically be dealt with by three drilling methods.
Issue 03 | 2009
Taking into consideration standards of the
global exploration activities, these three drilling
techniques can be called standard techniques
for exploration of mineral raw material deposits.
Because of their high quality samples, core
drilling basically has the greatest importance
for mineral exploration. Due to their varying
sample quality, both other methods come across
internationally varying acceptance. In addition,
the possible application of the methods should
be assessed differently due to topographic and
climatic differences of the project area.
The standard drilling methods are complemented by
less common drilling techniques, which are even popular
for other drilling applications. Therefore they are called
special technologies for exploration.
Core Drilling Technique
With the development of the core drilling method at
the beginning of the 19th century, a milestone was set for
the exploratory drilling technique. The technical principle
of cutting out a rock cylinder from the rock beneath the
bore hole bottom, with the help of a tubular drilling tool
was able to stand up to a multitude of competing drilling
methods, due to the high quality of the obtained samples.
An important contribution to the performance of the
method was the first application of diamond drilling tools in
1862 by the Swiss tunnel construction engineer A. Leschot.
However, the industrial manufacturing of diamond drilling
tools could only be realized in the 1950ies. Nevertheless,
the core drilling technique was closely connected to
diamond drilling tools, so that the expression diamondcore-drilling technique is often used to name this method
in exploration. Diamonds are characterized by a very high
degree of hardness (10 on the Mohs scale), through which
hard rocks with high share of quartz or pure quartzite
can be drilled under technically meaningful conditions.
The application of diamond drilling tools requires the
maintaining of a sufficient mud circulation for cooling.
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EDUCATION
Pic. 3: Schematic diagram of core drilling
In a further development the original core drilling
technique was expanded to a multitude of individual
core drilling methods, in order to cope with the various
exploration goals, which partly have a very specialized
character. Three core drilling methods have been
established in exploration of mineral raw material deposits,
which in the loosening and extraction technique are leaned
against the classic methods.
The applied core drilling methods are suitable to
completely obtain (almost) undisturbed samples. The
rock beneath the bore hole bottom is cut out in form of a
concentric rift with a core drilling tool, which is preloaded
with static pressure by the drilling tool and in is rotated in a
constant rotational speed. Since it is not the entire bore hole
axis that is processed, centrically a rock cylinder remains,
the so called drill core. The cuttings which result from the
Issue 03 | 2009
cutting out of the annulus are continuously removed with
circulating mud. Inside the drill string the mud is first lead
to the core barrel, gets out at the drill bit into the annulus
and flows loaded by cuttings back to the surface through
the annulus (direct direction). The remaining drill core is
constantly rising into the core barrel, until its length does
not allow any further take up. The rock column is connected
to the surrounding rock by its lower surface and has to be
loosened by lifting of the bore string (see picture 3). This
is done by a core lifter, which is located between the core
barrel and the drill core in a conical cavity. While pulling
the drill string the core lifter wedges the drill core through
a friction locking (see picture 4). The core barrel with the
inside drill core is drawn mechanically to the surface by
pulling out all drill rods out of the hole.
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EDUCATION
Pic. 4:
Diagram core lifter
Core drilling with Single Core Barrel
The constructional composition of the single core barrel
is limited to the basically needed components of a core
drilling tool. Picture 5 shows the setup of a single core
barrel. The multi-part drill set is composed of:
•The core bit
•The reamer
•The core lifter
•The core barrel
•The head of the core barrel
Pic. 5:
Setup of a single core barrel
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EDUCATION
Due to the slim construction of single core barrels,
the core bits are equipped with a thin cutting edge. The
measurement of the required widths of the edge is derived
from the wall thickness of the core barrel + outer annulus
(space between drill string and drill hole wall) + inner
annulus (space between core barrel and drill core). The
wall thickness of the core barrel is 3.5 to 4.5 mm, an extra
3.5 mm have to be added for both the inner and outer
annulus. The inner annulus creates a clearance between
the drill core and the inner core barrel wall while the core
is rising into the core barrel. Furthermore the mud is lead
through this annular space along the core to the bit. The
outer annulus ensures a friction-less rotation of the whole
drill string and the path for the mud back to the surface.
The reamer, which is directly positioned above the core
bit, has the task of stabilizing the core barrel and ensuring
a constant bore hole diameter. With the progress in drill
hole length wear off in the gauge of the bit is unavoidable.
Without the application of a reamer the bore hole diameter
would decrease steadily.
During the entire time of the coring interval, the drill
core is subject to the hydraulic influences of the mud,
as well as the mechanical influences of the rotating and
advancing core barrel. The high degree of disturbing
factors can negatively influence the quality of the sample,
as well as the drilling process. The mud flow, which is
directly running along the drill core, washes out all fines,
e.g. rock veins or clay-beds. It is almost impossible to avoid
a mechanical impairment of the core through rotation
influences. Radially acting strains on the drill core, which
are caused by vibrations and unbalances in the drill string,
have to be added. Results of this can be impairment of the
sample quality, as well as considerable disturbances in
the drilling process through broken core pieces. In case
fragments of the broken drill core get jammed in the core
barrel, the penetration rate is either strongly reduced or
completely stopped. The entire length of the core barrel,
which is between 1 and 3.5 meters in single core barrels,
cannot be completely drilled out. Along with the restriction
of the possible length of the cored section, additional round
trips are needed for the achievement of the final depth.
These additional processes have negative effects on the
gross drilling performance. The extraction of the drill core,
which in a single core barrel is done through the removal
of the entire drill string (round trip), requires a significant
amount of time, particularly with advancement into greater
depths. In addition, core fragments in the core barrel are
not optimally retained by the core lifter. These fragments
may loosen under the strains of the mechanical extraction
process, and fall back on the bore hole bottom. In case
of such a concurrence of unfavorable circumstances the
efficiency of the drilling process, as well as the sample
quality is again strongly impaired.
Issue 03 | 2009
The application of single-core barrels is limited to
exploration of regular and compact hard rock formations
that are close to the surface. In such circumstances very
good drilling progress can be made with the narrow cutting
edges of the core bits. In comparison with other competing
core barrel constructions, less rock volume needs to be
removed from the core bits of the single core barrels;
therefore it is possible to achieve a faster penetration rate
with a comparatively lower energy expense for pressure,
torque and mud flow. The advantages of the lower specific
cutting work have particular effect on application of
small drilling equipment, whose feeding force is limited
due to its dead weight. In addition, the narrow cutting
edge of the core bit leads to a more favorable relation of
the bore hole diameter to the core diameter. Next to the
technical advantages, the single core barrels require a low
investment and have relatively cost-effective wear parts.
Two types of single core barrels are distinguished in the
technical nomenclature. The single core barrels with the
model name B are produced from thin-walled material and
need core bits of a cutting edge width of 7 mm. A more
robust standard single core barrel with the model name Z,
which needs a cutting edge width of 14 mm is also available.
In the next issue, further details for the dimensioning of the
bore diameters and the resulting core diameters will be
given.
Core Drilling with Double Core Barrel
The double core barrel is a versatile drilling tool in the
exploration technique for complete extraction of complete
cored samples. The range of applications varies from
exploration work in friable structures and weakly solidified
formations to drilling of compact quartzite rock. With a
modification of the “classical” double core barrel it is also
possible to extract cores from loose rock formations. Due
to the engineering design of the double core barrels, which
in principle are characterized by one inner tube for the
core recovery and one outer tube for power transmission,
the following criteria should be ensured:
•The protection of the drill core from hydraulic influences of
the mud
•Protection of the drill core from mechanical influences of
rotation
•The friction free inclusion of the core into the drilling
process
•The secure extraction of a cored section, which should be
as long as possible
•The non-destructive extraction of the core from the core
barrel
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EDUCATION
In comparison with the single core barrel, the technically
more complicated construction of the double core barrel
consists of the following components (see picture 6):
•The core bit
•The outer tube
•The reamer
•The head of core barrel
•The core lifter bush and
•The core lifter ring
•The inner tube
•Inner tube with swivel
Issue 03 | 2009
Pic. 6:
Composition of a double core barrel)
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EDUCATION
The power and energy transfer onto the core bit is done
exclusively through the thick-walled outer tube, which is
considerably more robust than the inner tube. The inner
tube only serves to contain the drill core. The inner tube
is connected to the core casing head of the outer tube
through a swivel, in order to protect the drill core from
the mechanical influences of the drilling process. The
bearing decouples the torque, as well as the rotary motion
of the outer tube from the inner tube. The drill core is only
influenced by the cutting force of the core bit. The mud,
which is directed from the drill string over the head of the
core barrel, flows in the annular gap between the outer
and the inner tube to the core bit, alongside of the newly
cut drill core.
The contact area of the drill core and the drilling fluid is
reduced to 5 to 10 cm by the path of the mud escape from
the core lifter bush till the cutting edge of the core drill. Even
if the contact surface is low, in un-solidified sediments,
the mud contact leads to washing out of fine elements, up
to the complete loss of the core. For this reason double
core tubes are equipped with a modified core lifter casing
in loose rock formations, which elongates the inner tube
beyond the core bit, so that the core can be held without
contact with the mud. It should be noted that the core is
“cut” by the non-rotating inner tube, and not by the core
bit. In this application a considerable wear-off needs to
be provided for. The spectrum of application is basically
limited to loose rocks. The core lifter rings of the hard rock
drilling technique are exchanged with core a lifter clip,
which closes the entire diameter of the inner tube with the
lifting of the drill string, and thus allows for the complete
discharge of the un-solidified drill core. With double core
tubes it is possible to obtain samples of adequate quality
in almost any formation. Highly alternating rock stabilities
and grain adhesion are particularly challenging. The rock
loosening process always has to refer to components
with higher stability. Satisfactory results can be obtained
in strongly unstable and weathered hard rocks with
conventional double core tubes, which are equipped with
special core lifter bush and core bits.
The core lifter bush is extended to the cutting edge, so
that the annulus gap is strongly reduced for the mud outlet.
The core bit has inner mud channels, which only exit at
the cutting matrix. The disadvantage of these special core
bits is their sensitivity towards small drilling mistakes, so
that their application remains limited to difficult mountain
conditions.
Four standard systems are offered in industrial
manufacturing of double core barrels, as well as of the
corresponding core bits; each one is specific to the
respective manufacturer. Their main difference is in the
Issue 03 | 2009
dimensioning of the tube wall thickness and the required
edge width of the core bits. The double core barrel
systems are characterized by the coding TT, T-2, T-6, D and
K-3. Individual components are not compatible with each
other.
The global application of double core barrels for the
search and exploration of mineral raw material deposits is
dominated by the T-2, T-6 und D systems. Core diameters
of 22 mm to 84 mm are drilled with core barrel systems
T-2. They have a low pipe wall thickness, so that core bits
with small cutting edge thicknesses of 7 mm to 8.5 mm are
used. Core diameters of 47 to 123 mm are obtained with
core barrel systems T-6 and D. The cutting edge width of
the core bits is between 9.5 and 12 mm. The next issue will
provide further explanations on dimensioning of the bore
hole diameters and the resulting core diameters.
Taking into consideration an economical, as well as
a technically meaningful and achievable final depth, the
application range of conventional single and double core
barrels is limited by the mechanical extraction of the drill
cores, through the extension of the entire drill string to
exploration horizons of up to 300 m. With increasing drilling
depth the time expense for round trips of the drill string for
the core extraction accounts for a considerable share of
the effective drilling time. The individual steps that have
to be taken into consideration in the drilling performance
are:
•Running of the drill string to the hole bottom
•Drilling process
•Breaking off the core
•Extraction of the drill core through removal of the drill string
out of the hole
•Removal of core
The final depth, which can in fact be reached with
economically justifiable expenses, is mainly influenced by
the following factors:
•The length of the cored section that is actually extracted
above ground. The maximum length of the cored section corresponds to the inner core barrel length. In case this length
is reduced, due to jamming in the core barrel or due to core
losses during extraction, the total efficiency is also reduced,
subject to the time of circulation of the tool. With increasing
depth of the bore hole, the length of the cored section which
is to be extracted, should increase.
•The effective time for a round trip, which is influenced by
technical parameters and the operation method of the drilling team. The technical factors basically comprise of the
length of the individual drilling rods (and as such the threaded connections that are to be disconnected), the solubility
13
EDUCATION
of the individual threaded connections and the driving speed
of the lifting unit or the top drive of the rig. In order to achieve
fast installation and removal of rods, a perfect functioning
of the drill pipe system has to be ensured. In principle the
technical factors are subject to the correct selection of the
equipment, as well as to its maintenance. As a prerequisite,
the professional handling of the technical equipment, as well
as a command of the tasks to be achieved, requires corresponding qualification of the drilling team.
•The unexpected geological disturbances in the bore hole.
Each exploratory drilling in unknown rock is linked with imponderabilities. These are easier to handle with a careful assessment of possible incidents and timely implementation of
precautionary measures. This includes for example a casing
plan, provision of plugging material to confine mud loses and
of fishing tools for removal of junk from bore hole averages
etc.
A particular challenge for the application of single and
double core barrels is the penetration of unstable rock
formations. Due to the procedural installation and removal
of the entire drill set, the bore hole wall, which is partly to
completely uncased, is subject to application of hydraulic
and mechanical forces. During the fast lifting of the drill
string the core barrel, which corresponds to the bore hole
diameter, can produce a piston-like effect in the mud-filled
bore hole. Thus it is possible that a hydraulic vacuum
is produced immediately under the core barrel, which
may lead to caving or even a bore hole wall collapse.
Furthermore the bore hole wall is mechanically strained
by possible contact to the moved drill string. There is a
possibility that parts of the bore hole wall cave into the bore
hole from unidentified and unsecured weak zones. The
operation safety can be impeded by caving, particularly
in deep drillings. In case weak areas cannot be handled,
the installation of a casing is unavoidable. The maximum
diameter of the drill string for the deepening of the drilling
to the final depth is then limited by the inner diameter of
the casing. The penetration of unstable mountains with
conventional core barrels requires diligent planning of the
casings to be installed.
One advantage of the round trip that is required for
the extraction of the core, is the continuous checking
of the equipment wear-off. The state of the core bit and
the drill string can be checked after each cored section.
Furthermore, a flexible adaptation of the core bit to the
changing rock characteristics is possible.
Core Drilling with wireline core barrel
drill cores without a round trip, has opened up a range for
application of the drilling technique for complete extraction
of undisturbed samples, which significantly exceeds
limiting conditions of conventional double core barrels.
With the available wireline core barrel systems, which
consist of a wireline core barrel assembly and special wire
line drill rods, it is possible to achieve depths of over 1000
m in routine operations. In big drilling projects it has been
possible to advance to depths of 3500 m under the surface
with wireline coring systems. However, the performance of
the wireline coring has its complete effect only in deeper
drillings from 50 – 150 m. Therefore wireline coring systems
are applied complementary to the double core barrels, as
they show their strength for shallow exploration targets.
However it is expected that the importance of wireline
coring will further increase, taking into consideration the
development towards deeper target horizons.
The engineering design of the wireline coring systems
is composed of the wireline core barrel assembly, a latch
and special wireline drill rods. The wireline core barrel
assembly is geared towards the double core barrel, but the
difference is that the conventional head of the core barrel
has been replaced by a bolt mechanism, which locks the
inner tube for the drilling process at the outer tube and can
be unlocked for the extraction process. In order to protect
the drill core from mechanical rotation influences, the inner
tube is connected with a swivel. In picture 7 the design of a
wireline core barrel is presented as an example.
Industrial manufacturers offer combinations of inner
and outer tubes, with which cored sections in lengths of
1 to 9 m are feasible.
The wireline core barrel systems are characterized
through advantageous core removal, which can be done
without the time-consuming round trips of the entire
drill string. The drill core is recovered together with the
core barrel by a rope. This is done by stopping the mud
circulation after the drill-out of the cored section, then
breaking off the core from the rock by slightly lifting the
bore string, and by consecutively disassembling the top
drive from the drill rods. The rope with its overshot is
lowered into the drill string by a winch, until it locks at the
latch of the wireline core barrel assembly. Simultaneously
the locking mechanism of the outer tube is disconnected.
The diameters of the special wireline drill rods are adapted
to the core barrel, so that it is possible to pull the whole
core barrel assembly inside the drill rods. After the core
removal the inner tube can again be inserted through the
drill rods to the bore hole bottom.
The wireline core barrel is a further development of
the double core barrel, which is specially constructed to
mechanically extract the bore core without the need to
remove the entire drill string. The method of extracting
Issue 03 | 2009
14
EDUCATION
Pic. 7:
Composition of a
wireline core barrel
Issue 03 | 2009
15
EDUCATION
This is done:
•Through free fall in perpendicular to moderately inclined bore
hole distances ( less than 45% deflection out of plumbness),
in which an adequate mud level is available
•Through insertion at the winch in perpendicular to moderately inclined bore holes that are almost or completely get dry
through mud loss
•Through attachment of the top drive onto the drill rods and in
highly inclined bore holes and through the use of a moderate
pump rate, so that the inner tube is transported to the core
barrel from the hydraulic flow rate.
As a principle, before inserting the inner tube, the
extracted length of the cores section has to be checked.
In case a core stump remains in on the bore hole bottom or
in case cuttings are not discharged, a correct engagement
of the inner tube can be prevented. In this case the drill
string has to be pulled until its lower end is located above
the core stump.
During the core removal the drill rods can take over
the function of temporary casing through the geometric
dimensioning and the installation. This could stabilize the
borehole wall in regions with friable zones. Furthermore
potential caving out of the bore hole wall is separated
from the core sample, which is pulled inside the drill string.
However, this cannot substitute a complete casing along
bigger disturbance areas, since the drill rods rotate with
the required rotary speed and an outer annulus for the
mud has to be maintained during the drilling process. In
disturbed rock mass areas that are too big and high mud
losses are to be expected, the rod friction between drill
string and bore hole wall can be highly increased. Under
these circumstances it is necessary to install a casing. The
advantages of a temporary casing by the drillstring can
be found in a higher operational safety during the drilling
process, as well as in the possibility of overcoming limited
disturbance areas. Moreover the wireline coring drill rods
offer the option of attaching measurement tools to them,
for example to determine the bore hole direction. This
contributes to a higher reliability and quality of the core
samples.
Three different wireline coring systems that are
manufactured with industrial standards are available. They
mainly differ in their construction of the locking and latch
systems (see picture 9 and picture 10).
The system that is marked with the coding SK 6 L and
NSK, has been specially designed for low drilling depths of
up to 300m, the system that is marked Gebor S is designed
for medium drilling depths up to 500 m, and the system called
CSK has been designed for depths from 500 m upwards.
Issue 03 | 2009
Pic. 8:
IInner tube with locking
mechanism and latch of the
wireline core barrel system
CSK
16
EDUCATION
The bandwidth of the bore hole diameters starts at 48 mm
and ends at 176 mm, whereas core sample diameters lie
below the diameters of the single and double core barrels,
due to the broad width of lips of the core bit.
Compared to single and double core barrels, the
application of wireline core barrel systems basically
requires a higher performance of the drilling rigs. This is due
to the fact that the bore rods have higher weights and there
is a higher rod friction in the drilling process. Furthermore,
a high-performance winch with a corresponding length of
the rope has to be available for pulling the inner tube. In
connection with the higher expenses for investment and
the arising spare part costs fore bore string and core bits,
the specific initial costs are higher than in the application
of conventional core barrel systems. However, the higher
gross drilling progress in deeper drillings of final depths
more than 50 to 150 m and the relatively easy handling
of difficult drilling conditions compensates for the higher
operating costs. The next issue will deal with the selection
of core bits and the dimensioning of drilling parameters.
Pic. 9:
latch and overshot, system CSK
Pic. 10:
latch and overshot, system NSK
Issue 03 | 2009
17
EDUCATION
Bibliography
[1]
Arnold, Werner: Flachbohrtechnik; 1. Auflage,
Leipzig, Deutscher Verlag für Grundstoffindustrie GmbH,
1993
[2]
Buja, Heinrich: Handbuch der Baugrunderkundung;
1. Auflage, Düsseldorf, Werner Verlag GmbH & Co.KG,
1999
[3]
Entenmann, Dr. Winfried: Baugrunderkundung, 2.
Auflage, Renningen, Expert Verlag, 2008
[4]
Happel, Martin; Homrighausen, Dr. Reiner:
Bohrkerngewinnung zur Exploration von Baugrund
und Rohstoffen, in: BBR Fachmagazin für Wasser und
Leitungsbau, S. 42 – 49, Heft 12/2008
[5]
Wirth Maschinen- und Bohrgerätefabrik GmbH:
Bohrtechnisches Handbuch, Version 1.0, 2002
[6]
Comdrill Bohrausrüstungen
Bohrausrüstung, 7. Ausgabe, 2007
GmbH:
Katalog
[7]
Internetinformation der Firma Archway Engineering
(UK) Ltd: www.archway-engineering.com, August 2009
Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki
studied from 1977 to 1980 at the Mining College of Shahrud (Iran); following several years
of work in the mining industry, he completed
his mining study at the RWTH Aachen in 1989.
Since 1992 he was Chief Engineer at the Institute for Surface Mining (Bergbaukunde III) of
the RWTH Aachen, mainly active in the field of
open cast mining and drilling technique. He did
his doctor degree in 1993 and qualified as a university lecture in
1997. In 1998 the Venia Legendi was awarded to him be the RWTH
Aachen for the field “Rock and Earth Open Pit Mining”. In November 2001 he was appointed as Professor for Surface Mining and
International Mining at Clausthal University of Technology.
He already has over 25 years of experience in the field of project
planning and cost-benefit analysis within the frame of various mine
planning projects. The international tasks rendered by him mount
up to more than 300 international raw material-related projects.
| tudeshki@tu-clausthal.de | www.bergbau.tu-clausthal.de |
Dipl.-Ing. Heiko Hertel, born 1975, graduated
in the years 1995 to 1998 trained as a well
constructer. The activities of the well
constructer he held until 2001. Immediately
following the same year he began the study
of Geotechniques, Mining and Petroleum
Engineering at Clausthal University of
Technology. He completed his studies
successfully in 2007 and is engaged in silk
as a research associate at the Institute for
Surface Mining and International Mining at Clausthal University of
Technology.
| heiko.hertel@tu-clausthal.de | www.bergbau.tu-clausthal.de |
Issue 03 | 2009
18
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Issue 03 | 2009
19
Impact of financial crisis on the German & global commodity market and
the mining industry
by Moritz Kellner
Geotechnique, Mining, petroleum/gas engineering |Institute of Surface and International Mining | Clausthal University of Technology | Germany
Introduction and Background
The collapse of commodity prices
The crash of commodity prices in the second half of 2008
has been an unexpected happening. Although a declension
was predicted, a historical collapse at an average of
about 50 % within five months was surprising. The oldest
commodity index, 1957 founded CRB (Commodity Research
Bureau), collapsed that quality after its historical peak in
july of 2008. The position at the energy markets seemed
to become even worse. The cruide oil price crashed from
150 US $ / barrel to 35 US $ / barrel within that period, i.e. a
declension of about 76 %. Only the gold price lasted stabil.
Reason here has been the role of gold as crisis metal, while
traders lost their belief on currencies and bonds /1/.
Reasons for the rising and declension of commodity
prices
The reasons for the historical declension of commodity
prices are to find in direct periphery to the global financial
crisis. Global deleveraging, i.e. the procedure of borrowing
equity to substitute the debt, has been performed for
debt retirement. Traders turned away from the class of
investment “commodities” due to the possibility of still
making profit. Together with the signals of a recession
the declension became a dynamic process. Danger of
excess of supply on the worldmarkets lowered the prices
even more. Especially the industrial nations got under
considerable strain.
To find a conclusion why commodity prices reached that
high levels, which made a crash possible, there are to take
parallels to the financial crisis. As on the financial market,
the prices had been pushed up speculative /1/.
Energetic and industrial commodities prices climbed
much more, than a normal price increase would do. The
rising prices over the last years let mining companies
capitalize onto exploration projects, profit seemed to
be possible at reserves and resources that have been
unprofitable before. Beginning excess of supply on the
world markets, for example iron ore, had been ignored.
Prices much higher than average prices (for example
copper was at four times higher than usual) were tempting.
Finally, the commodity bubble burst /2/.
Issue 03 | 2009
Controversy – Grudge or blessing for the industrial
nations?
The economic impacts of the declined commodity prices
are discussed controversial these days. Different views
say, that the commodity crisis may be a grudge or blessing
for the economics of the western world. In principle,
following thesis is correct: Cheap commodities must have
a good impact to push foreign economies.
The International Energy Agency (IEA) came to that
conclusion: Due to fallen crude oil prices, the industrial
nations save costs in a height of one trillion US-Dollars.
This must be enough to secure all foreign efforts to push
economic activities.
The other side dissents that view. The German Institute
of economics analysis (Rheinisch-Westfaelisches Institut
fuer Wirtschaftsforschung) can see, that this amount of
money now is missing at the producing countries. The result
is a global stand-off situation. Germany reduced costs
around 40 Billion US-Dollars, money that is now missing in
the middle east, Russia or Venezuela. Producing countries
do not have any chance now to invest on world market
products – for example German products. Furthermore,
although there is saving, the economy looses consumer. In
that case, the sense of efforts to push activities becomes
senseless. The interdependencies between global financial
crisis and flagging global economies as well as commodity
prices are nontransparent. Although the IEA comes to the
conclusion, that commodity prices do have an important
influence onto global economies, but the other side of the
view seems to be sensible as well: Flagging economies
were the reason for the oil price crash, just moments later
commodities crashed as well /3/.
Influences on the German commodities:
Steel industry & Limestone and caking
coal
Influences on the steel industry
Once there are signs of commodity crisis, steel industry
is one of the first that gets hurt. Although at the first moment,
cheap commodities, in that case iron ore and caking coal,
seem to be an offer to the steel industry, but consumers
got lost.
20
Pic. 1: Freight rates
Of course, the steel crisis is a global problem. Iron ore,
that has been pushed up by produces like Vale, lost that
much value, that the production had to be cut down about
30 to 40 percent /1/. The biggest influence on development
of the global iron ore price has the biggest consumer,
China. If the Chinese steel industry, that wasn’t hurt that
brutal as Europe or the United States starts buying ore in
2009 again, the price will become stabilized again.
The influence of the problems of the steel industry on
the caking coal market began few times later. In October
and November of 2008, steel production sank about 20 to 30
% in Germany. The impact was now viewable at the caking
coal producers, for example BHP Billiton. The market
for caking coal shrank around 40 percent compared to
spring of 2008. The situation became even worse, as the
caking coal price was unnaturally high in summer due to
production shortages at one of the most importing coal
supplier, Australia. The price on the spot market crashed
form 300 US $ / t to 150 US $/t.
Another indication of steel industry weakness are
the low freight rates from producing countries to China
or Rotterdam. The influence on freight rates was directly
visible as they crashed down to values, that were common
in 2002 /4/. (Picture 1)
Issue 03 | 2009
From global declension towards German mining
industry
The flagging German steel industry of course does have
influence onto German mining industry. The mining industry
stands at the end of series of interplays between sectors of
industry. One simple model is able to show that interplays:
The financial crisis directly hits the German automobile
industry. Enterprises as Daimler-Chrysler or Opel start
purchasing less commodities, i.e. steel. Germany’s largest
steel producer Thyssen Krupp has to reduce production.
Now the global crash hits one key industry of western
world countries. /5/ This has consequences on the mining
industry, for example limestone production or hard coal
mining.
Declension of caking coal price – German hard coal
mining in difficulties
As already said, the caking coal price crashed from
300 US $/t to 150 US $/t, demand sinks. But mostly, the
collapse of the steel production put pressure on “RAG
Aktiengesellschaft”, the German hard coal mining
company. One-fifth of the hard coal production is directly
sold to the steel sector. The power plant section, which
makes 76 % percent of the hard coal usage, sinks as well.
The reason here is a lower power demand from the whole
industry.
21
The captive coking plant, “Prosper” at Bottrop is actually
producing at a capacity of about 70 %, after producing over
the capacity border and above all profitable last summer.
The last mines at the Ruhr-area (West, Prosper Haniel,
Auguste Victoria and Ost), politically in any case disputed,
are mainly producing directly to the stockpile.
The high spot market prices during the last years until
the summer of 2008 and an enormous demand from China
let the German hard coal mining became more and more
stand in better light. Now, the declined prices brings the
German hard coal mining industry back into harsh and
controversial discussions again /6/.
Rheinkalk: The largest limestone producer of
Europe without market
Beside the coal industry the limestone production is hurt
as well by flagging steel industries. Limestone is elementary
in metallurgy for producing iron and steel, because it
reduces the melting point of the slag and is able to bind
silicates. About 30 percent of the produced limestone goes
into that sector /7/. If you focus on the largest limestone
open pit mine, Flandersbach near Wuelfrath, the amounts
of annual production of the past few years and upcoming
years can clearly show the impacts. In 2008, Flandersbach
reached nearly 10 Million tons, which has been an historical
height for the company. The average over the last years
always was around 8 to 9 million tons. Now in 2009, the
amount is estimated at around 6 million tons. Furthermore,
short-time work became necessary actually /8/.
Consequences for the Third World at the
example of diamond mining
Direct impacts of the financial crisis on the
developing countries
When the first information of financial trouble arrived
to the developing countries, many of their governments
showed careless reactions. Reason was a simple
advisement: The developing nations did never invest into
the American estate market, so there would result no
consequences as the crash became reality. However,
consequences commenced, but temporally delayed. The
sunken willingness to invest of the western nations let
markets of the developing countries shrink. While western
nations were in fund to secure the social costs of growing
unemployment the impacts on third world countries were
even harder. A view on the global diamond trading is able
to show that results in special.
Issue 03 | 2009
Diamond market – A backlash for producers and
processing industry
Around 50 % of global diamonds are mined at African
countries. While the other diamond producing countries,
i.e. Canada, Russia or Australia, have the possibilities
of modern and western standard mining technologies,
countries as the Democratic Republic of the Congo do
have diamond properties near the surface, but do not
have means over that technologies. More than a have
million people live from diamond mining at the Congo and
other producing countries like Tanzania, Angola, Sierra
Leone or Liberia. Most of them are working without any
social coverage and clear judicial situations, i.e. in the so
called “informal sector”. Due to shrinking world markets
consequences for these people are striking. Processing
countries like India solve the same problematic.
The most important market for diamonds was and is the
United States. That market is shrinking since September of
2008. In 2009, there will be an estimated market lowering of
60 %. The price for diamonds, that has been on a historical
height in September of 2008, already fell about ten percent.
The end of that development will not appear in 2009 say
experts.
So the diamond prospectors in the African nations do
not have markets anymore. Furthermore, countries as the
D.R. of Congo employ many people in national copper and
cobalt mines. More than 300.000 people got unemployed
already. For a nation that makes 40 % of its national budget
out of taxes of the commodities industry, this equals a
national insolvency /9/.
The declension of the diamond price
In principle, following assumption seems to be correct:
The diamond price should hold steady as the gold prices
does. But while gold became an investment in turbulent
times, diamonds seemed to be luxurious goods, on what
people could abdicate. In addition, the diamond market
is directly linked to the sector of industrial diamonds,
which cope with the same impacts as other industries do
/10/. Picture 2 shows the declined price within the last 12
months. The percentage on the vertical axis indicates the
price development. Reference is an amount of 100 % from
June of 2004. The climax was reached at a value of 131 %
in summer of 2008.
22
Price developments of
metals
Gold – Precious metal with
special status
The gold price lasted solid over
the last months, even climbed
partially. A correlation is obvious:
A global downturn of commodity
prices lets the gold price rise.
The special status of gold can
be made even more visible if you
have a look at other precious
metals. They were hit by the global
downswing in the same way as
the other industrial commodities.
The special status of gold can
be made visible by the so called
“Nickel to gold price ratio”. That index compares the
current price of the ounce of gold and the price of a ton of
nickel. If the ounce price of gold is at 1000 US $ and the ton
price of nickel at 15.000 US $ the “Nickel to gold price ratio”
lasts at the nondimensional account of 15. The nickel price
on the spot market is directly linked to the steel industry
due to its role as a refiner. The “Nickel to gold price ratio”
reached its climax in may of 2007 at an account of 70 and
declined down to the account of 15 in the end of 2008 /4/.
Pic. 3: Development oft the gold price over the alst 12 months
The pictures show two aspects: One the one hand
you can clearly see the solid behavior of gold, on the
other hand the declined nickel prices in fall of 2008. The
account of 15, that was reached last December is valid up
to now. Crashes of the “Nickel to gold price ratio” were
always visible in the past at times of recession as picture 4
emphasizes. (Picture 4).
Pic. 2: Development oft the nickel price over the alst 12 months
Issue 03 | 2009
23
Pic. 4:
Development of „Nickel to gold
price ratio“
Platin Group Metals (PGM)
Most important reason for the declension of the platinum group metals (palladium and rhodium besides platinum) is their
usage in the automobile industry (catalysts). The shrinking market directly led into overplus on the global markets. A rising
is not cognizable, nevertheless the prices are behave solid since the end of 2008 /4/.
The very limited usage of the platinum group metals is the reason that there is no fast rebound. Rhodium is used in
catalysts for 85 %. For the whole PGM there is an amount of 50 % going into the catalyst fabrication. The consequences for
the producing countries, especially South Africa and even more drastic Zimbabwe are similar to the diamond producing
countries in central Africa.
Pic. 5:
Development oft the platinum
price over the alst 12 months
Issue 03 | 2009
24
Pic. 6:
Development of “Platinum to
gold price ratio” and
“Palladium to gold price ratio”
PGM Complex prices compared to gold
For the declension of the precious metals of the PGM complex apply the same results as at the nickel price. Both “Platinum
to gold price ratio” and “Palladium to gold price ratio” showed crashes. In case of palladium, the value already crashed in
fall and winter of 2001 and now even declined. Platinum experienced a declension, that was worse than the crash in the
shadow of 9/11 terror attacks. Picutre 6 indicates the price declining /4/.
Industrial commodities
The most important emporium for commodity prices, London Metal Exchange, observed the crash of all industrial
commodities back to prices of the year 2003 in the second half of 2008 /4/. Picture 7 shows the development of the zinc price
in US $ the last ten years. Clearly visible besides the declension starting in summer of 2007 is a constant development up to
2005, when the price started to grow extra-ordinary.
Pic. 7:
Development oft the zinc price
over the last 10 years
Issue 03 | 2009
25
Pic. 8:
Development oft the copper
price over the last 15 years
Looking at the copper prices over the last 15 years makes obvious, that the sharp rising starting in 2005 only could occur
by speculations, i.e. runs on the deposits. Also, the metal exchanges at London, Shanghai and New York incorporated
shortages on the global markets.
Largest consumer of copper was and is the People’s Republic of China. The crash of key industries as the construction
sector hit China as well. Therefore, the global copper price is linked to the Chinese exporting rates.
Many experts consider that copper has the best chances to get stabile in pricing already in 2010. The graphic of the
copper price development over the last six months indicates that fact.
Pic. 9:
Development oft the copper
price over the last 6 months
Issue 03 | 2009
26
The role of China
Canada’s oil sands
The energy demand of China over the last years has
been the main reason for global growing on commodities
demand. Mathematical models deliver the coherences
of economic implications of the European Union and the
United States relative to the rates of growth in China. They
consider that a retardation of the commodity demand in
Western Europe and North America of one percent leads
to a declension of seven percent at China’s export rates.
Regarding the expectation, that the commodity demand
in 2009 will fall about 3 percent in the G7-nations and the
Chinese export rates climbs at 10 percent in comparison to
2007, a declension of around 20 % considering the export
is to expect.
Generally spoken it is remarkable, that the current crisis
hits China harder than the Asian economic crisis 10 years
ago. Although the demand for commodities will rise in 2009
and 2010, but less than the last years, namely 7 % this year
and 6,6 % in 2010. Compared to other countries and regions,
the rates would be extra-ordinary high, for example in
Europe, but for the huge imports of commodities of China
these rates are indices for a crisis /4/.
The Canadian oil sands projects deliver exemplarily how
branches of commodity producing can be hit by unsteady
price developments. That affects the temporary boom of
Canadian oil sand industry that started about five years
ago as well as the problems that arrived nowadays since
the oil price turned down.
Regarding picture 10, it becomes visible that the oil
price between 2001 and 2008 was extremely rising,
especially since January of 2007. The low level in autumn
of 2001, i.e. in the periphery of the N.Y. terror attacks, made
clear, that a constant level that low can not be normal in
the future. Constant rising together with predictions of
growing demand made oil sand mining became more and
more profitable. The crash of the crude oil price in autumn
of 2008 to a level of 40 US $ per barrel was that striking,
that the value now was lower than it would have been by
standard rising values. Picture 11 now shows, that now
quiet a stabile and slow rising oil price is to expect until
2010. Price will last around 60 US $ per barrel.
Location of the oil sands boom is the Canadian province
Alberta. Around 1.7 trillion barrel are expected, one third
of the global oil sands reserves. Oil sand in this region is a
conglomeration of 83 % of sand, 10 % bitumen plus water
and clay. The part of bitumen fluctuates between 1 % and 18
% and is the value that makes the profit possible. Generally,
contents of at least 6 % of bitumen lead to profit.
Pic. 10:
Development of the cruide
oil price between
2001 and 2008
Issue 03 | 2009
Development of the criude oil price between 2001 - 2008 (12. Dec)
27
Pic. 11: Development of the cruide oil price and outlook until end of 2010
Now the expansion plans are showing first signs of
slowdown, a correlation to the declined oil price seems
to be visible. According to the president of the Mining
Association of Canada the oil sand projects are challenged
nowadays in its entirety.
For the Canadian projects exist three starting points,
every one for a different way of mining and processing,
that mark the edges of profitable economics:
•Oil sand projects that need so called upgrader to process
the oil sand after mining require a long-ranging oil price of at
least 100 US $ per barrel.
•Oil sand projects that are mining per steam injection and do
not need upgraders require a long-ranging oil price 70 US $
per barrel.
•Oil sand projects, which export the mined bitumen directly to
refineries in the U.S. (that are able to process the heavy oil)
require a long-ranging oil price of 50 US $ per barrel.
Compared to figure 11, that “break-even-points” make
clear that today only the third way, i.e. the export of
unprocessed bitumen is profitable. It also makes clear, that
the planed upgrader projects are deferred for the present
or will be delayed. All upgrader projects were close to
realization by nearly all global petrol concerns.
Besides the fallen oil price a result of the financial crisis
became important. Canadian oil sand projects are inherently
more capital-intensive than conventional mining projects.
Issue 03 | 2009
Some of them are afflicted with binary billion values. That
leads to negative results during the financial crisis. The
consulting company McKinsey comes to the conclusion,
that Alberta’s bitumen has a cost disadvantage of 15 US $
per barrel on the important US-American market.
As seen above, upgrader projects need oil prices of 100
US $ per barrel. Furthermore there has to be a significant
difference in prices between bitumen and synthetic crude
oil. If Alberta processes crude oil and delivers less crude
oil to its most important consumer, the United States, the
US demand for bitumen grows. That leads to a smaller
price difference, the most important requirement for the
upgrader projects. Instead of that, export of bitumen is
more profitable. However, lots of capital was invested
in upgrader projects, so profitable economic activities
are hardly to realize today. Concerns as Shell and Statoil
delayed plans for new mines by now.
That also has consequences for the region. The absence
of skilled personnel into the summer of 2008 perhaps leads
into thousands of unemployed people in the Athabasca
region /11/ /12/.
28
The failure of the mega-deal
In the direct periphery of the events on the global energy
and commodities market in the second half of 2008, one of
the largest takeovers in history failed. British-Australian
mining company BHP Billiton, largest global mining
company, tried to overtake n°3, also British-Australian
Rio Tinto. The takeover price firstly lay around 140 Billion
US Dollars. If the takeover would become reality, a quasi
monopoly would have lasted as a result. The huge iron ore
production of Rio Tinto together with the very important
role that BHP Billiton plays in hard coal mining would have
let the new concern control one third of the global raw
material for steel production. Therefore the competition
commission of the European Union demanded already in
the forefront that BHP has to give up other commercial
lines in case of realization of the takeover. The reason was
to prohibit a monopoly position.
consumer of commodities reduced import rates clearly.
Excess supply let prices crash, for example the one of
copper. Exploration projects that were profitable at high
prices are delayed up-to-date.
Commences a betterment considering the purchasing
power in the industrial nations, price risings over the
average rates are possible again. The lowering of the
production rates of the OPEC nations as well as the missing
investments in new projects because of lacking exports
and a low oil price can lead into a rising in the medium term
when the economies of the consumer nations become
solid again.
The beginning declension of the commodity prices in
the second half of 2008 firstly led into a declined takeover
price down to 58 Billion US Dollars. Reason was, that BHP
Billiton wanted to pay with own stocks. They had been
fallen already because of the starting global recession.
The final cancellation had the same reasons in principle.
The new and unexpected market conditions and the
economical lowering led into the decision to delay the
takeover /13/ /14/.
Abstract & Outlook
The aftermaths of a global recession and financial
crisis lead into direct consequences on the energy and
commodity world market. The links often are very complex
and nontransparent. Since the year of 2005, commodity
prices were pushed upwards speculatively.
Regarding crashing commodity prices, economic
impacts appear temporally delayed as well for import as
export nations. The interlocking of the events that started
as first global crashes and ends at foreign or German mining
companies is now clearly visible. The lowered propensity
to invest of the western world becomes now, some months
later, noticeable in the Third World countries, whose
economics ground on commodities export. Furthermore,
aftermaths become visible that the global commodities
markets are changing if import rates of Chinese goods
decline in the western world. China as the most important
Issue 03 | 2009
29
bibliography
/1/ /2/
/3/
/4/
/5/
/6/
/7/
/8/
/9/
/10/
/11/
/12/
/13/
/14/
Handelsblatt: Rohstoffpreise fallen ins Bodenlose
www.handelsblatt.com/finanzen/rohstoffe-finanzen/_b2118623
Die Welt: Spekulanten lassen Rohstoffblase platzen
http://www.welt.de/die-welt/article2281070/Spekulanten-lassen-Rohstoffblase-platzen.html
Wirtschaft T-Online: Billige Rohstoffe verschärfen Wirtschaftskrise
http://wirtschaft.t-online.de/c/17/46/44/46/17464446.html
DB Commodities Outlook 2009; Deutsche Bank AG /London
Wirtschaftswoche: Einbruch in der Stahlindustrie
www.wiwo.de/unternehmer-maerkte/einbruch-in-der-stahlindustrie
Handelsblatt: RAG leidet unter Kohlepreisverfall
www.isht.comdirect.de/html/news/actual/main.html?C_Timeframe
Heidelberg Cement
http://www.heidelbergcement.com/de/de/country/produkte/kalk/einsatzbereiche/eisen_stahl.htm
Rheinkalk AG, Werk Flandersbach
Friedel Hütz-Adams: Diamanten – Finanzkrise trifft Förderer und Verarbeiter hart
Handelsblatt: Diamantenmarkt fehlen kaufkräftige Baker
www.handelsblatt.com/finanzen/rohstoffe/diamantenmarkt-fehlen-kaufkraeftige-banker; 2242473
Germany Trade & Invest: Kanadas Ölsandprojektestocken
www.gtai.de/fdb-SE,MKT200811068015,Google.html
DiePresse.com: Ölsand-Industrie tritt auf die Bremse
www.diepresse.com/home/wirtschaft/international/441538
Focus: Finanzkrise lässt historischen Milliardendeal platzen
www.focus.de/finanzen/news/bergbau-finanzkrise-laesst
Börse ARD www.boerse.ard
Moritz Kellner studies
mining at Clausthal University of Technology.
This work was created
last summer as a part of
a seminar at the institute
for Surface Mining and
International
Mining.
The presentation of this
work was held on 18
May 2009.
Issue 03 | 2009
30
Round Table at Hannover Messe 2009:
Climate-Friendly and Energy-Efficient Raw
Material Extraction
Clausthal University of Technology presents “Energy-Efficient Conveyor Technology and
Climate Protection“ study at the ContiTech booth - Panel discussion with experts from
mining, industry and government
Hannover Messe, 2009. Conveyor belt units are
the energy savers and climate protectors in haulage
technology. They consume only a fraction of the energy
required by conventional means of transport and emit
much less CO2. With them greenhouse gas could be cut
by 340 million tonnes in the next thirty years. This is a
conclusion arrived at in the “Energy-Efficient Conveyor
Technology and Climate Protection” study, initiated
under the direction of Dr. Hossein Tudeshki, professor at
Clausthal University of Technology’s Institut für Tagebau
und Internationalen Bergbau [Eng.: Institute of Surface
and International Mining]. At Hannover Messe, Professor
Tudeshki is presenting his study for the first time as part
of a round table event sponsored by ContiTech AG. He
will then discuss the findings with a panel of experts from
industry, mining and government.
Raw materials make the world go round. For years now
the economic coming of age of threshold and developing
countries and the mushrooming of the planet‘s population
have been upping the demand for metalliferous ore,
industrial minerals, fossil energy sources and raw materials
for construction – what one finds, in other words, in virtually
all articles of daily use, in everyday consumables and in
buildings and other structures. A growth in demand at an
average of four percent a year is forecast for the future.
What impact does haulage technology
have on the environment and the global
climate?
The environment and the global climate are, of course,
not unaffected by the corresponding increase in raw
material haulage. That is why the Clausthal University of
Technology took a closer look at the consequences that
the different transport options have on energy consumption
and CO2 emissions. Raw materials are seldom processed
where they are extracted. On average no less than 25%
of the energy required for raw material extraction goes
Issue 03 | 2009
for the internal transport of these solid mineral resources
(currently more than 12.3 billion tonnes a year worldwide)
and the related overburden (approx. 28.84 billion tonnes).
And for mine operators, the question thus posed is: What
are the most effective, the most cost-efficient and the safest
processes – as well as the best from the standpoint of global
climate pro-tection – for transporting raw materials from
where they are extracted to where they are processed?
To answer this question, the study compares conveyor belt
units with special-purpose heavy-duty trucks, the chief
means to date of hauling away what is mined.
The key conclusions: In the next thirty years, 340 million
tonnes of CO2 can be cut by simply making more rigorous
use of conveyors for raw material extraction. What is more,
the study clearly shows that conveyor belts achieve a
much better energy scorecard, requiring only about twenty
percent of the energy needed by heavy-duty trucks. This
translates into a big advantage for both the environment
and industry.
Energy generation during raw material
transport
During the panel discussion, Hans-Jürgen Duensing,
general manager of the ContiTech Conveyor Belt Group
business group, evoked the example of a mine operated
in Jamaica to highlight another point: Conveyor belts not
only consume less energy and reduce CO2 emissions.
They can also generate electric power. At the Jamaican
mine, a RopeCon conveyor unit transports 1,200 tonnes of
bauxite an hour across a distance of 3.4 kilometers and an
altitude difference of 470 meters. The braking force applied
during downhill transport is harnessed to generate electric
energy. In concrete terms this works out to 1,300 kW.
„The RopeCon concept itself is of advantage wherever
high conveying capacity is required across impassable
terrain, wooded areas or wide rivers,” adds Hans-Jürgen
31
Duensing. “In Jamaica we were able to save the whole tree
population by forgoing construction of a road to haul away
the raw materials. The system makes up for the equivalent
of 1,200 truck runs a day and eliminates the corresponding
amount of CO2 and particulate emissions.”
Environmental and climate protection
with conveyor belt systems
It is easy to understand why conveyor belt systems
are a more energy-efficient alternative and less grievous
polluters of CO2 emissions than the heavy-duty trucks
mainly used in mining operations. As batchwise operating
conveyances, heavy-duty trucks do both outward –
loaded – runs and inward – empty – runs. The vehicle’s
considerable deadweight is another key factor. For a truck,
therefore, the ratio of overall mass moved, on the one
hand, and payload, on the other, is around 2.2-2.6 to 1. By
contrast, for a continuously operating conveyance like a
belt system, the ratio is just 1.2 to 1. Simply stated, belts are
much more efficient. A belt system’s conveying resistance
is also much lower than what a heavy truck is up against.
It comes as no surprise, then, that the specific energy
requirement for heavy-duty truck transport works out to
1.09 to 1.17 kW per tonne and kilometer, whereas a belt
system gets by with a mere 0.14 to 0.25 per tonne and
kilometer, i.e. just a fifth of what a truck needs.
Reduced CO2 emissions
But industry and the environment have much to gain from
rigorous use of conveyor belt systems.” According to
the mining expert, though, exploiting this potential would
require that the proportion of belt systems be upped from
thirty percent at present to fifty percent in 2034, and then
held constant at that level. Taking into account the fourpercent annual increase in the demand for raw materials,
belt haulage would increase by three hundred forty-five
percent through 2034 and by another twenty-two percent
through 2039. Should this happen, the specific mass moved
by belt systems would grow from 46.97 billion tonnes and
kilometers a year at present to 254.29 billion tonnes and
kilometers by 2039. In the whole thirty-year forecast period,
CO2 emissions would be cut by over 340 million tonnes as a
result of the expansion in conveyor belt haulage described
here.
Economic benefits
Higher efficiency, a major reduction in CO2 emissions
and in energy consumption, virtually no negative impact
on the natural environment, and the possibility, under ideal
circumstances, of generating electric power as well – these
are a number of the ways conveyor belt units can serve
the environment and, at the same time, provide economic
benefits. A cut in the energy costs incurred would, in effect,
lower the overall expense for raw material extraction.
Following ContiTech AG’s round table discussion, HansJürgen Duensing noted by way of summary: “This is an
aspect that would certainly give mining companies a strong
incentive to greatly step up their use of conveyor belt units
and thus do the environment a big favor.“
Accordingly there are also differences in the amounts of
CO2 greenhouse gases emitted. Worldwide, power stations
emit an average of 0.285 kg of CO2 per kW generated.
0.293 kg per kW is emitted in the combustion of diesel
fuel. “When these values are applied to conveyances in
mining,” notes Professor Tudeshki, “a heavy truck can
be seen to have a specific CO2 emission rate of 0.331 kg
per tonne and kilometer. The corresponding rate for a
belt system is only 0.055 kg per tonne and kilometer. The
specific reduction potential thus comes to 0.276 kg CO2 per
tonne and kilometer.”
What exact conditions must be met to achieve a
reduction in CO2 emissions of 340 million tonnes in the next
thirty years? The amount cite represents, by the way, well
nigh exactly the CO2 equivalent amount that the European
Union pledged itself to achieving under the terms of the
Kyoto Protocol adopted in 1997. Professor Tudeshki makes
one thing clear: “Maximum flexibility is demanded in the
mining of raw materials. This means that conveyor belt
systems will not completely replace heavy-duty trucks.
Issue 03 | 2009
ContiTech Conveyor Technology corporation
Breslauer Straße 14
37154 Northeim | Germany
Tel.: +49 (0) 5551 702 207
Fax: +49 (0) 551 702 504
eMail: transportbandsysteme@cbg.contitech.de
Internet: www.contitech.de/transportbandsysteme
32
ContiTech conveyor belt systems carry the earth’s valuable resources and protects
our planet’s natural richness • Active worldwide • New plant in Brazil • Optimistic look
into the future
The demand for raw materials is growing. Experts
estimate that the worldwide requirement is growing at an
average rate of four percent a year. As a manufacturer of
conveyor technology, ContiTech‘s Conveyor Belt Group
business unit participates in this growth and, accordingly,
views the future quite optimistically. At the same time,
the products developed by the company are climate- and
eco-friendly. “Working with rubber, a material with much
promise for the future, we create technological solutions
for industry and the environment,” explains Hans-Jürgen
Duensing, general manager of the ContiTech Conveyor
Belt Group. Here energy-optimized conveyor belts, which
also reduce CO2 emissions, play just as big a role as does
the generation of energy in downhill transport operations.
In the case of more comprehensive interconnected
systems, ContiTech also cooperates closely with scientific
research centers.
At ContiTech’s booth (A16) in hall 5 at Hannover Messe,
the Clausthal University of Technology, for example, is
presenting a development for acoustically identifying
material. With the enclosed SICON® conveyor belt, ContiTech, moreover, is showing how sensitive goods can be
protected from moisture and contamination while being
conveyed and how spillage and dust emissions can be
prevented.
With sales of €469 million, the Conveyor Belt Group is
The participants at the RoundTable:
•Dipl.-Ing. Ralf to Baben: Head of the Technology Center Mining/HW of RWE Power AG, Frechen
•Hans-Jürgen Duensing: Division Manager ContiTech Conveyor Belt Group, Northeim
•Dr. Heinrich Sönksen: Head of underground-mininig technique K + S Aktiengesellschaft, Kassel
•Prof. Dr.-Ing. habil Hossein Tudeshki: Head of Institute of Surface and International Mining, Clausthal
University of Technology
Moderator:
•Andreas Lorek: Free TV and Radio Journalist
Issue 03 | 2009
33
the world‘s leading conveyor belt manufacturer and the
second largest of ContiTech AG’s sev-en business groups.
With a current workforce of around 3,000, the company
manufactures belts for mining as well as special conveyor
belts for the most diverse transport tasks in machine and
plant engineering. The product portfolio encompasses
several hundred offerings. Aside from its standard range,
the company also develops individually customized
solutions. It is thus always in a position to supply exactly
the right products to satisfy cus-tomer requirements.
Active throughout the world –
now in Brazil as well
Conveyor Belt Group products are in use all around the
globe. Because of the products’ enormous volume and
weight, transporting conveyor belts to where they are to
be used can be a very involved and expensive undertaking. For this reason the Conveyor Belt Group produces in
the markets in which its customers work – in Mexico, Chile
and China, in India, Greece and Serbia, and in Hungary,
Slovakia and Germany.
Before the year is out the Conveyor Belt Group will
be stepping up its activi-ties in South America, where a
new plant will be opened in Ponta Grossa in southeastern
Brazil. At a 5,000 m² facility there, a workforce of ninety
will be producing textile and steel cord belts. Brazil is the
major South American market for conveyor belt systems,
accounting for roughly fifty percent. “Thanks to the new
plant and the existing one in Chile, we are well poised to
establish a firm foothold on the South American market.
We shall greatly expand our market position,” explains
Hans-Jürgen Duensing the business unit’s strategy.
Eco-friendly and energy-efficient raw
material extraction
Conveyor belt systems are the energy savers and climate
protectors in raw material extraction. This is the conclusion
that the „Efficient Conveyor Technology and Climate
Protection“ study comes to. It will be presented at a panel
discussion at the ContiTech AG booth in hall 5 at the Messe.
The study was the brainchild of Dr. Hossein Tudeshki,
professor at Clausthal University of Technology’s Institute
of Surface and International Mining. It demonstrates how
conveyor belts make much more efficient use of energy
and emit considerably less CO2 than the heavy-duty trucks
usually used in mining. What is more, conveyor belt units
are also capable of generating current. “Wherever raw
materials are transported downhill, braking energy can
Issue 03 | 2009
be transformed into electrical energy – as in the case of
a streetcar or a hybrid vehicle,” explains Hans-Jürgen
Duensing.
Energy generation in the case of raw
material transport
In Jamaica, for example, a RopeCon® conveyor belt
is in operation hauling more than 1,200 tonnes of bauxite
an hour over a distance of 3.4 kilometer and an altitude
of 470 meters. The transformation of braking force into
electric energy yields 1,300 kW. The current is fed into
the local power grid. Functioning in much the same way
as a ropeway, for which reason it requires only a few
tower stations, the RopeCon® system is of major benefit
for the environment. “In Jamaica we were able to save
the tree population by forgoing construction of a road
for the transport of raw materials,” reports Hans-Jürgen
Duensing. The system makes up for the equivalent of 1,200
truck runs a day and eliminates the corresponding amount
of CO2 and particulate emissions.
“For us it is not only a matter of transporting the world’s
resources but also of protecting our planet’s environment,”
emphasizes Duensing. “Responsibility for the environment
also guides us in the development, manufacture and
transport of our products.“
Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki
studied from 1977 to 1980 at the Mining College of Shahrud (Iran); following several years
of work in the mining industry, he completed
his mining study at the RWTH Aachen in 1989.
Since 1992 he was Chief Engineer at the Institute for Surface Mining (Bergbaukunde III) of
the RWTH Aachen, mainly active in the field of
open cast mining and drilling technique. He did
his doctor degree in 1993 and qualified as a university lecture in
1997. In 1998 the Venia Legendi was awarded to him be the RWTH
Aachen for the field “Rock and Earth Open Pit Mining”. In November 2001 he was appointed as Professor for Surface Mining and
International Mining at Clausthal University of Technology.
He already has over 25 years of experience in the field of project
planning and cost-benefit analysis within the frame of various mine
planning projects. The international tasks rendered by him mount
up to more than 300 international raw material-related projects.
tudeshki@tu-clausthal.de
www.bergbau.tu-clausthal.de
34
ContiTech Conveyor Belt Group | Phone +49 5551 702-207
transportbandsysteme@cbg.contitech.de
ADVERTISEMENT
Issue 03 | 2009
35
Thyssen Krupp Fördertechnik (conveyor technique):
Fully Mobile Crawler-Mounted Crushing
Plant for Large Open-Pit Mines
Introduction
As part of a priority research and development
project launched in 2006, engineers at Thyssen-Krupp
Fördertechnik developed the concept for a fully mobile
crushing plant to enhance mining operations in large open
pit mines (Fig. 1). The key innovations lie with the unique
functionality and mobility of the machine which allow it to
work along side the mining shovel at the mine face. The
crushing plant feeds a dedicated belt conveyor system and
the need for large haul trucks is eliminated.
The use of continuous mining technology not only
brings economic benefits in the form of higher production
performance with reduced capital cost (particularly when
compared to a discontinuous
system using trucks), it is
also more environmentally
friendly because it reduces
CO2 emissions. In a crosssegment cooperation with
ThyssenKrupp
Steel,
the
developers investigated the
use of high strength steel and
utilized liners with special wear
properties to provide adequate
protection from the abrasive
nature of the ore.
to a conveyable size.
The crushing plants can be stationary (mounted on
concrete foundations) or semi-mobile style, supported on
steel pontoon feet. As the mining operation progresses, the
semi-mobile crushing plants can be relocated within the
mine using multi-wheeled trailers or transport crawlers.
Typically, shovels load the ROM ore on to heavy-duty haul
trucks that transport the ore to the crushing plant and
relocating the crushing plant as the mine expands reduces
the distance that the large trucks need to haul the ore from
the working face.
The objective of the new development was to totally
eliminate the need for trucks by having the shovel feed
the ROM ore directly to a continuous material handling
Background
The use of continuous mining
systems is primarily dependent
on the type and properties
of the ore being mined. In
the case of light and loose
earth, bucket wheel excavator
technology, combined with a
system of conveyors, offers
the advantages of a continuous
mining system. In order to take
advantage of continuous mining
in harder ore, such as minerals
and hard coal, crushers are
required to reduce the ROM ore
Issue 03 | 2009
Fig. 1:
Fully mobile crushing plant for an open pit coal mine in China
36
system. The crushing plant would
need to be fully mobile such that
it could follow the movements
of the shovel, would have to be
designed to suit the movement
of the shovel boom and bucket
and would have to match the
operating capacity of the shovel.
To achieve this result,
ThyssenKrupp developed a
fully mobile crawler-mounted
crushing plant which allows for
continuous material handling
while providing an economical
solution not yet realized in a high
capacity mine.
Fig. 2:
Feed hopper and skirtboard lined
with XAR®400 wear
resistant plates
Cross-segment
improvements in
material use
Possible
changes
and
improvements to the fully
mobile open-pit mining system
were investigated at an early
stage in the priority project and
various products produced
by ThyssenKrupp Steel were
reviewed and analyzed. A
common approach to reducing
the construction weight of the
supporting structural steel work
is to use higher strength steel. To
optimize the heavy components,
it was found that further benefits
could be realized by utilizing
special alloy fine grain structural
steels.
The know-how possessed by ThyssenKrupp Steel, along
with valuable feedback from the employees at ThyssenKrupp
Marine Systems, resulted in employing structural steel in
ways that could improve those components not governed
by fatigue, such as the large crawler assemblies.
The demand for abrasion resistant wear materials
increases with highly abrasive ore. There is a definite benefit
to employ wear resistant steel where load bearing members
must be protected against abrasion caused by continuous
direct contact with the conveyed materials. In a fully mobile
crushing system, typical high wear areas are the hopper,
chutes and feeder skirtboard. For the referenced facility
Issue 03 | 2009
in China, the customer was convinced by the advantages
offered by wear-resistant XAR®400, a special purpose
structural steel manufactured by ThyssenKrupp Steel
(Fig. 2). When working with hard rock, XAR®400 offers two
to three times the expected life compared to conventional
steel.
Customer benefits
High level of system availability
Conventional shovel / truck operations in open-pit
mines leads to loss of efficiency due to the discontinuous
transportation of the ore because the shovel needs to wait
37
Fig. 3: System chain shovel – fully mobile crushing plant – mobile transfer conveyor – bench conveyor
for the loaded truck to leave and for the empty truck to spot
itself beside the shovel. Depending on the number of trucks
available, the shovel waiting time can be a few minutes
or more per truck. In contrast, the fully mobile crusher is
always positioned next to the shovel meaning that shovel
operation is not interrupted. Ideally, the crushing plant is
as mobile as the shovel such that neither has to wait for
each other as they advance along the working face.
The crusher comminutes the ore to a conveyable size
and discharges to a system of shiftable and fixed mine
conveyors. To increase the flexibility of the system a short
mobile transfer conveyor can be added to the system (Fig.
3).
In most cases, existing cable shovels or hydraulic
excavators can be used if a mobile crushing plant replaces
the truck fleet. The hopper height and geometry is similar
to the truck box so the shovel operation is similar if loading
trucks or the mobile crushing plant.
Lower operating costs
A mine based on truck haulage requires a large
number of drivers and support staff while a continuous
style operation allows customers to reduce personnel
without affecting production output as only 3 to 4 workers
are required per shift to operate and control a crusher /
conveyor system. In addition to saving wages and wage
related costs, customers can reduce their safety related
costs as well. One of the hidden benefits of the continuous
system is the fact
that the scarcity of tires for the large haul trucks
becomes a no issue. Further, it is common for large mines
to utilize trucks from several manufacturers and the
expense involved in stocking duplicate spare parts can be
considerable while the spare parts inventory for a crusher
/ conveyor system can be tailored to meet the clients exact
needs.
Environmental considerations
Fully mobile crushing plants with conveyors operate
exclusively with electrical power which leads to the overall
CO2 balance favoring a continuous mining system over the
diesel-powered haul trucks, as illustrated in the following
Issue 03 | 2009
examples.
Thanks to the overall saving of a truck operation, savings
of the large truck tires is another benefit. Compared to
the rubber necessary for belt systems, for comparable
transport systems the rubber is reduced by up to 95 %.
Use of a continuous system
In many cases, the replacement of a truck transport
system with an innovative fully mobile crushing system
forces customers to think of other technology that they can
use to make their systems more efficient. ThyssenKrupp
Fördertechnik has a broad range of products for such
needs, extending from long overland conveyor systems,
stockyard equipment, ore process plants, train loading and
unloading systems as well as port facilities.
Long life expectancy extending in some cases to
several decades
A characteristic feature of continuous open-pit mining
technology is the long life expectancy. The large number
of such examples includes the in-pit crushing system
at the Morenci open-pit copper mine in the USA which
commenced operations in the late 1980’s. Another example
is offered by the open-pit mining facilities and equipment
employed by RWE in the Rheinish lignite fields.
After Sales Service
The expected long life noted above yields a positive
image and provides the potential to create long-term
customer loyalty with regards to repeat business and after
sales service.
Cost savings for customers
Efficient use of capital
Due to the high system availability previously mentioned,
a continuous system directly contributes to the efficient use
of invested capital. Associated with this is an increase in
the capacity utilization of the shovel or hydraulic excavator
and the downstream process equipment.
38
Reduction of operating costs
Because fewer employees are needed, ongoing operating costs are reduced not only as a result of lower personnel
costs, but also with regard to safety. The ratio of each ton of extracted mineral to applied cost is optimized through the
decreased cost of wear parts, the standardization of spare parts, and, above all, the elimination of truck transport and the
associated significant reduction in diesel and tire costs.
Fully mobile crushers can attain hourly output rates that could otherwise only be achieved with a large number of large
mining trucks. These trucks have useful payloads of between 140t and 350t and the tires need to be replaced, on average,
once per year. Depending on the size of the truck, a set of six tires currently costs between € 90,000 and € 300,000 and
delivery can take up to two years.
Innovation and degree of implementation of fully mobile crushing plants from
TK Fördertechnik
The high degree of innovation is characterized particularly by the following:
The primary features are the plant’s degrees of freedom in combination with a single slewing discharge conveyor as well
as the arrangement of the supporting structure. The large machine is supported on the two crawlers without the need for
additional supports, thus providing for a “true” fully mobile crushing plant.
In the fall of 2007, the first fully mobile crushing system commenced operation at the YiminHe open-pit mine in China.
The crushing plant processes ROM coal at a rate of 3,500t/h. Fig. 4 shows the crushing plant while being relocated from the
assembly area to the mine face while the continuous conveyor system is visible in the background.
Fig. 4: Reference plant in China on its way to its operating site
Issue 03 | 2009
39
Fig. 5:
Winter operation in temperatures
down to -48° C
Once commissioned, the fully mobile system was able to demonstrate in harsh winter conditions – in Inner
Mongolia down to -48° Celsius – that with optimum operation of all system components, the required production
rate is met. Heating plates installed at the receiving hopper guarantee the trouble-free discharge of the coal from
the hopper by the apron feeder (Fig. 5).
Another plant will be supplied by Krupp Canada, a subsidiary of ThyssenKrupp Fördertechnik, in the near future and
will go into operation as the first fully mobile crushing plant operating in the oil sand mines of Northern Canada.
Recently, the company has signed a contract with another Chinese customer, in this case for the supply of four
fully mobile crushing systems, three for handling overburden at an hourly nominal capacity of 6,000 tons. Figure
6 shows the existing open pit coal mine preparing for the future conveyor technology with fully mobile crushing
plants.
Fig. 6:
Open pit coal mine Baiyinhua – In preparation for conveyor technology
Issue 03 | 2009
40
Worldwide market potential
Summary
The continuous crushing system has worldwide market
potential particularly in the area of mining for coal and oil
sand. Not least the economic boom of China and India is
resulting in a rising coal demand in the Asian-Oceanic
region.
The fully mobile concept can conceivably be utilized in
all mining operations where a shovel can excavate the ore
directly at the face, with our without blasting.
For large open pit ore mines, which on account of
the deposit characteristics mainly extend downwards,
potential applications are currently being examined.
Compared to coal and oil sand mines, which typically have
relatively wide benches, the planning and realization of a
fully mobile concept in an iron ore mine is com-plicated
by the chiefly vertical alignment of the deposits. The fully
mobile system, however, promises considerable savings
in capital and operating costs and it is very likely that a
solution can be realized.
The newly developed concept of a fully mobile crawlermounted crushing plant has already proven successful in
worldwide surface mining.
The innovative feature of this new concept is the facility
for moving the crusher during operation, guaranteeing
flexibility and mobility. In combination with a continuously
operated conveyor, the entire truck transport that would
otherwise be necessary is eliminated.
A first reference plant has been successfully operating
now for almost one year in China, working at full production
rate since the first day. A second plant is soon set to go
into operation at a Canadian oil sand producer.
In addition to the cost savings to the customer, the fully
mobile crushing system has huge potential for reducing
operations related CO2 emissions providing a greener
footprint.
Environmental Contribution of the CO2
Reduction
Accompanying the development of the fully mobile
concept, potential CO2 emission savings were examined
based on the use of a fully mobile crushing system
compared to conventional shovel truck operation. The
result was CO2 reductions of up to 100,000 t per year. Key
factors contributing to CO2 reduction are lower transport
distances, lowering of the masses and rolling resistances
as well as the utilization of electric energy.
As an example, in China a fully mobile crushing system
with associated conveyors replaced about 26 large haul
trucks. The mining trucks consumed about 190 liters of
diesel for every hour of operation. Considering that annual
production remains constant and factoring in the higher
availability of the continuous system, the diesel fuel savings
amounted to 22 million liters per year leading to a favorable
carbon footprint for the continuous system.
Another environmental consideration is the savings
in rubber that can be achieved. In the scenario just
described, the expected life of the conveyor belt is 8 years
and, comparing this to the tire needs of the 26 trucks over
the same time period, a savings of 400 t of tire rubber could
be realized.
Issue 03 | 2009
ThyssenKrupp Fördertechnik corporation
Altendorfer Str. 120
45143 Essen | Germany
Tel.: +49 (0) 201 8 28 04
Fax: +49 (0) 201 8 28 45 10
eMail: info@tk-mining.com
Internet: www.tk-mining.com
41
VOLVO CONSTRUCTION EQUIPMENT:
VOLVO FLEET UNDER GROUND - All Good Things
Come From Above
In a genuine logistic work of art a transport chain, consisting of Volvo-construction
machines, spectacularly arrive at the lowest point of Europe.
How can the extraction of a big underground mine
receive new impetus? How can productivity and delivery
rate be increased? Actually the answer is obvious: through
the application of an effective Volvo transport chain.
However, in this case, this is easier said than done. The
reason is that the construction machines we are talking
about – two L110E and four articulated dumpers A25D
(4X4)- cannot just roll into the drift system of the potash
mine and start their work. Rather, all six Volvo-construction
machines have to be taken apart and be lowered piece by
piece into a narrow material pit of only five meters.
Such an enterprise required a lot of know-how, an
extensive planning, and an elaborate logistics. After all,
the re-assembling of the dismantled machines “down”
in the mine was to be done in narrow and difficult
circumstances, including the test-run and test-application.
In addition, numerous modifications were needed to adapt
the Volvo-standard machines to the extreme conditions
in the mining operation. For this reason the experts of
Volvo CE came together with the appointed dealer of
“Baumaschinen Könicke GmbH & Co. KG” and the “K+S
KALI GmbH”, Sigmundshall plant, in order to work out a
very special logistics concept. Furthermore the delivery
of the underground mining fleet meant a rearrangement
of mining and extraction techniques of the mine, which
required further detailed planning.
Issue 03 | 2009
42
The K+S KALI company breaks new grounds with its application of
the Volvo- construction machines in underground mining. The aim is
to give up complicated customized constructions resulting from the
use of wheel loaders and dumpers, and to use well-proven standard
machines of high quality instead.
Among the factory-owned modifications of the Volvo equipment are
a lower driver’s cabs, axial oil cooling, fire extinguishing equipment,
coolers, air filters and air conditioners with higher performances, as
well as other details for underground operation. It has to be taken into
consideration that the equipment has to operate in depths of 1,400 m
and below, and in rock temperatures of 40 to 60 degrees Celsius – and
all this in very dust-laden pit air, in three shifts and for 7 days a week.
The responsible parties hope that the construction machines have
significantly higher extraction- and transport performance than the so
far used 17 tractor shovels, with shovel capacities of only 12 to 17 tons.
Issue 03 | 2009
After all, each one of the four A25D (4x4) has a
payload capacity of 24 tons. This is double the
amount of a tractor shovel.
Being a compact and versatile articulated
dumper, the four-wheeled A25D (4x4) that has a
broad rear wheel track, a 13m3 shovel content
and up to 53 km/h speed, is also suitable for
quarries and other extraction operations.
However, under ground, the speed is limited
to a maximum of 35 km/h. In special cases,
the vehicle is adapted to specific application
profiles like for underground mining; in this
case it was equipped with a low driver’s cab.
The Volvo low-emission motors of the
dumpers efficiently use the fuel and achieve
high engine torques at low number of
revolutions. A board computer controls
the automatic transaxle, so that an exact
adaptation to driving conditions can be done
at any time. Thus fuel savings in the planned
inclination drives with load should be ensured.
A loaded A25D, which weighs up to 44 tons,
cannot exactly be called a slight vehicle.
Actually it is 3.13 meters wide and 8.9 meters
long over its outer edge. Whether it was the
rear end of a wheel loader, or one half of the
split shovel, there was always too little space
available to lower the components, which
were split to a an exactly defined maximum
size, as well as the assemblies of the Volvoconstruction machines. They all had to be
lowered to a depth of 940 meters into the
“Kolenfeld” pit. There was no room for any
bad planning.
The disassembling of six big construction
machines, the “just-in-time” delivery at the
mine, which was according to schedule,
the sequential fitting of all components and
assemblies into the material pit, and lastly
the assembly under narrow and difficult
circumstances under ground, all these require
an extremely precise logistic, which runs like
clockwork.
In collaboration with the plant management
of the Sigmundshall plant, the specialists of
the Volvo-authorized dealer of construction
machines set themselves a tight timeframe:
The disassembly, delivery, the fitting in the
Kohlenfeld pit, the assembly under ground, as
well as the first test-runs were to be completed
within only six weeks.
What appeared to be relatively daring and
delicate, in reality proved to be excellently
planned and optimally prepared: Under the
leadership of Hanno Schoene - in charge of
service and assembly at Koenike – and the
43
underground mining-engineer Dr. Jan Tegmeier
of the Sigmundshall plant, the disassembled
construction machines took shape almost one
kilometer under ground, exactly according to
the timeline.
Why should conventional construction
machines be used in the Sigmundshall plant
instead of the so far used tractor shovels?
“Proven and tested serial machines offer
numerous advantages over small series engine
like tractor shovels. This is not only related to
the availability of spare parts, but also to the
service”, Dr. Tegmeier explains. “We have
found a clear-cut solution with “Baumaschinen
Könicke“, he adds, “our workshop personnel
on the 940 m brine is already running at full
capacity. Therefore we have agreed with
Könicke on a full service program. This includes
an 85% contractually committed availability of
Issue 03 | 2009
Volvo machines. In case you believe this is too
little: under ground an availability of 85% is very
high, Dr. Tegtmeier explains.
However, through the application of wheel
loaders and dumpers the personnel expenses
by no means are doubled. The reason is that
only one driver will operate both the L110E, as
well as an A25D (4x4), alternately. When times
of circulation amount up to 20 minutes, the
waiting time for the drivers will be too long, and
he can also be assigned to a articulated dumper
each. During application, the equipment has to
defy the most difficult circumstances. Most
of all, the extreme temperatures and the high
dust formation can be mentioned. Within the
framework of the full-service program the
service technicians of Baumaschinen Könicke
will attend to all emerging services on site in
the fully equipped main repair shop on the 940
m brine.
The flexibility, with which Volvo CE
altered the machine fleet to the desired
low-height construction deserves special
44
acknowledgement: Through special low-profile driver’s cabs the L110E were “shortened’ from a height of 3.36m to 3.09 m,
the dumpers were even lowered to only 3.05 m. Dr. Tegtmeier is full of praise and says: “This is really not seen everywhere.
According to our knowledge no other manufacturer offers wheel loaders in low-height construction”.
In this connection it is even possible to define some new terms: If someone calls these wheel loaders and dumpers
construction machines, he does not really get the point. In fact, these modified specialists that are applied around the clock
are no construction machines any more. They can therefore safely be called high-performance underground construction
machines.
How did the salt get under the earth?
Whoever drives through the landscape west of Hannover, who might want to visit the beautiful lake, the
“Steinhuder Meer”, can hardly imagine that the enormous salt dome “Bokeloh” is located up to 3.5 km
under this landscape and extends itself in a length of twelve kilometers and a width of 1.4 km. The question
that arises is: How could these unimaginable salt masses get under the earth? The conditions under which
this salt was formed, have to date not been definitely clarified. Besides other scientific theories the socalled BARREN theory is believed to be the most likely. 250 million years ago, in the coal-mine-stone age
(ZECHSTEINZEIT), central Europe was mainly covered by a marginal sea. Shallow straits – called BARRENseparated the inland sea from the open ocean. In those times a desert-like climate prevailed, even in our
latitudes. Due to the strong solar radiation, the water of the inland sea evaporated like in a giant pan.
As a result the salt content of the water was increased, until the solute minerals crystallized and formed
potassic layers.
Thus several hundreds of meters of huge sedimentations were formed; they were covered by waterimpermeable layers during the further geological development and therefore protected from being dissolved
again. Therefore the raw material from the salt dome is counted a natural product, which was created by
the heat of the sun from pure sea water.
At the lowest point of Europe
The potash and magnesium products of the K+S KALI GmbH are being exported globally and are mainly used
in agriculture and the industry, either for the production of fertilizers or in chemistry. The K+S group, to which the
Sigmundshall plant belongs, globally belongs to the top flight of the suppliers of special and standard fertilizers,
plant protection/-care and salt products. In the global potash production scale of 2006, the K+S group occupied
the fourth rank with 6.7 million tons and a total share of 13 percent. The enterprise is continuing on the road to success: In the second quarter only, their sales volume increased by eleven percent at 778,6 million Euros, this is 78.5
million Euros more than in the previous year. Above all the global strong demand for potash and nitric fertilizers
has contributed to this result. Visitors, who drive in a conveyor cage into the old-established Sigmundshall mine
(located near Wunstorf close to Hannover), are mostly amazed because they see one of the biggest potash mines
of Europe. Annually 778 employees extract more than 2.8 million tons of raw salt. Between the six main brines that
lie between 350 and 1.400 m, a gigantic transport network, which is already longer than 250 km, has been formed.
On the lower brine you are at the lowest point in Europe: The walls of the mine hall emit temperatures of up to 60
degrees Celsius, a fact that makes extreme demands on both man and machine. The reason for this unusual heat
for this depth is the salt dome, which has set itself vertically in the past. Since salt is a good heat conductor, the
high temperatures of the interior of the earth descend into the mine and as such into the mine openings.
Salt has been extracted for more than 100 years in the Sigmundshall plant. The first pit drilling was done in 1898,
extraction started from 1905. The value and the economic worth of the potassium salt were only recognized mid of
the 19th century. The chemist Justus von Liebig discovered the worth of the carelessly stashed away potassium
salt as fertilizer for the agriculture. At that time, the booming expansion of the potash mining promised lucrative
profits not only to the mine operators, but also opened a welcome source of income. The dimensions which the
mine has to deal with can be shown alone by the ventilation: In the widely ramified route system the amount of
22.000 m3 fresh air is delivered. This air supplies and cools the workplaces of 422 men under ground.
Issue 03 | 2009
45
Volvo-construction machines in a
coil
The new Volvo fleet is to work in a coil, which
is to be driven into further depths. The 1,800 meter
long coil, in which the dumpers carry their load
on an inclination of 16 percent, leads them to one
third through useful material and to two thirds
through rock salt. In increasing depths, separate
intermediate levels are dirft in useful material, as
five to seven meter wide roads, up to a length of
800 meters and tangentially continuative from the
coil. It is there that the two L110E and A25D (4x4)
are loaded. Here considerably higher extraction
and production performances can be expected.
The so far used tractor shovels, which are difficult
to maneuver, are inefficient for transport distances
of over 400 m. Due to the fact that the visibility
conditions of the tractor shovels are neither ideal
over the shovel nor the engine hood, in the future
the drivers will be in a much better position to
work better, more secure and more speedy. Due
to its compact design the A25D (4x4) has a curve
inside radius of only 3.2 meters, despite its high
payload. This is ideal to cruise the seven meters
wide gallery of the coil.
It is important to note the unique characteristic
of the underground version of the A25D (4x4): It
can always cruise the coil forward, therefore the
driver has an optimal sight. The articulated dumper
has a patented reversing device, which has been
developed by the Volvo engineers, and with which
it can turn 180 degrees in a gallery width of 9.5
meters in only 25 seconds.
Through a supported traverse that can be
hydraulically lowered, the empty or even loaded
rear end can be lifted. In case the articulated joint
is activated with blocked front wheels, the rear end
rolls over on two wheels which are located under
the supporting traverse, to the maximum possible
kink angle of the frame, making it possible to turnover in the narrowest space.
Further advantages of the Volvo-dumper:
With increasing length of galleries the time of
circulation of the dumper can more than double
and thus halve the extraction performance. Then
more articulated dumpers have to be used, and
care has to be taken that they come across each
other without colliding, therefore they have to
ensure optimal view for the driver. Furthermore
the dumpers have to fit into the curved roads of
the coils, together with the vital air tubes (big,
long, flexible hoses for ventilation). Furthermore
the rims should not be too high, so that there is
Issue 03 | 2009
46
enough room for the wheel loaders under the stick-ridge for quick loading. And lastly the shovel should also
not be too long, because otherwise it would use up too much space over the underground crusher plant while
tilting.
Shift in Direction in 25 Seconds!
Thanks to a patented turnover-device, the A25D (4x4), it can turn 180 degrees in less than
half a minute and in a width of only 9.5 meters. Only a width of 9.5 meters is required,
so that the A25D (4x4) turns 180 degrees in a three-step maneuver. The turning wheels
are operated hydraulically from the driver’s cab and lift the empty loading unit in way
that the steering hydraulic can swing the loading unit for 90 degrees.
On 17 Juli 2006, Walter
Michels, the Volvo CE Europe
Company, met for an initial
conversation with Dr. Jan
Tegtmeier from the K+S KALI
Company. Shortly after he visited
the Sigmundshall plant, together
with Erich Kribs, Volvo CE Europe
GmbH, and Dirk Rinne (area
manager Nord Baumaschinen
Könicke), in order to get a first
hand impression of the local
circumstances. The aim was to
exactly determine the passage
height and width, as well as to
consider the entire routing and
the extreme temperatures deep
inside the earth for their project
planning. Is the driver’s cab of
a conventional Volvo-dumper
of type A25D low enough?
Issue 03 | 2009
47
Will the entire electronics
bear up to the aggressive
surroundings? Is it technically
possible at all, to cope with
the standard equipment of
Volvo? These were only some
of the many questions, which
needed to be answered. Erich
Kribs prepared a drawing, in
order to determine the exact
special circumstances. Walter
Michels,
Hanno
Schöne
(Könicke) and Scelder Clas
Schwarze (Könicke) visited the
Swedish Volvo-plant in Braas,
in order to monitor the taking
apart of the modified dumper
1. Zum Wendeplatz vorfahren,
mit Zugeinheit bis zum vollen
Lenkeinschlag
schwenken
und die Bremse eingedrückt
halten.
2. Ladeeinheit anheben und
maximal 90 Grad einschlagen.
3. Ladeeinheit absenken und
vom Wendeplatz aus zurücksetzen.
in separate parts and arrange
for the consecutive transport
to Germany to Baumaschinen
Könicke. The modified dumper
had a heightened and elongated
shovel (15.5 m³).
The four articulated A25D,
whose maximum speed was
reduced to the 35 km/h, which
is prescribed under ground, all
have special Goodyear tires.
The motors of the dumpers
were also specifically certified
for Erich Kribs. The two A25D,
which are being used in the
roadheader (WAV), possess a
turning device. The other two,
Issue 03 | 2009
48
which are en route in the coil,
do not need this.
“It was clear after the first
conversations and the visit
to the pit that planning and
implementing this project
would be a huge challenge.
But through the intensive
cooperation of all involved
parties and the well thoughout logistic we managed to
bring the slightly modified
construction machines to the
desired location and prepare
them for the challenging
application.“ Walter Michels,
Sales Engineer Hauler &
Loader Business Line.
“With this unique project of
K+S KALI Company, the Vovo
CE, the Volvo certified dealer
Könicke
Baumaschinen,
as well the responsible
staff of K+S have entered
completely new grounds. This
big challenge could only be
met with a constructive and
highly efficient cooperation
between the Volvo-plants, the
Volvo CE Europe GmbH, the
Könicke Baumaschinen GmbH
and K+S“ Erich Kribs, Sales
Engineer Volvo-Radlader.
Issue 03 | 2009
49
by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki | Dipl.-Ing. Tao Xu
Surface Mining and International Mining | TU Clausthal | Germany
Introduction
Oversized rocks, which emerge during mining of mineral
raw material, are called boulders. The geometrical size and
frequency of occurrence of boulders in excavated material
are determined by two main factors the evolutionary
history of the mountain on one hand, and the technology of
extraction on the other.
Boulders are usually found in accumulations of loose
rocks, which have sedimented in a relatively short distance
from the previously weathered block of hard stone. Such
circumstances are encountered in glacial and fluviatile
sediments. A further frequent manifestation is the deposits
of dumpings in slopes and mountains.
In areas near to the surface of hard rock formations,
boulders that are formed through weathering appear; they
have volumes of up to several cubic meters. In deeper
mountain zones, which are less affected by weathering,
tectonically-related slicks in form of disturbances and clefts,
as well as stratigraphically related inhomogenities assume
a major role in the formation of boulders. Furthermore the
type and quality of the blasting technique in open cast
mining has a significant influence on the number and size
of emerging boulders.
Boulders reduce the performance of loading equipment,
due to low filling of the shovel. In extreme cases boulders are
too big for the shovel. In the latter case a time-consuming
sorting of the rock pile needs to be done. Consecutively
the separated boulders need to be crushed up separately.
Big, loadable rocks can lead to damage of the loading
area/shovel during loading of the transport vehicle. At the
primary crusher, boulders bring about a reduction of the
throughput and can even lead to the complete obstruction
of the plant.
It is for this reason that extraction businesses strive
to avoid or at least minimize occurrence of boulders.
Nevertheless these blocks more or less emerge in
almost every hard rock opencast mining. Therefore the
boulders that emerge during the loosening process have
to be crushed prior to the loading process. For this further
crushing, methods such as autogeneous crushing, drop
ball, buster or hydraulic breakers, as well as explosives
and boulder busters are applied. In the current document
these methods are introduced, and their advantages and
disadvantages, as well as their areas of application are
compared.
The commonality of all methods is the fact that
boulders initially have to be uncovered and separated.
The secondary crushing is usually done when a sufficient
Issue 03 | 2009
number of boulders accumulate, in order to avoid disturbing
the operations and conducting a concentrated special
operation. Based on the amount of boulders they can be
crushed in-house, or the service can be outsourced.
Methods and Appliances of Boulder
Crushing
Autogeneous Crushing
In autogeneous crushing one boulder is lifted by a loading
device and is dropped on another boulder. Compared to
the following methods this method only frees relatively low
forces, as only gravity, in connection with the net weight of
the material, act as components. In addition, this technique
is limited to boulders that can be lifted with the bucket of
the loading device. Furthermore it cannot be influenced,
which boulder is crushed to which degree.
Drop Ball
Drop balls are often used in quarries for secondary
crushing. In this simple method an iron ball of several
tons weight is lifted by the loading device and dropped on
the boulder that is to be crushed. The impact of the ball
produces stress peaks in the boulder, which spreads with
various speeds and lead to crushing.
The drop ball usually has a weight of 3 to 9 tons, with a
diameter of 1 to 1.3 m. Along the lines of the autogeneous
crushing, in this method potential energy is transformed to
kinetic energy. In case the drop ball is lifted to 3 to 5 m above
the boulder, approximately 90 to 450 kJ potential energy
is accumulated in the ball. In free fall the accumulated
potential energy is transformed into kinetic energy and
upon collision with the boulder, it is released as destruction
energy.
Due to its simple structure, crushing with the free-fall
ball is a particularly low maintenance method and needs
little repair. However, in highly abrasive material there is
a possibility that a pronounced wear-out can occur on
the ball, which then looses weight and at the same time
efficacy, due to the abrasion.
An efficient application of the drop ball can only be
achieved with a face shovel dredger with a clamshell,
since only this type of dredger can grasp the ball and,
what is more important, can vertically drop the ball. Backactor dredgers or wheel loaders have difficulties in loading
50
Pic. 1:
Face shovel dredger with free-fall-ball
the ball, as there is the possibility of inadvertent rolling.
On the other hand, due to the rolling of the ball up to the
cutting edge, there is always a horizontal component with
a resulting bent falling curve, which makes an exact hit
difficult.
In principle there is a danger of an uncontrolled rolling
of the ball after the collision. This leads to the fact that the
loading device cannot perform while standing, but often
has to be moved unproductively.
During the collision of the ball there is the danger of
chipping and flying rock splinters. Therefore the front
screen of the driving cab of the dredger needs to be
equipped with a protective device (grid). Furthermore it
has to be ensured that no other persons are present in the
danger area.
A very import role in bouldering with drop balls is
assumed by the operator, since the efficiency of the stroke
is dependant on the marksmanship of the ball. The same
applies to the stroke frequency, which can reach up to
6-times per minute by experienced operators.
The advantage of applying the drop ball is that no more
technical equipment is needed. Furthermore it is possible
to use idle time of the loading device for bouldering, so that
the method is often a cost-effective alternative.
Hydraulic Breaker
Hydraulic breakers are also often used in boulder jobs.
They are attached as accessory equipment on a suitable
Issue 03 | 2009
support frame (usually backactors) which supplies them
with hydraulic energy. The high pressure oil affects a
pressure reservoir (e.g. a nitrogen accumulator with a
membrane), that in turn abruptly releases the pressure to
the subjacent ram of the air hammer. The oil then flows
back again through the output pipe from the hydraulic
breaker to the support frame.
The energy of the ram of the air hammer is transferred
to the plug tool, the bit, and through that it is transferred to
the material to be crushed. For different material, different
plug tools are used in form of single-point thread chaser,
chipping chisels, or blunt chisels.
The forward motion of the chisel through the socket
is detained by a holding wedge in the lower area of the
hammer. In order to avoid damage to the holding wedges
and the socket, the hammer should not be idly operated,
i.e. without stroke resistance.
The hammer mechanism is usually embedded in a closed,
damped casing, in order to absorb noise and vibration.
This casing is usually wider at the top, since there the
hammer mechanism, the hydraulic control, as well as the
distribution is located, and narrower at the bottom, since
this part is only needed for the sliding of the chisel through
the socket and the lock-axis.
For the operation of a hydraulic breaker it s necessary
on one hand to rightly adjust the hydraulic pressure (in
Bar), and on the other hand the correct adjustment of the
oil flow (in l/min) in the hydraulic system of the support
frame is necessary. Furthermore attention has to be paid to
the oil temperature and the counter pressure on the reflux
51
oil pipe.
Globally
there
are
many
manufacturers of hydraulic breakers.
Both the dimensions, as well as the
areas of application keep increasing.
Meanwhile the large equipment classes
are seen as economical alternatives to
blasting in the explosive-free extraction
of rocks, and as such they are not only
been applied in the secondary crushing,
but also in the primary crushing.
In Bauma 2007, Atlas Copco presented
the 10 ton hydraulic breaker HB 10000,
and as such, after over a decade,
replaced the HB 7000 (7t), which had
been the biggest serial hydraulic
breaker up to that date. The new breaker
requires a minimum excavator weight of
85 t. Envisaged application areas are
direct mining in quarries and the heavy
retreat. The frequency can be regulated
between 250 and 380 hits per minute.
Based on specifications provided by
Atlas Copco, the breaker, which has a
chisel diameter of 240 mm, achieves an
impact of 16 kJ and 760 t respectively.
Attached to a Komatsu PC1250, the new
HB 10000 reached 50% higher excavation
rate in comparison with the HB 7000.
The technical data of the model range is
depicted in the following table:
Pic. 2:
Heavy hydraulic breaker as accessory equipment on a hydraulic excavator
Pic. 3:
Hydraulic breaker at the crushing of boulders in hard rock mining
Issue 03 | 2009
52
Buster
A buster is a tool, with which the stroke impulse is
created by the by the free fall of a weight, which is directed
in a pipe. Currently two different models are offered, which
are explained in the following.
The buster is accessory equipment for backacters,
whose active principle is based on a drop weight, in analogy
to the drop ball. The weight, which can be over 10 tons, is
conducted in free fall on the rock to be crushed in a tube.
Contrary to the drop ball this hit can be directed to an inch,
by the boom of the excavator. The buster is connected to
the hydraulic circuit of the support frame. The redirection
of the falling weight to its initial position is done after the
stroke through a hydraulically operated appliance.
Pic. 4:
Technical data of HB hydraulic breakers of Atlas Copco
HB Hydraulic breakers
HB 2200
HB 2500
HB 3000
HB 4200
HB 5800
Category of the support
frames
t
26-40
29-43
32-50
42-75
55-100
Service weight
kg
2200
2500
3000
4200
5800
Oil flow rate
l/min
140-180
170-220
210-270
250-320
310-390
Operating pressure
bar
160-180
160-180
160-180
160-180
160-180
Number of blows
/min
280-550
280-550
280-540
270-530
280-460
Plug tool
mm
150
155
165
180
200
Thanks to technological developments, much can be
expected from the hydraulic breakers of the heavy range:
•Maximum performance
and highest productivity
Pic. 5:
“Stone- and Steel- Buster“ from Fractum Company
•Robust layout and high
durability
•Optimum Energy conversion and excellent running smoothness
•Consistent impact energy, independent of the oil
supply of the supporting
frame
Issue 03 | 2009
53
The energy which is generated in free fall is conveyed through a icone point to the boulder which is to be crushed. Based
on the type, hardness and size of the boulder differently shaped cone points from steel are available. They are easily to be
exchanged, without having to change the entire drop weight.
Compared to the drop ball, a buster reaches a higher number of strokes of 6 to 20 strokes per minute, according to the
building dimension.
The “stone and steel buster”, which has been developed by the Fractum Company from Switzerland, is specially suited
for the effective crushing of big concrete elements, rock blocks and slags. It is the biggest hammer in the world and can
unleash energy of up to 400 kJ with each stroke.
The stone and steel buster, which has a weight of up to 15 tons, can be attached to almost any commercially available
dredger; however with increasing size of the buster bigger support frames are needed. The assembly is done in one hour
only. The technical data of the series developed by Fractum company can be reviewed in the following table.
Pic. 6:
Technical data of the series
by the Fractum Company
Model
Model 80
Model 100 Model 200 Model 400
Energieniveau [J]
80.000
100.000
200.000
400.000
Gewicht [t]
4,5
5,5
10
14,5
Hydraulik-/Öldruck [bar]
180
180
215
290
Hydraulik/Ölfdurchluss [l/min]
160
160
200
260
Min carrier-stick mount t
23-27
30-35
50-60
65-70
Min carrier-boom mount t
20-23
25-27
35-40
50-60
The “stone and steel buster” is particularly suitable for oversized boulders, since it pass the strokes in a quick sequence
into the rock and as such can create a crack (see picture7).
A second version of the free fall hammers are the so-called crash-crushers of the TERMINATOR-series, which were
developed by the ROCKTEC Ltd. company from New Zealand. Contrary to the stone and steel buster, the free fall weight itself
does not collide with the boulder, but the kinetic energy of the drop weight is conveyed to the rock through a chisel. As such
this technology combines the mode of operation of the free fall hammer with the hydraulic breaker.
The dimensions of the TERMINATOR
series are smaller than the ones from
the „stone and steel buster“. The weight
of the device is only up to 8 tons. They
offer a single stroke energy of up to 100
kJ (RX750). The shock crushers can strike
every three seconds (RX100) and five
seconds (RX750) respectively. Accordingly
even bigger rocks can be crushed within
one minute.
Pic. 7:
Crushing of an approx. 150 t basalt boulder
by a “stone and steel buster 200”
Issue 03 | 2009
54
Pic. 8:
Composition and mode of operation of the
TERMINATOR of ROCKTECH company
Technical data
RX 100
RX 200
RX 300
RX 500
RX 750
13.500
27.500
38.000
62.000
100.000
20
18
15
12
12
[kg]
1.265
2.020
3.345
5.100
8.350
Required pumpage
[l/min]
80
130
130
160
250
Hydraulic operating
pressure
[bar]
125
160
125
160
160
Diameter of the beating
chisel
[mm]
100
125
150
180
195
Total working height of the
Teminator
[mm]
4.360
5.500
6.000
6.370
6.780
Minimum weight of the
dredger (Assembly on the
boom)
[kg]
8000
12000
17.500
30.000
40.000
dredger (Assembly on the
oscillating motion boom)
[kg]
10.000
18.000
22.000
38.000
60.000
wheel loader
[kg]
7.500
15.000
18.000
30.000
40.000
Power of impact per
stroke
[Nm]
Number of strokes per
minute
Weight without support
and quick die change
equipment
Pic. 9:
Technical data of the
TERMINATOR
Issue 03 | 2009
55
Blasting of Boulders
Besides the above-mentioned special technologies,
it is also possible to apply explosives for secondary
crushing. In principle however, blasting of boulders leads
to considerable noise emission and there is the danger of
flying rocks. In order to reduce the danger of flying rocks,
each rock to be crushed has to be measured separately,
so that an exactly adjusted amount of explosives and
positioning can be reached.
Blastings of boulders are divided, based on type of fitting
of the explosive on the rock:
drilled holes. The cartridges to be applied are the same for
both impulse tubes.
•With applied load
•Blasting in a borehole.
In boulder blastings with applied load the
explosive charge is applied flatly on the boulder and ignited.
This type of boulder blasting is quick and easy, however
it has the disadvantage of high noise emission and high
consumption of explosives (low effectiveness).
Compared applied load, in boulder blastings with
borehole, only 30% of the amount of explosive charge
is needed. Here the effectiveness is increased, while at
the same time there is lower noise emission compared to
applied load. The explosive is applied into the previously
drilled bore holes, where the explosive effect unfolds
directly in the boulder. The disadvantage of this method is
that the bore holes usually have to be drilled manually, so
that there are considerable mechanical, temporal, as well
as personal additional expenses.
Theoretically the blasting method has no limitation of
use, since the size and position of the boulder to be blasted,
as well as the type of rock only play a secondary role in
this method. However, the boulder blasting method has
progressively become less important, due to the high cost
of labour, the difficult drilling per hand, the environmental
disturbance and the danger of flying rocks. As a result, the
above-mentioned automated methods are increasingly
used.
a
b
Boulder Buster
Besides the blasting, the „boulder buster“is another
method that works with usage of bore holes. However, in
that case, a so-called hydrodynamic impulse is applied
instead of explosives.
As portrayed in picture 11, the boulder buster is a
portable device. Its function is similar to a shotgun. A
specific cartridge can be loaded into the boulder buster
and ignited. In principle the boulder buster consists of an
impulse tube, a sealing body and an ignition unit, as well as
of an additional safety mat (see picture 11). For transport
and storage, the components of the buster can be packed
in a suitcase. Two different impulse tubes with diameters
of 26 mm and 34 mm can be used, based on the size of the
Issue 03 | 2009
c
56
d
e
Pic. 10:
Boulder blasting: Measurement, drilling, loading, blasting and check-over (Pic. a, b, c, d, e)
Pic. 11:
Boulder Buster and its
schematic design
Issue 03 | 2009
57
a b
c d
e f
g h
Pic. 12:
Steps of procedure of boulder crushing with boulder buster (a – h)
Issue 03 | 2009
58
Picture 12 shows the procedure for the application of
the boulder buster. In order to prepare the boulder to be
crushed, a bore hole is drilled in its middle (a), which is
consecutively filled with water (b). It is then closed with a
cap (c) and the safety mat is added (d). After the insertion
of the loading unit (d) and the attachment of the ignition
unit (e and f), they are ignited. The ignition of the loading
unit can be operated by remote control (g). Compared to
blasting, this method is safer. It is only necessary to secure
the area in a radius of approximately 10 meters.
The energy, which is unleashed through the ignition of
the loading unit, is prevented to be directed to outside, due
to the weight and elasticity of the rubber mat. Instead it
is mostly directed inside the boulder through the medium
water in form of a hydrodynamic impulse and can crush the
boulder. Furthermore the safety mat significantly reduced
noise and flying rocks.
For types of rocks which have high water permeability
or boulders with clifts it is obviously difficult to keep the
water inserted into the bore hole. In order to tackle this
problem, a gel can be used instead of water as a conducting
medium. The types of rocks and their characteristics have
an influence on the required amount of charge. While
the blast wave is better conducted in hard and stable
rock, it can be mostly absorbed in plastic rocks. Here the
application of a multiplyer charge is necessary.
The boulder buster can crush rocks that are bigger than
2 m in diameter, and is therefore an alternative to blasting
methods for boulders. Thanks to its safety there is no need
for a blasting license, and there is almost no danger for
transport and storage. It is for this reason that it can be
applied in versatile ways, in cases where blasting is not
possible or can only be done with high effort. This method
can even be applied in closed rooms and in canalization.
Conclusion and System Comparison
The so-called boulders, i.e. oversized rocks, can be found
in almost every hard rock open cast mining. The boulders
significantly affect all open cast mining processes. It is for
this reason that boulders need to be separately crushed
after the extraction process, and before they are delivered
to consecutive quarry and processing processes. This
article deals with the description of various methods and
appliances to crush boulders. In summary, the following
system characteristics can be put on record:
Drop Ball: The drop ball with a weight of 3 to 9 tons is
being dropped on a boulder by a loading device from a
height of approximately 4 to 5 meters, and crushes the
boulder through the impulse of the clash. This method is
cost-effective and almost maintenance-free, however it
requires a high degree of precision, because the boulder
has to be exactly hit for an effective crushing. With a drop
ball it is possible to achieve 3 to 6 strokes per minute.
Hydraulic breaker: A hydraulic breaker is a hydraulic
accessory equipment for a hydraulic dredger. The support
frame supplies the hammer with hydraulic energy through
high pressure tubes. The technological development of
the hydraulic breakers has lead to very high application
weights of up to 10 tons and high impact energy of up to
16 kJ, as well as to a rate of strokes of several hundreds
per minute. As a result the performance of the devices
has greatly increased and the areas of application vastly
been expanded. A significant advantage of the hydraulic
breakers results from their application possibilities on
operational extraction equipment.
Buster: The working principle of a buster can be compared
Pic. 13:
Dimensions of the crushable boulder with boulder buster
with a directed drop ball. A drop weight of up to 10 t hits
the boulder to be crushed in a tube-like conduct in free fall.
Contrary to the drop ball the stroke can be directed to an
inch. Like the hydraulic breaker, the buster is accessory
equipment, which due to its weight of up to 10 t requires a
hydraulic dredger of a weight of a minimum of 40t. Contrary
to the hydraulic breaker, the hydraulic energy is only
needed to elevate the drop weight, therefore the energy
consumption is significantly lower. The rate of strokes is
comparatively low at up to 7 strokes per minute. Due to the
very high impact energy of up to 100 kJ these devices are
suitable for extremely big and hard boulders.
Boulder blasting: In classical boulder blasting the
explosive is applied on the boulder or is applied in bore
holes which were previously drilled. The blasting method
is universally applicable and almost unbound to application
borders. Disadvantages are the high noise emissions, the
personnel and time expenses and the danger of flying
rocks, which cannot be excluded. Therefore this method is
increasingly loosing importance.
Issue 03 | 2009
59
Boulder Buster: Besides blasting, this technique is
another method that works with bore holes. In this method
the bore hole is filled with water and consecutively a
specific cartridge and boosters are applied with the help of
boulder busters. The energy, which is unleashed through
the ignition of the loading unit, is conducted in form of a
hydrodynamic impulse through the water to the body to be
crushed. Thanks to its safety mat almost no flying rocks
appear in application of this method and the noise is also
reduced. In fact no blasting license is needed for this.
However, the preparation work and drilling of the bore hole
still require a high expenditure of time.
In conclusion the four introduced methods are compared
in a table with the help of significant decision criteria:
Abb. 14: Vergleich der Knäpperverfahren
Drop ball
Hydraulic breaker
Buster
Boulder
Boulder
Buster
Size of boulder
Up to medium
size
Up to very big
big
unlimited
big
Rock hardness
limited
big
big
unlimited
unlimited
Location of the
boulder
Highly limited
Partly limited
limited
Almost
unlimited
Almost
unlimited
Noise emission
low
medium
medium
Very high
low
Vibrationof equipment
Very low
high
low
-
-
Commotion in the
surroundings
none
None up to very
low
none
low
none
Danger of flying
rocks
low
(onky splinters
im suroundings)
low
(onky splinters im
suroundings)
low
(onky splinters
im suroundings)
high
Almost none
Investition
low
high
high
medium
medium
Personnel
medium
medium
medium
medium to
high
mittel bis
hoch
Suport frame required
yes
yes
yes
no
no
Crushing performance
low
high
moderate
Very high
low
Suitability for extraction
nein
yes
no
yes
no
Technical Data
Limitation of use
Environmental
pollution
Costs
bibliography
[1] Road Building International Internetinformation: www.boulderbuster.co.za; 05/2009
[2] TEREX GmbH Internetinformation: www.ok-mining.com; 04/2009
[3] ROCKTEC Ltd. Internetinformation: www.rocktec.co.nz; 04/2009
[4] Atlas Copco Internetinformation: www.atlascopco.com; 04/2009
[5] Fractum GmbH Internetinformation: www.fractum.com; 04/2009
[6] Volvo Internetinformation: www.volvo.com; 04/2009
[7] Atlas Copco Construction Tools GmbH Bautechnik Report Spezial: Einsatzmöglichkeiten in der Gewinnung; 2003
[8] H. Tudeshki; L. Kaup: Terminator- Der Aufprallbrecher für den Steinbruch; in: World of surface mining; 0472005; S.244-248
[9] STBG Steinbruch-Berufsgesnossenschaft Schriftenreihe: Steinbrüche, Kies- und Sandgruben, 1989
Issue 03 | 2009
60
by Dr. Eike von der Linden
JJordan Energy & Mining Ltd (JEML) is developing the oil-shale deposit Al Lajjun in Jordan.
Syncrude from oil-shale will contribute to the global supply of oil supported by a long term oil
price forecast of USD 90/bbl.
The project has gone through a full FS with 80,000 engineering hours and including infill drilling,
trial mining and processing of 500t representative samples in the ATP pilot plant in Calgary. The
expenditures were born by a private placement which raised funds of USD 32m. The project will
be in compliance with environmental thresholds related to carbon emissions, water consumption
and other relevant criteria. The key findings of the bankable FS are:
•based on NI 43.101 certified 2p reserves 29year mine life in the northern Al Lajjun concession
field
•Total oil-shale mined 210m t containing 140-150m extractable barrels
•Barrels per stream day approx 15,800
•Net carbon emission 210 kg CO2/bbl
•Water used (predominantly brackish water) about 0.5 m³/bbl
•70 MW power generated partly for power export
•Engineering and construction 42 months
•Total initial capex before financial costs USD 1,500 million
•Cash unit costs approx. USD 22/bbl, full costs approx. USD 55/bbl
Dependence of global Supply
on unconventional Oil
Serious forecasts on future energy markets
like the example of the Cambridge Energy
Research Associates (CERA) presented
below are predicting the dependence of oil
supply on unconventional oil, i.e. syncrude
from oil-sands and oil-shale. While oilsands have seen already a remarkable
development during the last three decades,
in the first instance in the Athabaska Region
in Canada, the development of an oil-shale
industry is on the threshold of realization.
Pic. 1: Development of unconventional oil
Issue 03 | 2009
61
Oil Price Outlook
In the long term the oil supply costs of newly developed conventional and unconventional oil fields
will have a determining influence on future oil prices superimposing short term effects of supply demand
balances and hedging.
Current 2009 finding and development costs to generate 2p reserves are in the order of USD 23/bbl. This
is before production, processing for transportation and transport. Current full marginal cost of production
reach USD 80/bbl. Average full costs of worldwide new sources of supply are in the order of USD 60-80/bbl.
These data are supporting the following oil price outlook:
Tab. 1: Oil Price Outlook
Year
2008
2009
2010
2011
2012
long term
Brent USD/bbl
98,52
45,00
55,00
80,00
85,00
90,00
WTI USD/bbl
99,65
45,00
55,00
80,00
85,00
90,00
Global Oil-shale Resources
Oil-shale, amongst others, was used during World War II in Germany. Since the 1950-ies oil-shale
mining is the basis of power and syncrude generation in Estonia. Recent pilot and demonstration size
developments on oil-shale are taking place in the US (Colorado, Utah), in Russia, in China and Australia.
In Jordan a number of international companies like Shell, BP, Total, Petrobras, Energia Estonia are
pursuing projects in addition to JEML, which may be farthest advanced in project development.
Tab. 2: Major Oil-shale Resources/ Reserves and Oil-sand Resources by Countries
Issue 03 | 2009
Demonstrated Oilshale
Resources
[Billion bbls]
Proven Oilshale Reserves
[Billion bbls]
USA
1539
560
China
500
Russia
147
2
Australia
145
12
Jordan
102
28
Marocco
100
10
Brazil
80
11
Heavy Oil & Tar
Sands
800
Canada
1700
Venezuela
1300
62
Environmental Aspects
A major criterion for the development and the funding of
unconventional oil projects is environmental compliance
with international and national regulations. While oil-sands
are confronted with high water consumption for pipeline
transportation of r.o.m. sands, for hot or cold water oil
extraction and with discharge of water contaminated with
hydrocarbons, oil-shale processing is mainly confronted
with CO2 emissions.
Carbon Emissions
JJEML retained DMT/TÜV Nord for a study on carbon
emissions and benchmark operations. The independent
consultant was ask to compare the CO2 footprint of “Al
Lajjun net” with other potential oil sources for the supply
of Jordan. Al Lajjun net was derived from “gross” by
deducting offsets for the sale of spent shale to the cement
industry, for mining of rock phosphate underlying the
oilshale without further waste stripping, for the sale of
sulphur to the phosphate industry in Jordan and for the
sale of excess power to the grid.
merely no other GHG (methane, etc.) a full GHG emission
comparison shows even a more favourable picture for Al
Lajjun.
Water Consumption
In addition to carbon emissions the water consumption
of Al Lajjun was benchmarked with comparable sources
of supply.
The retorting process selected for Al Lajjun is the
Alberta-Taciuk-Process (ATP). The scheme of the process
is shown in picture 8. The major component of the retort
is a rotary kiln with an inner pipe. Water is used for
quenching of spent shale for cooling and for the avoidance
of dust emission when the spent shale is disposed on the
dump side of the open pit. For the purpose of quenching,
brackish water can be used which can be extracted from
a water table with salty water.
The total water consumption including cooling water for
oil up-grader and power plant cooling is 0.5 m³/bbl.
As being demonstrated in the following graph, Al Lajjun
produces a net carbon emission of 209 kg CO2/BOE and lies
in a comparable range with alternative sources of supply
for Jordan. Since oil-shale mining and processing emits
Pic. 2: Carbon Footprint JEML and Benchmark Operations
Issue 03 | 2009
63
Environmental Guidlines
Environmental design criteria for the project were
developed based on Jordanian standards, International
Finance Corporation (IFC) Performance Standards and
EHS Guidelines with:
•air emissions that meet Jordanian regulatory requirements
and that has one of the lower emissions rates
The shareholding of JEML subsequent to a private
placement for funding of a full bankable FS is:
•RAB Capital (London) – 28%
•The Sentient Group – 25%
•Founders – 25%%
•JP Morgan – 7%
•Others (each less than 5%) – 15%
•zero water discharge from the site, maximizing water recycle
and reducing makeup water requirements
•noise reduction and attenuation, as required
•set backs and methods of operation to minimize the impact
on local communities and historical sites
Milestone
•re-establishment of local olive groves that exist at the proposed site
A development plan put forward by JEML in its Proposal
to the Jordan Government in April 2006 was divided into
four phases as follows:
•community interface planning, information sessions and
community information centre
•establishment of a research chair at the university of Karak
•consideration and minimization of the impact on traffic in the
area
Jordan Energy & Mining Ltd
•Phase 1: complete conceptual / Pre-Feasibility stu-
dies and framework commercial agreements allowing
JEML to scope and budget a Bankable Feasibility Study (BFS) and raise additional funds either by listing
JEML on the AIM market in London or seek additional
funding through Private equity or other sources of Pre
Initial Public Offering (Pre- IPO) funds.
•Phase 2: Complete a Bankable Feasibility Study (initially July 07 to June 08 but now formally extended to
July 09)
The Company
•Phase 3: Construct an initial Commercial Plant produ-
JEML operates from offices in Tunbridge Wells and
London in the United Kingdom and Amman, Jordan. The
board and senior management of JEML consists of the
following experienced staff:
•Phase 4: Following successful operations of initial
cing ~15,000 BD shale oil (January 2010 to June 2012)
plant construct a full scale commercial plant producing
50-100,000 BD shale oil for +30 years
•Dr. Peter Klaus – non-ex. Chairman
•Mr. Christopher Morgan – Managing Director
•Mr. David Pedley – Finance Director
•Eng. Munter Akroush – Director Jordan Operations
•Mr. Chris Nurse – Legal Advisor/Government Relations
•Dr. Eike von der Linden – Technical Director
•Dr. Peter Cassidy – Non-Executive Director
•Ben McKeown – Alternate Non-Executive Director
Issue 03 | 2009
64
Projekt Al Lajjun
Pic. 3: The complete Al Lajjun project
The Al Lajjun Project Feasibility Study
The Concept Study/ Pre-FS (amongst others with DMT
and Lahmeyer) was prepared during 2007/08 resulting in
encouraging results enabling JEML to raise some $ 32m
by a private placement and initiating a full FS including
infill drilling, trial mining and processing of a 500 t oilshale
sample in the ATP pilot plant in Calgary.
For the FS some 80,000 engineering hours have been
consumed so far with ongoing activities for optimizations.
The FS documentation consists of 11 volumes, 24 binders
for drawings, all together containing some 7000 pages.
The FS has been compiled by using not only in house
JEML staff but also a range of internationally recognised
consultants and contractors, namely:
•Hatch Limited – overall study coordination (Canada)
•UMATAC / ATP Systems - oil shale processing and oil upgrading (Canada)
•Krupp Polysius - engineering and cost estimating of retorts
and support systems (Germany)
•DMT Montan and Marston International – geology, oil shale
reserves and resources, mining and materials handling aspects (Germany and Canada)
•Lahmeyer International – power generation (Germany)
•Citrus Partners – environmental, health, safety and social /
community assessments (UK)
Issue 03 | 2009
65
Concession Area
Pic. 4: map of concession area with map section enlarged
Issue 03 | 2009
66
Pic. 5: detail map of concession area
Resourcen und Reserves
The oil-shale resource and reserve assessment has
been certified by an independent qualified person to be in
compliance with the NI 43.101 of the TSX.
Out of these resources a tonnage of some 210 mt 2p
reserves shall be mined at an average kerogene grade of
11.6%. The waste to shale ratio is 1.3:1.
Issue 03 | 2009
It is noteworthy that the costs for generation of 2p
oil-shale reserves were in the order of USD 0.3/bbl.
For comparison reason the actual 2009 finding costs to
establish new conventional 2p oil reserves are reported to
be USD 23/bbl.
67
Mining
Tab. 3: Oil-shale Resources
Catergory
Million t
Drill hole
spacing
Oil-shale
gemessen
218
0 - 500 m
Oil-shale
indiziert
11
500 - 1000 m
Total
m+i
228
Overburden
300
Mining is a shallow flat lying open pit stripping
operation with a r.o.m. production rate of some
7.5 m t of oil-shale. Both conventional truck and
shovel operation and inpit crushing belt conveying
have been investigated in dependence of the oil
respectively Diesel price.
Processing
The following graphs present the principle
process flow diagram and the plant layout.
Pic. 6: Process Flow Chart
Issue 03 | 2009
68
Pic. 7: Plant schematic
Retorting
The initial commercial capacity of the project is 2 x 500 t/h processed in two parallel trains with an ATP Processor each.
The ATP Processor is a horizontal rotary kiln consisting of four internal zones as shown in the following picture.
Pic. 7: ATP Processor Flow Schematic
Issue 03 | 2009
69
Oil Upgrading
Key findings
JEML intends to start with a production rates with 2 ATP
retorts of 500 TPH capacity each, producing approximately
15,800 BPSD of raw crude shale oil. The different fractions
can be hydro-treated separately under different reactor
conditions of temperature and pressures.
The initial intent of the hydro-processing unit is to
develop a synthetic crude oil (SCO) blend that can be sent
to refinery (Zarqa in Jordan) for processing to finished
products. At some higher capital investment, it is also
possible to go directly for the finished products.
The hydrogen will be produced on the basis of natural
gas delivered by the Egypt-Amman pipeline.
The key findings of the bankable FS are:
Power Generation
Fuel gas with a calorific value of approx. 50% of NG and
excess steam from processing will be used as energy for a
70 MW gas turbine. The internal power requirement is up
to 60 MW. The excess power shall be sold to the grid.
Infrastructure
Al Lajjun is located in a favourable infrastructure close
to the main highway Amman-Aqaba. A connection highway
runs through the concession area to Karak, a city in 15 km
distance with 37,000 inhabitants and a university.
Parallel to the highway Amman-Aqaba runs a high
voltage power line and a gas pipeline importing gas from
Egypt to Amman.
•based on NI 43.101 certified 2p reserves 29year mine life in
the northern Al Lajjun concession field
•Total oil-shale mined 210m t containing 140-150m extractable
barrels
•Barrels per stream day approx 15,800
•Net carbon emission 210 kg CO2/bbl
•Water used (predominantly brackish water) about 0.5 m³/bbl
•70 MW power generated partly for power export
•Engineering and construction 42 months
•Total initial capex before financial costs USD 1,500 million
•Cash unit costs approx. USD 22/bbl, full costs approx.
USD 55/bbl
Sources of Information:
•Bankable FS and internal supporting documents
•DB Ressearch: Commodities Outlook, Jan. 2009
Dr. Eike von der Linden:
Objective:
Senior Executive with engineering and financial background with board level functions in international operating companies
Current positions: Managing Director of Linden Advisory; Director and Member of the Board of Zhaikmunai LP; Director Jordan Energy and Mining Ltd;
Member of the Board GLR Resources, Canada; Mem-
Capex
The initial capital cost is some US$ 1,500 million before
financial costs. The major lump sum turnkey packages
have a total value of up to US$ 775 million. Most of the
supplies can and may be delivered from Germany.
ber of the Board of Schüllermann AG; Independent financial advisor to national and
international companies and financial institutions in the field of natural resources,
utilities and extractive industries
Education:
Technical University of Clausthal (Mining engineering); Technical University of Munich (Economics)
Qualifications:
Dipl.-Ing., Dr.-Ing. ; Bergassessor (Senior Government Mine Supervisor)
Opex
Cash unit opex are in the order of USD 22/ bbl. Full opex
are in the order of USD 55/bbl.
Work experience:
1985 – present: More than 35 years experience in senior management, more than
20 years experience in board functions, Project funding with particular focus on
national (German) and international guarantee instruments and subsidies; Independent Advisor to financial institutions and companies in the fields of natural resources, utilities and extractive industries for equity investment, mezzanine and debt
funding (Project Finance), Feasibility Studies, independent auditing, market value
and risk assessments; 1972 – 1984 Metallgesellschaft AG; 1982-84: Member of the
supervisory board of Metallgesellschaft AG; 1980-84: Branch manager with Lurgi’s
natural resources branch; 1972-80: Various appointments with Metallgesellschaft’s
domestic and international mining division; 1970 – 1972 University of Clausthal Postgraduate Study and Scientific Fellow; 1968 – 1970 Bavarian Bureau of Mines Trainee
(Senior Government Mine Supervisor)
Issue 03 | 2009
70
>>The most intelligent chapter in
mining history was written by German
Engineering<<
T
he German Brown Coal industry is not only contributing heavily to the national energy supply,
on which our economic prosperity is based, but during the past one hundred years it has also
lead to a globally unparalleled and valued place of expertisefor mining technologies, which
also needs to be preserved.
We observe in all European industrial nations that the
importance of raw material production, as the basis of the
value chain and energy production is increasingly being
repressed from the consciousness of all people. Although
mineral material is indispensable for the production of
almost all commodities, and access to raw material is
geo-politically becoming increasingly important, they
are seen as sources of irritation which impede access to
goals of climate and landscape, even in industrial regions.
However, the trend in global increase of requirements is
irreversible and its political and economic waves have
long reached us. The search for new deposits is in full
swing, even in regions of Europe, where mining already
was an attraction in museums.
Investment in international mining
companies, the establishment of
new mining enterprises, as well
as the obtaining of licenses for
raw material are on the agenda
of many companies.
In Germany the extraction of
and the power generation by
brown coal is particularly at the
center of the conflict between
secure and cost-effective energy
supply and ecology. In no other
country the question of the
„right“ energy-mix is discussed
as vehemently as in this country.
Hereby the debates often carry
a tone of rejection of energy
systems, which do not fit into the world view of the respective
speaker. At the same time there are high expectations; The
responsibility towards future generations need to be met,
international law obligations need to be observed, and the
living standards need to be kept. All these demands are
justified, however, it should be noted that it is exactly our
established energy mix, on which our economic prosperity
is based, and on which such demands can be formulated
in the first place.
In such debates the complementary meaning of energy
and raw material production for the location of Germany
is very often disregarded.
The innovation potential in
our mining technology is
unparalleled. As an example,
the technology for continuous
surface mining, which was
developed at the beginning of
the last century in the German
brown coal districts, has lead to
enormous efficiency increases
in extraction, production and
dumping processes, which
again is also ecologically
relevant. A mass movement
of more than 30,000 m³ could
be achieved already in the
year 1930. Nowadays we have
extraction and mining chains
that allow for daily outputs of
240.000m³. This is the reason
>>The German Surface mining technology
has an enormous innovation potential.<<
Issue 03 | 2009
71
why the large open cast pits
of the Rhenish, Lausitz and
central German brown coal
districts achieve the by far
highest delivery rates and
mass movements in the global
brown coal mining.
The fact that open cast
mining technology is no
isolated application for the
German brown coal districts
only, but also has international
market potential, has been
proven by manufacturers
having Innovation, flexibility
and the ability to adapt to
the various circumstances in
mining. It was already in the
sixties that the bucket wheel
excavator and other solutions
of the excavation technique
was applied first in the US,
and later in various open
cast mining operations in
almost all parts of the world.
This development was made possible mainly because of
the internationally strong relevant branches of German
Universities. The engineering services of the numerous
and renowned consulting firms are also much in demand.
They have also contributed to the knowledge transfer for
optimum application of the giant equipment technology.
show that both the industry and science have actively
taken up the challenges of energy supply - from energy
efficient mining technology up to climate-friendly power
generation through coal.
>>The brown coal industry has
long outgrown its role as a
supplier.<<
Within the context of the often prognosed fast growth
in the world‘s energy consumption, innovation impulses
for an ecologically and economically and ecologically
balanced energy supply, which is according to needs, are
indispensable. In the future almost no political economy
with coal deposits can and will do without this affordable
energy feedstock. Some promising development projects
Issue 03 | 2009
Hence, the importance of the
brown coal industry has long
surpassed the role of a national energy supplier. In over
100 years, a globally acknowledged place of expertise,
which combines practical and scientific know-how, has
developed. The advancement of technological innovation
on the basis of the achieved standards remains a national,
European and international contribution to growth and
prosperity.
72
TECHNOLOGIETRANSFER
Innovative and Efficient Solutions
for challenging tasks in extraction, surface mining and surface forming.
T1255 Terrain Leveler
Vermeer has transcribed its long-standing
experience in the area of rock mills into its new
surface mill.
The T1255 is characterized by protected technology, intelligent design, excellent production and system stability.
Meanwhile the Terrain Leveler can process an
area of up to 3.7 m width and 61 cm depth in
one single run.
The machine has been designed to ablate all
kinds of rocks, gypsum, coal and other material (e.g. concrete). This is done using a big,
hydrostatically steered milling drum, which
ablates the rock in a more efficient way and
with a higher cutting depth.
The result:
More coarse material with a low proportion of
fine fraction.
www.vermeer.de
Deutschland GmbH
Puscherstr. 9
90411 Nuremberg, Germany
Ausgabe 03 | 2009
Tel.: +49 (0) 911 5 40 14 0
Fax: +49 (0) 911 5 40 14 99
ADVERTISEMENT
73
NEWS & REPORTS
HOT SUCCESS!
Steelworks « Dillinger Hütte » & « Saarstahl »
D
Since 1953, the company BACKES is doing the preparation of slag in order of the steelworks
“Dillinger Hütte” in Dillingen (close to Saarbrücken). BACKES recycles the slag to gravel, which is
used as material for street construction. Still, a converter lime is produced from the steelworks slag,
which is used for fertilizer for the agriculture. BACKES is a Customer’s of ESCO’s dealer Peter KESSLER
GmbH &Co. During their visits ESCO District Manager and Kessler Dealer proposed that the company try
to equipped their Machines with ESCO products solutions parts. BACKES uses several machines in the
steelworks. For solving and loading of the hot slag the company BACKES use 3 LIEBHERR Excavators R984
Litronic.
Steelwork « Dillinger Hütte »
The temperature of the hot slag is up to 1100°C. At this high temperature, bucket
must be well protected by products with optimum performance. SUPER V® is the
best choice to meet this challenge!
Mr X, manager of the Subcontractor Backes needs the top Systems for Today’s
performance demands:
•Reliability
•Longer Wear life
•Lower
Maintenance
Costs (Faster and Easier
change-out)
•Better Penetration
Against this background,
BACKES, ESCO and KESSLER
agreed to use the esco
wearparts on two LIEBHERR
R984 Litronic to protect their
buckets.
Issue 03 | 2009
74
NEWS & REPORTS
The V71 ADHL is a specially designed point shape when digging Hot Slag operation. The ADHL has a heavier wear shoe,
as well as beefier ears and box section to stand up to the most punishing applications. In addition, ESCO engineering with
TSG designed a special V69/71HPNA pin, a little bit longer than the standard version which provides a very good locking.
SUPER V® V71ADHL points worn out after only 70-100 hours on average. Because of the self sharpening effect, the teeth
keep a perfect penetration until the end. TOPLOK® & KWIK-LOK® Runners are ideally suited for fighting abrasion in hot
slag so that buckets must be repaired after approximately 12 months instead of 3 months with previous Systems..
VIDAPLATE 17 on 10
KWIK®-LOK KLR02MB
TOPLOK 90x320-5
TOPLOK 90x320-6L
TOPLOK 90x320-6R
WING-SHROUDS
ES4410SA
SUPER V® points
V71 ADHL
Steelwork « Saarstahl »
The both steelworks SAARSTAHL and DILLINGER HÜTTE are
operating many telescope excavators in the two steel mills.
These special machines removes the hot-slag from the ladles.
The temperature of the ladles is between 600°C and 800°C. The
excavators also remove the unusable refractory liners form the
ladles.
This application is one of the most demanding metallurgical
expertise on the market.
ESCO alloy and SUPER
V® System can meet
that challenge. Together
with the ESCO Dealer
KESSLER in Völklingen,
ESCO could convince
the two steelworks to
Issue 03 | 2009
75
NEWS & REPORTS
convert the shanks of the telescope excavators to SUPER V® system V51SD
and V51SDX. The shanks of the telescope excavators are now equipped with
SUPER V® weld-on noses as well as the both different tooth shapes V51SD and
V51SDX. For this hot application, of course ESCO offers a special hot-slag locking
device. The alloy and the design of the both tooth shapes maximize the heat
dissipation capabilities of the SUPER V® system to minimize the affects of hotslag material. This points are a very good alternative when impact is causing
breakage in longer style points. With the SUPER V® tooth, the hot-slag can
be removed from around 25 - 30 ladles. The wear time of the teeth is approx.
30 hrs. The refractory liners of the ladles can be used for approximately 45 - 50
cast fillings. The refractory liner is also removed with the telescope excavators
afterwards.
The Operators likes the performance, the high wear time as well as the save
and easy handling of the SUPER V® System. They have explained with V51SD
and with V51SDX they have a better penetration and a better power transmission.
Thanks to the long lasting experience of ESCO in the steel technology, Saarstahl
and Dillinger Hütte can believe in SUPER V® tooth system. It has improved their
profitability by extending wear protection products. Following this HOT successful
story ESCO has offered this solution to many other German steelworks.
V51SD(X)
ESCO corporation
Tel.: +49 (0)2166 - 9684-0
Fax:+49 (0)2166 - 9684-22
eMail: infoesco@escocorp.com
Internet: www.escoeurope.com
Issue 03 | 2009
76
NEWS & REPORTS
Kleemann GmbH
Stationary plants now become mobile thanks to interlinked plants!
Kleemann demonstrates what is possible today with process know-how and highperformance plants:
500
t/h feed capacity, up to seven final fractions of which five comply with the strict standards for
asphalt and concrete production - and all this is possible using mobile plants? Using the plant
combination at Kelly’s of Fantane in Ireland, Kleemann demonstrated what can be achieved today using
mobile plants. Mobile crusher and screen plants are advancing more and more into output ranges that
up to a few years ago were only possible using stationary plants. Examples such as the one quoted
above are guiding the way for the future.
Kleemann Kelly´s of Fantane
Kelly’s of Fantane, Ireland: Three crushing and
screening stages, up to seven final fractions,
total capacity of over 500 t/h
What exactly are “interlinked plants“?
“Interlinked mobile plants are crusher and screen plants, which are coordinated to work together in terms of output
and operation“. Two, three or several plants can be combined for use in both natural stone quarrying and recycling. The
potential output of such plant combinations currently ranges from 100 t/h up to 500 t/h, whereby the upper limit has not yet
been reached:
Issue 03 | 2009
77
NEWS & REPORTS
Why are interlinked mobile plants
becoming more popular?
Experience shows that the licensing procedure for
mobile plants is, for the most part, considerably shorter
and less complicated than that for stationary plants. In
addition, the flexible use of the plants in spacious areas
and in technical applications reduces the investment risk.
The plants can also be resold, thus further lowering the
risk. An equally important contributory factor is the fact
that manufacturers such as Kleemann have been able to
offer plants for such large tonnage in various crushing and
screening stages.
operators of stationary plants who are about to make new
investments in machinery. This is also a feasible concept for
larger infrastructure projects as such projects are mostly
limited in terms of time or in scope and are often located in
sparsely populated areas. A suitable combination of mobile
plants could also be used for newly opened quarries, as
well as recycling projects which demand top-quality end
products.
Kleemann Lauchhammer
Reconstruction company Lauchhammer, Germany:
Concrete and rubble processed in final fractions
of 0 - 32 mm and 32 - 45 mm
What are the potential areas of
application?
Due to the development of these plants in recent
years, the mobile plant is increasingly becoming a real
alternative to the stationary version in a great number of
projects. For this reason, it is now examined more often
whether an original stationary concept with mobile units
is more economical. This is of particular benefit to existing
Issue 03 | 2009
Requirements and expectations
Of course, the requirements are high: On the one hand,
there must be a guarantee that top-quality end products,
with regard to cubicity and output, can be manufactured.
On the other hand, the process must be reliable and
economically worthwhile, which, of course, also applies
largely to the machines used.
78
NEWS & REPORTS
Kleemann LSR Zement
LSR Zement, Russia: Two-stage crushing
process for achieving four final fractions
Kleemann Maxwell
Maxwell, England: Two crushing and three
screening stages allowing up to seven final
fractions
Issue 03 | 2009
79
NEWS & REPORTS
There must be cost advantages, which are not
necessarily noticed in the procurement stage, but mainly
during the operation of the plant. For example, in quarries
which cover a large geographical area, it is often possible
to load the crusher directly at the wall. Thus the use of
heavy duty vehicles is partially or completely avoided.
This leads to considerable savings not only in vehicles
and machines, but also personnel costs. In the example
at Kelly’s of Fantane, Martin Flynn, Operation Manager,
explains that all machines are linked through a computersupported system. „The bottom line is we produce 500
tonnes per hour with only one man“, he added. He went on
to say that since they have been using Kleemann plants,
their costs have dropped significantly. „We now produce
more during a single shift compared to the previous twoshift operation“, he explained.
ideal for interlinked plant concepts. In addition, optimally
coordinated mobile screening units, available in double or
triple deck design, provide reliable end classification.
What does Kleemann specifically offer?
Kleemann not only offers the required plants but also
the relevant process know-how. Decade-long experience
in the construction of stationary plants combined with over
25 years‘ experience in the construction of track-mounted
crushing and screening plants means Kleemann can
offer its customers a comprehensive service. Therefore,
not only does Kleemann assess and design the required
technical process safely and reliably, but it also ensures
its successful implementation by providing support for
the customer during the difficult transition stage from
stationary to mobile plants.
The decisive factor is, however, the plants themselves.
Kleemann plants offer, on the one hand, the relevant
operations in the plant design, and, on the other, robust,
sophisticated, high-performance machine technology.
Jaw, impact or cone crushers have split feeding for optimal
loading (no blockades), large primary screens for optimal
final fraction quality, stable control voltage and separate
monitoring of the individual machines. They also have
ideal access, easy maintenance and, last but not least,
diesel-electric drives with the option of external power
supply (quarry machines) which also make feed capacities
of up to 700 t/h possible. All these characteristics are
Issue 03 | 2009
FOR MORE INFORMATION AND CONTACT:
Kleemann GmbH is a member company of the
Wirtgen Group, an expanding and international
group of companies doing business in the construction equipment industry. This Group includes the
four well-known brands, Wirtgen, Vögele, Hamm
and Kleemann, with their headquarters in Germany and local production sites in the United States
of America, Brazil and China. Worldwide customer
support is provided by its 55 own sales and service
companies.
Kleemann corporation
Mark Hezinger
Hildebrandstr. 18
73035 Göppingen | gERMANY
Tel.: +49 (0) 7161 20 62 09
Fax: +49 (0) 7161 20 61 00
eMail: mark.hezinger@kleemann.info
Internet: www.kleemann.info
80
NEWS & REPORTS
Wirtgen GmbH
New 4200 SM surface miner from
Wirtgen:
Maximum performance in
large-scale opencast mining!
T
he new 4200 SM is a high-performance machine for mine operators and customers in large-scale
opencast mining whose goal is to achieve an annual mining capacity in soft rock of up to 12 million
tons with a single machine while wanting to make full use of the benefits offered by Wirtgen’s selective
mining technology that enables cutting, crushing and loading in a single working pass. The surface
miner is available to customers in two different designs: as a powerful mining expert for hard rock,
such as iron ore, bauxite or phosphate, or for use in various types of soft rock including, for example,
coal or lignite. The miner has a cutting width of 4.20 m and is capable of working at a maximum cutting
depth of 83 cm in soft rock.
The 4200 SM is synonymous with
tremendous power
The heavy-duty machine is equipped with a 16-cylinder
diesel engine from Cummins, making it the ideal candidate
for a wide range of applications as its power of 1,194 kW
/ 1,623 PS offers tremendous reserve capacity. Being the
most powerful machine in the surface miner division, the
4200 SM complements Wirtgen’s product portfolio in the
upper performance class. Generously dimensioned tanks
Issue 03 | 2009
offering capacities of 2,900 l for diesel and 10,000 l for
water additionally increase the miner’s uptime.
A two-stage conveyor system with 1,800 mm wide
primary and discharge conveyors and a discharge
conveyor length of 12,000 mm or 16,000 mm respectively,
supports the miner’s impressive cutting performance of
up to 3,000 tons per hour. The discharge conveyor’s large
slewing angle of 180 degrees, flexible height adjustment
and variable belt speed ensure smooth loading of large
transport trucks even in space-restricted conditions.
81
NEWS & REPORTS
The right cutting technology – whether
in hard rock or soft rock
Fully equipped for long and tough mining
operations
Customized components manufactured to the high
quality standards of Wirtgen’s cutting technology have been
precisely adapted to the miner and the rock to be mined,
enabling the 4200 SM to achieve maximum production
rates at low cutting tool wear and tear. Depending on the
operation and the material to be mined, the cutting drums
are fitted with different numbers of cutting tools at different
tool spacings.
For applications in soft rock with unconfined compressive
strengths of up to 50 MPa, the 4200 SM is equipped with a
4.20 m wide cutting drum unit with larger cutting diameter,
permitting cutting depths of up to 83 cm. In soft rock, the
operation focuses on the throughput of large quantities of
the material to be mined.
The largest Wirtgen miner can alternatively be equipped
with a drum assembly offering a cutting width of 4.20 m
and a cutting depth of 65 cm for applications in hard rock
with unconfined compressive strengths ranging from 30
MPa to 80 MPa. It aims at achieving maximum cutting
performance in hard materials at reduced cutting depths.
Both cutting drums can optionally be equipped with the
tried and tested HT14 quick-change toolholder system for
the fast replacement of cutting tools.
Ergonomic design of the operator’s workplace was
another major point in the machine’s development as long
uptimes or even continuous operation are required in the
deposits to increase productivity and to ensure maximum
utilization for an economical operation of the large
machines.
The 4200 SM’s cabin has undergone a complete redesign:
It is located above the front, left-hand crawler track unit
and is isolated from the vibrations and noise emissions of
the engine and cutting drum by a parallelogram-type height
adjustment system. The fully glazed operator’s platform
offers the machine driver an exceptionally good view of
all areas relevant for cutting and loading of the mined
material. The cabin can additionally be swivelled about
45 degrees to either side, thus also permitting an optimum
view of the loading operation and steering of the crawler
tracks. The driver’s seat with all major controls installed
in the armrests can be swivelled about 135 degrees to
the left and right. The controls, which are integrated into
both armrests in a clearly structured fashion, comprise all
functions of the work process.
The operator’s cabin is soundproof and is supported
on special anti-vibration buffers to protect the machine
Wirtgen 4200 SM
Hallmarks of the new 4200 SM include high cutting performance, unmatched economic efficiency and projectspecific customization to on-site operating conditions
and local safety regulations
Wirtgen 4200 SM
The cutting drum unit with a cutting diameter of 1,500
mm is ideally suited to the mining of medium-hard to
hard rock, such as iron ore. The number of cutting tools
depends on the operating conditions
Issue 03 | 2009
82
NEWS & REPORTS
operator during the mining operation. To ensure pleasant
working conditions, the cabin is equipped with a powerful
air-conditioning unit for cooling or heating. These are all
factors to improve the machine operator’s performance
and power of concentration. The large machine’s
user-friendliness is complemented by wide opening
service panels offering excellent access to all points of
maintenance.
in the operator’s cabin. The cabin’s location on that side
of the machine opposite the embankment wall is yet
another safety criterion offering maximum protection to
the machine operator.
Wirtgen 4200 SM
The panorama cabin of the 4200 SM offers not only an
excellent view for permanent monitoring of the work
processes from the operator’s platform but also a high
degree of comfort for the operator in 24-hour shifts
Comprehensive safety package for
country-specific requirements
Safety regulations are tightened in mineral deposits
around the world. The new design of the 4200 SM takes
account both of the stricter safety requirements and
of new mining regulations. The miner’s comprehensive
safety package includes, among other things, a FOPS
roof to protect the operator from falling objects, a second
emergency exit in addition to the hydraulically operated
access ladders installed on both sides of the machine,
fire extinguishers, and covers on all rotating parts. The
access ladders and walkways are illuminated and consist
of anti-skid grating. Several emergency stop switches can
be actuated from the ground and are additionally installed
in the engine compartment, at the electrical cabinet and
Issue 03 | 2009
Wirtgen corporation
Press Relations
Reinhardt-Wirtgen-Str. 2
53578 Windhagen | Germany
Tel.: +49 (0) 2645 1 31 0
Fax: +49 (0) 2645 1 31 4 99
eMail: presse@wirtgen.de
Internet: www.wirtgen.de
83
NEWS & REPORTS
Improved performance out
in the open!
Substitution of screen panels
to help hard rock
quarry achieve increased
production
I
n Groß-Bieberau, the Odenwälder
Hartstein-Industrie AG – a holding
subsidiary of the Mitteldeutsche
Hartstein-Industrie AG – operates
a gabbro quarry which is well
known in particular to
railway fans. For well
over a century now,
the Odenwälder
Hartstein-
Industrie
(OHI) has been
producing railway
ballast
which
originally benefited
the local railway between
Reinheim and Groß
Bieberau. Today its range of
production is very much more
widely spread: apart from ballast,
there are chippings, grit, crushed
sand, filler, armourstone, mineral
mixtures, asphalt aggregates and many
other products besides.
Hand in hand with the increased scope of
the product range there are the more exacting
demands of an optimization of the output
performance. The aims of the operators make it
clear that the technical principles for processing
are once again under the microscope. Up to now it
was always assumed that the proven combination of
crushing and screening equipment was able to deliver 250
t/h of material. Closer inspection has however shown that
this target is seldom actually attained.
Trellexscreens
Rubber and plastic screening panels are much
more resistant to wear than wire screening panels
Issue 03 | 2009
84
NEWS & REPORTS
K
arl-Heinz Rossmann, responsible for product support of screen media at Metso Minerals,
summarizes the present situation in the following terms: „When crusher and screening machines
at least together fail to achieve the necessary productivity, closer examination is absolutely essential.“
Rossmann got the ball rolling by suggesting an impartial analysis of the technical situation at the site.
The initial condition was not to consider exchanging the screening machines for the time being to
restrict replacement investment costs to an absolute minimum.
New investments remain
within reason
With the aim of achieving the
throughput of 250 t/h originally quoted or to increase this in the short
or medium term to 300 to 350 t/h, the
first task was to take a look above all
at the screening machines. It was
very soon clear that optimization
could only be carried out in the field
of the screen panels, as no investment provisions had been made for
replacement of the screening machines themselves.
An initial examination on sight
brought to light the fact that all the
screens were fitted with different
panels to different designs in terms
of length, breadth, thickness and
perforations. „This in not necessarily
a fault“, says Karl-Heinz Rossmann,
„because the tasks for which the
machines were specified were different right from the start. What we
have to do now is establish the extent to which optimization is required
in each individual case“.
The investigations started on the
grit side – where the grains are always broken twice, if not three times.
Metso had to examine four screening machines in this area to find out
what the optimization requirement
of the screening panels was. At the
moment, there are 250 t/h screening machines by Krupp in service.
Upstream of these machines there are one conical crusher
and one vertical impacter. Initially, the solution was considered, to save a crushing stage, of replacing both crushers by the Metso HP 4 and to configure a new screening
machine. For the sake of simplicity, the latter would have
been fitted with wire screens to give a bigger screening
surface and thus to increase the throughput. This first idea
was however revised after further consideration.
Issue 03 | 2009
stucking grain
Clogging is often a problem where no rubber screening
panels are used. Specially when wire screen panels
are used, a supposedly open area may remain up to
80% unproductive
After it became clear that investment in new machinery
was not the operator‘s first priority,
Karl-Heinz Rossmann devoted his attention to a fullydetailed investigation of the effective screening areas actually available.
The result was two slightly different pictures with one
common denominator: partly, proper utilization of the open
screening areas was just not possible with the screening
85
NEWS & REPORTS
media in use, partly right from the start there were insufficient perforations in any case.
With the use of more effective screening media, the
question of service life arises. Does an extended service
life of the screens have priority, or is a heavier screen gauge with less holes more important? This inevitably means
that that a larger number of „blind spots“ in the screens
(areas without holes) mean a longer service life. But how
is that then reconciled with demands for a higher throughput? „Here it wasn‘t a matter of choosing between service
life and performance – both aspects are equally important
in the final analysis“.
Wire screen panels under conditions of
wear
The most important requirement was to reach a fundamental decision regarding the basic material: whether
synthetic screening panels or wire panels – at first glance,
the observer would be inclined towards a screening medi-
um with a large open screening area, to meet the demand
for a higher throughput. It would have been easy enough
to solve the situation existing by replacing all screening
panels by wire panels.
However, in the fundamental decision-making the application itself plays a critical role: gabbro, a hard, igneous
rock, is capable of wearing out a wire screening panel
within two to four weeks. „You can stand by and watch
the steel wire getting thinner and thinner and finally disappearing altogether“, says Karl-Heinz Rossmann. In the
fines area, where wear is not the decisive criterion, moisture frequently gets into the screen. In the case of wire
screens, this leads to undesirable caking and can cause
complete blockage. Clearing it with a hammer or some
other tool is useless, because deformation of the screens
would be unavoidable. There would be similar difficulties
with wire rod screens too. A further disadvantage of the
wire screening panels: An overlapping of wire meshs, such
as Metso found in some places in Bieberau, also leads to
slower material conveyance which can only be compensated by the screens being tilted by 2° more in comparison
with synthetic screens.
Requirements for an increased throughput cannot adequately be met in this way. Since on site we want to ensure
that the performance capacity of the screening machines
wide guide rail
Large areas of the screen panels remain
effectively unused due to excessively-wide
edges and large blind spots
Issue 03 | 2009
86
NEWS & REPORTS
keeps up with that
of the crushers, in
the final analysis
there are further
considerations militating against the
use of wire screening panels: their
comparatively short
service lives lead
to higher settingup times, which in
turn has the consequence of longer
standstill
times.
Productivity of the
plant as a whole
would suffer considerably, and increased personnel
and material costs
would be unavoidable. The fact that
immediately after
installation a wire
screening
panel
can under certain circumstances temporarily provide up to about 20% more screening surface, even after allowing for the
unused surfaces taken up by the traverses, is not really a great help.
There is no question that effective screening area can be increased, even with synthetic screening panels. In the context of the areas
available, KarlHeinz Rossmann
took great pains
to establish exactly how the effective proportion
of open surfaces
can be increased
to improve performance: screen
by screen, he
analyzed precisely where material should be
changed and /
or the number of
holes should be
increased, the
holes enlarged,
to make use of
spars or to break
up blind zones.
wire screen cloth
Screen areas
With wire screen panels, moisture can
which demonstblind area
Here there are possibilities for augmenting
the rows of holes: Metso Minerals can
optimize the design or the perforation
individually for the respective application
cause undesirable clogging which may
even result in complete blockage in places
Issue 03 | 2009
87
NEWS & REPORTS
rate a high rate of grain clogging are to be exchanged in
the future for rubber screen panels. Rossmann is reckoning that only by the elimination from plugging material,
an increased throughput of around 20% can be achieved.
In addition, he can demonstrate that by using rectangular
mesh in blind zones a further 10% increase in performance
is more than likely. The sum total of the examination in
Bieberau works covered about 100 m² of screening area.
The design of the screening media it will be necessary
to replace can be carried out flexibly by Metso Minerals.
Karl-Heinz Rossmann will be giving the manufacturer his
individual recommendations.
A works analysis is planned to determine the increased
proportion of correctly-sized grains at a later date and to
give information on the quality and quantity of saleable granulate in accordance with DIN and on the extent to which
the situation has actually altered since the installation of
the new screens.
Metso Minerals Germany corporation
Kantstrasse 22 – 24
44867 Bochum | Germany
Tel.: +49 (0) 2327 54 44 43
Fax: +49 (0) 2327 54 44 91
eMail: karl-heinz.rossmann@metso.com
Internet: www.metso.com
Adservice, press relations
Ralf Goffin
An der Wolfskaul 42 a
41812 Erkelenz | Germany
Tel.: +49 (0) 2423 89 08 09 0
Fax: +49 (0) 2423 89 04 42 9
eMail: ralf.goffin@adservice-web.de
Best results
lead to the
breakthrough
If crusher technology by Metso looks after
anything, then it’s your purse: the Barmac
vertical impact crusher protects the rotor which
controls the process in an autogenous layer of
feed material in crushing. The mobile Lokotrack
LT1415 protects the nerves, as its large intake
opening prevents bridging.
As a primary crusher, the LT140 saves time – in
conjunction with the flexible Lokolink conveyor
system it makes such progress in opencast
quarrying that you can save a large proportion
of your dumpers.
Talk to us about the possibilities of staying
successful even in difficult times.
Metso Lindemann GmbH
Business sector Construction
Obere Riedstr. 111-115
68309 Mannheim
Tel. ++49 (0) 621 72700 611
E-Mail: karl-heinz.hessler@metso.com
www.metso.com
ADVERTISEMENT
Issue 03 | 2009
88
NEWS & REPORTS
THE NEW bucket crusher BF:
MB ANSWER TO CUSTOMERS’ NEEDS! MB S.p.A. presented the new version
of the bucket crusher at the Paris trade fair Intermat.
Issue 03 | 2009
89
NEWS & REPORTS
MB S.p.A., a Vicenza company and worldwide leader
in the production and sales of bucket crushers, was at
the Intermat 2009 trade fair in Paris to present its latest
product,
– a new bucket crusher, the result of ongoing investments
in technological research and the continuous attention
to its customers’ needs. The company has decided to
present this new product during one of the most important
international trade fairs in the sector of construction, to
highlight the importance of this event.
crushers. Also, company participation in major national
and international events in this sector has enabled MB
to establish and strengthen relationships and loyalty with
clients, who always receive special attention.
At the Intermat fair, MB S.P.A. was presenting a historical
product of the MB house, in a modernised version, once
again demonstrating that the investments in research and
technology offered to clients ensure that the company
achieves the maximum levels of quality and satisfaction.
The historical model has been
transformed to offer an even
more revolutionary product on
the market, thanks to the indepth research of the MB team
and technical engineers.
The company is committed to
the constant satisfaction of
customers’ requirements, ever
attentive to their needs, carefully
listening to all problems faced
every day on construction sites,
finding solutions most suited
to the various international
situations in which MB S.p.A.
operates. It is also thanks to the
long-lasting relationships and
loyalty of clients that MB can
produce bucket crushers that
represent a valid work tool. The
new version of the bucket crusher
is in fact more resistant in work,
featuring a more compact size
and improved structural layout to
facilitate operator manoeuvres
on the excavator.
Despite the world crisis affecting
all sectors, MB confirms its
success and keeps on investing
in research and development,
giving priority to vertical
specialisation in the production
of a single product that enables
the guarantee of high quality
and top performing bucket
Issue 03 | 2009
90
NEWS & REPORTS
MB S.p.A. set up in Breganze
in 2001, now exports to 100
countries and is acclaimed
for innovation and technology
of its products and quality
of its service. The ability to
respond to market demands
and technical assistance on
offer to their numerous clients
have contributed to the growth
of the MB brand worldwide.
MB S.p.A.
eMail: info@mbcrusher.com
Internet: www.mbcrusher.com
Issue 03 | 2009
91
NEWS & REPORTS
The AVANT TECNO Concept of MultiFunctional Loaders Wins
Transporting sand from A to B is easy. For this, only the
“one-dimensional” output of the loader is important.
However, in GaLa Construction, demolition, commune,
channel construction, industry, etc., very often various
demands have to be met within very short timeframes
and on narrow construction sites. Such demands can
only be met by an efficient, high-performance, robust
and multi-functional loader. In addition, the good quality
of accessory equipment (AVANT is delivering over 100)
is very important and of significant advantage. This fact
is increasingly being acknowledged and used by the
costumers. “We are very happy to note that up to now, the
current business year has not brought us a total collapse;
on the contrary, it has brought about a turnover, which is
almost at the same level as last year. The reason for this
fact can surely also be seen in the innovation of AVANT. At
the beginning of this year, we created a new and expanded
application horizon with our 700 Series (up to 1.75 t of
usage weight; 36 kW/49 PS motor)”, said Thomas Sterkel,
managing director of AVANT TECNO, Germany. The high
interest of visitors of the industry exhibition in demopark
in Eisenach in multifunctional loaders was clearly felt.
AVANT had taken the exhibition concept seriously, which
was to show machines in action. This led many visitors to
the big booth, and evoked a lot of interest in the machines
and their approach. With regard to the 40 (out of more than
100) accessory equipment, which could be tested, Sterkel
balanced a good exhibition result.
Opening up New Areas of the Industry
Many enterprises in the industry take new directions
and open up to new branches. In order to do this, there
is a demand for multifunctionally applicable and compact
machines that at the same time are very powerful. In such
a case the multifunctional loaders of AVANT provide the
right solution. With their five series and ten machines of
an application weight of 0.6 to 1.75 t and more than 100
available accessories of best quality, they are efficient and
profitable helpers. “Furthermore, our customers appreciate
the quality of our area-wide network of dealers, which
provides consulting, sales, renting and services. Besides
the quality of the machines, this is also a guarantor for our
leading position in the market in this year and beyond.”
Sterkel says. You can verify these advantages locally with
the relevant regional dealer (information can be obtained
from www.avanttecno.de). Or visit at Agritechnica, 8. – 14.
11. 2009 in Hannover.
AVANT TECNO Germany corporation
Max-Planck-Straße 3
64859 Eppertshausen | Germany
Tel.: +49 (0) 60 71 98 06 55
Fax: +49 (0) 60 71 98 04 53
eMail: info@avanttecno.de
Internet: www.avanttecno.com
AVANT multifunctional loader
Manifold tasks can efficiently be tackled
with the AVANT multifunctional loaders of
0.6 to 1.75 t application weight
Issue 03 | 2009
92
NEWS & REPORTS
T
he new ROC T35M combines the straightforward design concept of Atlas Copco’s former CM line
with the well-tested features of the ROC family, in a new modular design developed for the next
generation of Atlas Copco‘s surface crawler drill rigs. All with focus on productivity, cost-efficiency
and hole quality for our customers.
ROC T35M is a fuel efficient drill rig equipped with a
highly productive rock drill. The well-proven COP 1840 rock
drill with 18kW drilling power provides high penetration
rate. It gives more drilling power for less input energy,
resulting in less fuel consumption. The hydraulic based
control system COP Logic adjusts the feed speed, feed
pressure and impact pressure in realtime according to the
rock condition.
Bo-Göran Johansson, Vice President, Marketing, at
Atlas Copco SDE adds: “Every contractor dreams of higher
penetration rates, straighter holes and better accessory
life. The ROC T35M drill rig employs a cylinder-driven
aluminum feed system that fulfills this dream by providing
optimal penetration rates and drill steel life. Its rod handling
system, with a streamlined number of parts, ensures easy
adjustment and maintenance. The well proven aluminum
feed profile is sturdy and highly resistant to bending.”
Issue 03 | 2009
93
NEWS & REPORTS
ROC T35M
RROC T35M is equipped with the well-proven
COP 1840 rock drill
ROC T35M is built of modules and parts common to Atlas
Copco Surface crawler portfolio. This makes training easy
and parts stocking requirement reduced for contractors
with different Atlas Copco rig models. Maintenance is
simplified thanks to all around access to service points and
good hose management with bulk heads. Maintenancefriendly design together with ROC Care and COP Care
service agreements mean less breakdowns, increased
availability and reduced service costs.
ROC T35M
Maintenance on ROC T35M is simplified thanks
to all around access to service points and good
hose management with bulk heads
Issue 03 | 2009
94
NEWS & REPORTS
The Atlas Copco Simba W6 C rig
available for new markets!
A
fter having proven itself at LKAB, in Sweden, one of the world’s leading producers of iron ore products,
Atlas Copco is now releasing the production drilling rig Simba W6 C to the market. Patrik Ericsson,
Product Manager Simba rigs, Atlas Copco, says:“Our commitment to the customer is to provide the best
possible tool for their application. Working together with a leading mining company such as LKAB has
proven that high demands create great solutions.”
Focusing on high productivity, reliability and hole
accuracy, Atlas Copco and LKAB have a common history
in developing production drilling rigs for successively
longer holes with a minimum of hole deviation. This focus
has paved the way for increasing the distance between the
sub levels. The Simba W469 rigs, introduced in 1995, have
been working successfully in both Kiruna and Malmberget.
In 2006/2007 these rigs were complemented by the Simba
W6 C rigs. The Simba W6 C rig is specially adapted to the
Wassara water driven in-the-hole hammer and gives long,
straight holes with a minimum hole deviation of less than
1 percent. Besides long hole drilling, the Simba W6 C can
also be modified for slot hole drilling, a method that is used
in LKAB’s Malmberget mine.
Issue 03 | 2009
The Simba W6 C rigs have now been in production for
more than two years in LKAB’s Kiruna and Malmberget
mines and the results have so far lived up to the company’s
high expectations.
The Simba W6 C rigs are equipped with a rig control
system which optimizes the performance for in-the-hole
hammer (ITH) applications. The Simba W6 C rigs offer
unattended drilling in full fan automation, enabling the
operator to supervise several drill rigs at the same time. In
cases where manual operation is preferred, the rig’s cabin
offers a good working environment with air conditioning,
vibration dampening and noise insulation.
95
NEWS & REPORTS
An important feature is the water pump system which gives high efficiency, low water spillage and low overall cost. An
air venting system ensures long pump life, and the pump pressure control optimizes hammer efficiency and life length.
Simba W6 C
The Simba W6 C rigs are equipped with a rig
control system specially designed for in-thehole hammer (ITH) applications
Surface Drilling Equipment is a division of the
Construction and Mining Technique business area of
the Atlas Copco Group, with its main manufacturing
center at Örebro, Sweden. The division develops,
manufactures and globally markets rock drilling
equipment for various applications in civil engineering,
quarrying and open pit mining. A strong focus on
innovative product design and aftermarket support
systems provides added customer value.
Atlas Copco Underground Rock Excavation is a
division within Atlas Copco’s Construction and Mining
Technique business area. It develops, manufactures,
and markets a wide range of tunneling and mining
equipment for various underground applications
worldwide. The division focuses strongly on innovative
product design and aftermarket support systems,
which give added customer value. The divisional
headquarters and main production center is in Örebro,
Sweden.
More information can be found at http://www.atlascopco.com
Surface Drilling Equipment
Simba Bohrgeräte
Bo-Göran Johansson (VP Marketing)
Patrik Ericsson (Product Manager)
Tel.: +46 (0) 19 670 72 59
Tel.: +46 (0) 19 670 74 10
Mobil: +46 (0) 70 321 21 11
Mobil: +46 (0) 70 347 87 28
eMail: bo-goran.johansson@se.atlascopco.com
eMail: patrik.ericsson@se.atlascopco.com
Internet: www.atlascopco.com
Surface Drilling Equipment
Sandra Lagerqvist, (Com. Professional)
Tel.: +46 (0) 19 503 1240
Mobil: +46 (0) 73 337 8028
eMail: sandra.lagerqvist@se.atlascopco.com
Issue 03 | 2009
Tunnelling & Mining Equipment
Anna Dahlman Herrgård, (Com. Professional)
Tel.: +46 (0) 19 670 73 82
Mobil: +46 (0) 733 26 73 82
eMail: anna.dahlman.herrgard@se.atlascopco.com
96
NEWS & REPORTS
Diamond scrap heap
Cat-machines process one of the world’s largest
scrap metal stock piles in Namibia!
First discovered by German prospectors during the early 1900s, major diamond finds along Namibia’s Skeleton
Coast in regions like Lüderitz subsequently led to the rise of thriving mining communities at the turn of the 20th century.
Attracting fortune hunters from around the world, many of these centres later became ghost towns as deposits were
exhausted and have now subsequently been reclaimed by the mountainous sand dunes of the Namib.
Up until 1994, the largest player in this country was Consolidated Diamond Mines (CDM), which at the time
was a wholly owned subsidiary of De Beers. In that year a new agreement was concluded with the Republic of
Namibia, resulting in the formation of the Namdeb Diamond Corporation. The latter is jointly owned by the Namibian
government and De Beers Centenary AG.
Given the high intrinsic value that diamonds hold, all Namdeb mining operations are governed by strict security
protocols concerning how processed diamonds are transported to market. This means that all equipment going into
any diamond mining area – whether it’s a dozer, a pick-up truck or an excavator - never comes out again.
However, given the scale of Namdeb’s operation (and CDM’s before it), this has meant that a large stockpile of
redundant equipment has steadily gathered at Namdeb’s various mining sites. Recently, both for environmental and
practical reasons, Namdeb took the decision to clear these waste dumps, with Cape Town, South Africa, based
company SA Metal, securing the contract to systematically recycle and process the materials on site prior to their
release from these secured areas.
Issue 03 | 2009
97
NEWS & REPORTS
The task of cutting up these redundant machines and other materials is being tackled by two Cat 330DL hydraulic
excavators fitted with boom mounted S340 shears, sold and supported by Barloworld Equipment Namibia, the local
Caterpillar® dealer. A Caterpillar Work Tools team flew out from the factory in Holland to help install the shears, as
well as to provide training for SA Metal’s operators.
Issue 03 | 2009
98
NEWS & REPORTS
Uubvlei
According to SA Metal’s Xavier Fazakerley the contract, which commenced in July 2008, is open-ended and
expected to be ongoing for around three years. During this period, SA Metal expects to commercially process
around 250 000t of saleable material.
“This is one of the world’s most corrosive regions and metal items don’t last long in this environment,” explains
Fazakerley. “This means that any scrapped metal items prior to the mid-1960s will have in most instances turned to
dust long ago.”
The largest sizeable scrap metal source is located at Namdeb’s Uubvlei operation, situated some 10km north of
the Orange River and stretching approximately 1km inland.
“This represents one of the world’s largest scrap metal stockpiles,” says Fazakerley. “In fact the scale of the
operation is so big that the footprint of the site is clearly visible from Space - a final resting place for worked
out earthmoving machines, commercial vehicles and just about anything else no longer usable. During dumping
operations, everything was mixed in together. This means we have to separate metal and non-metal materials in
sourcing items such as copper, steel, lead and zinc. Currently we are processing around 5 000t per month.”
At Uubvlei, SA Metal expects to process around 100 000t of steel, with the balance sourced from an estimated 15
satellite mines spread over a distance of some 110km up and down the coastline.
Caterpillar
For more than 80 years, Caterpillar Inc. has been
building the world’s infrastructure and, in partnership
with its worldwide dealer network, is driving positive
and sustainable change on every continent. With
2008 sales and revenues of $51.324 billion, Caterpillar
is a technology leader and the world’s leading
manufacturer of construction and mining equipment,
diesel and natural gas engines and industrial
gas turbines. More information is available at
www.cat.com.
Press Inquiries Europe, Africa and Middle East
Mia Karlsson
Tel.: +41 (0) 22 849 46 62
Fax: +41 (0) 22 849 99 93
eMail: Karlsson_Mia@cat.com
Internet: www.cat.com
Issue 03 | 2009
99
EVENTS
2009
THE AMS-EVENT CALENDER
October 2009
03 - 04 Oct 2009 2009 Toronto Resource Investment Conference
Toronto ON, Canada
www.cambridgehouse.ca
05 - 07 Oct 2009 International Conference on Non-linearities and Upscaling in Porous Media
Stuttgart
www.nupus.uni-stuttgart.de/index.p
hp?module=events&file=stuttgart
06 - 08 Oct 2009 MiningWorld Uzbekistan 2009
Tashkent, Uzbekistan
www.miningworld-events.com
06 - 09 Oct 2009 2009 APCOM Symposium
Vancouver BC, Canada
www.cim.org/apcom2009
08 - 09 Oct 2009 Bergbau- und Steine- und Erden-Tag 2009
Neuburg a. d. Donau
www.abbm-bayern.de
08 - 09 Oct 2009 Mining Magazine Congress
Ontario, Canada
www.miningcongress.com
12 - 14 Oct 2009 NEXT 2009
Shanghai, China
www.next2009.com
12 - 14 Oct 2009 Tenth Mill Operators Conference
Adelaide, Australien
www.ausimm.com/content/wsc.
aspx?ID=17
13 - 15 Oct 2009 FILTECH 2009
Wiesbaden
www.filtech.de
14 - 17 Oct 2009 Mining Indonesia 2009
Jakarta, Java, Indonesia
www.pamerindo.com
Walzbachtal-Wössingen
www.gdmb.de
16 - 18 Oct 2009 Tag der Steine in der Stadt
Berlin
www.geo.tu-berlin.de/steine-inder-stadt/tag_der_steine_in_der_
stadt
19 - 23 Oct 2009 IMWC — International Mine Water Conference
Pretoria, Südafrika
www.wisa.org.za/minewater2009.
htm
15 - 16 Oct 2009
GDMB-Arbeitskreis Tagebautechnik im Fachausschuss "Steine, Erden,
Industrieminerale"
21 Oct 2009 MIRO-Ausschuss "Rohstoffsicherung, Umweltschutz, Folgenutzung"
www.bv-miro.org
IFAC MMM 2009 IFAC Workshiop on Automation in Mining, Mineral and Metals
Vina del Mar, Chile
20 - 22 Oct 2009
Industry
www.ifacmmm2009.com
20 - 22 Oct 2009 CHINA MINING Congress & Expo 2009
Tianjin, China
www.china-mining.com
21 - 23 Oct 2009 TZMI Asia in Focus Congress 2009
Singapore, Singapur
www.tzmi.com
21 - 23 Oct 2009 WCSB4 — The 4th World Conference on Sampling and Blending
Kapstadt, Südafrika
www.wcsb4.com
26 - 30 Oct 2009 World Gold 2009 — SAIMM World Gold 2009 Processing Workshop
www.worldgold2009.com
27 - 29 Oct 2009 China Coal and Mining Expo 2009
Beijing, China
www.chinaminingcoal.com/2009
27 - 29 Oct 2009 Mining & Energy SA
Adelaide, South Australia,
Australien
www.miningandenergysa.com.au
28 - 29 Oct 2009 Forum MIRO 2009 Kolloquium und Ausstellung
Würzburg, Maritim Hotel
www.bv-miro.org
27 - 30 Oct 2009 ENTSORGA-ENTECO 2009
Köln
www.entsorga-enteco.com
Issue 03 | 2009
100
EVENTS
2009
THE AMS-EVENT CALENDER
November 2009
02 - 04 Nov 2009 MINE-TECH International
Johannesburg, South
Africa
www.MineTechExpo.com
04 - 06 Nov 2009 Valuation of Mineral Projects
www.edumine.com/pd/valuation
09 - 12 Nov 2009 Flotation 09 — 4th International Flotation Conference
www.min-eng.com/flotation09
09 - 11 Nov 2009 Slope Stability 2009
Los Andes, Santiago,
Metropolitana, China
www.slopestability.cl
Essen
www.gvst.de
10 - 12 Nov 2009 Stainless Steel World Conference & Exhibition 2009
10 Nov 2009 Steinkohlentag 2009
Maastricht (Netherlands)
www.stainless-steel-world.net
10 - 13 Nov 2009 Metal-Expo 2009
Moscow (Russia)
www.metal-expo.com
11 - 12 Nov 2009 Hochschul-Kupfersymposium 2009
Duisburg
www.kupferinstitut.de/symposium
10 - 12 Nov 2009 China Mining 2009
Beijing, China
www.china-mining.com
Kairo, Ägypten
www.npg.sabrycorp.com/conf/
npg/09
13 Nov 2009 Fachtagung Asphalt in Freiburg
15 - 19 Nov 2009
Nano Petroleum, Gas and Petro-Chemical Industries Conference: “Providing
Nano-Powered Solutions”
16 - 19 Nov 2009
SWEMP 2009 — 11th International Symposium on Environmental Issues and
Banff, Alberta, Kanada
Waste Management
17 - 19 Nov 2009 Geothermiekongress 2009
ww.mpes-cami-swemp.com
Bochum
www.geothermie.de
Leonardo Hotel Weimar
www.iff-weimar.de
21 - 22 Nov 2009 San Francisco Hard Assets Conference
San Francisco CA,
Australia
www.hardassetssf.com
23 - 24 Nov 2009 CoalMine Methane
London, UK
www.smi-online.co.uk
23 - 24 Nov 2009 Comparative Decision Analysis in Mining
www.edumine.com/pd/analysis
01 - 03 Dec 2009 FEM 2009 — 7th Fennoscandian Exploration and Mining
Rovaniemi, Finnland
www.lapinliitto.fi/fem2009
01 - 03 Dec 2009 STUVA Tagung 2009
Hamburg
www.stuva.de
02 - 04 Dec 2009 PROCEMIN 2009 VI International Mineral Precessing Seminar
Santiago, Chile
www.procemin2009.com
02 - 05 Dec 2009 EuroMold 2009
Frankfurt
www.euromold.com
London, Großbritannien
www.minsoc.ru
Mumbai (India)
www.cemat-india.com
18 - 19 Nov 2009
16. Internationale IFF-Fachtagung: „Verfahren und Ausrüstungen für die
Herstellung von Betonwaren und Betonfertigteilen“
December 2009
07 Dec 2009
Nature's Treasures: Minerals and Gems (MSGBI Joint meeting with the Gemmological Association of Great Britain and The Russell Society)
10 - 13 Dec 2009 ENERGY INDIA, MDA INDIA, CeMAT INDIA, Industrial Automation INDIA
Issue 03 | 2009
101
EVENTS
IV International Conference on
Mining Innovation
first announcement
and call for papers
23 ---> 25 june 2010, Sheraton Santiago Hotel & Convention Center, Chile.
Planning for Sustainable Mining
participants
The Department of Mining Engineering of the Universidad de Chile and the Mining Centre of the
Pontificia Universidad Católica de Chile, are pleased to invite executives, academics, professionals
and technical experts to participate in the iv international conference on mining
innovation - minin 2010, to be held on 23 – 25 June 2010, in Santiago, Chile.
objectives
areas of interest
MININ 2010 is organised to provide an international forum where
experts may analyse and discuss innovations and recent developments
in mine planning, operations optimisation, equipment development
and management of the mining business. The Conference aims to:
— Mine Planning
— Sampling and Geostatistics
— Geomechanics and Geotechnics
• Promote the exchange of best practices and
experiences applied to mining processes
— Mine Unit Operations
• Discuss emerging trends and developments and
identify best practices in the mining industry
— Expansions and New Projects
• Promote the development of an interdisciplinary
international network for technical collaboration
and exchange among professionals engaged in the
planning and development of mining processes
abstract submission
Prospective authors are invited to submit a 300 word abstract
in English, until 11 October 2009, to minin@minin2010.com The
abstract must be in MS Word, including a 100 character title,
full author’s name, position, company, business address, phone
number and email. If accepted, a full article up to 10 pages long
will be required by 23 November 2009. All final papers accepted
for publication will be included in the Conference Proceedings.
The technical program will be comprised of oral and poster
presentations; the form of presentation for each paper will be
decided upon the receipt of its final version. English–Spanish
simultaneous translation will be provided during the Conference,
thus, the oral presentation may be made in either language.
Organised by
— Optimisation of Mining Processes
— Integrated Mine Management
— Mineral Economics
— Innovation Management
deadlines
abstract submission
11 october 2009
notification to authors
23 october 2009
full paper submission
23 november 2009
comments to authors
30 december 2009
final paper submission
29 january 2010
early registration
23 march 2010
executive committee
Diego Hernández
chairman
minin 2010
BHP Billiton, Chile
Romke Kuyvenhoven
technical coordinator
minin 2010
Gecamin, Chile
enquiries
Isis Galeno
minin 2010
event coordinator
Gecamin, Chile
Issue 03 | 2009
Carlos Barahona
executive director
minin 2010
Gecamin, Chile
Telephone (+56-2) 652 1514
Fax: (+56-2) 652 1570
E-mail: minin@minin2010.com
www.minin2010.com
102
IMPRINT
PUBLISHING COMPANY
AMS Online GmbH
An den Wurmquellen 13 a
52066 Aachen | Germany
eMail: info@advanced-mining.com
Internet: www.advanced-mining.com
St.-Nr.: 201/5943/4085VST | USt.-ID: DE 262 490 739
03
2009
EXECUTIVE MANAGER
Minka Ruile
PUBLISHER
Prof. Dr.-Ing. habil. Hossein H. Tudeshki
University Professor for Surface Mining and
International Mining
eMail: tudeshki@advanced-mining.com
EDITORIAL TEAM
Prof. Dr.-Ing. habil. Hossein H. Tudeshki
Dr. Monire Bassir
Dr.-Ing. Stefan Roßbach
Dipl.-Umweltwiss. Christian Thometzek
eMail: redaktion@advanced-mining.com
DESIGN & LAYOUT
Dr.-Ing. Stefan Roßbach
eMail: rossbach@advanced-mining.com
Dipl.-Umweltwiss. Christian Thometzek
eMail: Christian.thometzek@advanced-mining.com
ADVERTISEMENT
03
2009
BANK CONNECTION
Bank: Sparkasse Aachen, BLZ 390 500 00
Account-No.: 1070125826
SWIFT: AACSDE33
IBAN: DE 27390500001070125826
EDUCATION
Methods for Exploratory Drilling of Deposits of Mineral Commodities
TECHNOLOGIETRANSFER
Impact of financial crisis on the German & global commodity market and the mining
industry
GRAPHICAL DESIGN
Tudeshki, H. ; Hertel, H.
Surface Mining and International Mining |
Clausthal University of Technology | Germany
Kellner, M.
Geotechnique, Mining, Petroleum Engineering | Surface
Mining and International Mining | Clausthal University of
Technology | Germany
Round Table at Hannover Messe 2009: Climate-Friendly and Energy-Efficient Raw Material ContiTech Conveyor Technology
Extraction
corporation
Northeim | Germany
ThyssenKrupp Fördertechnik (conveyor technique): Fully Mobile Crawler-Mounted
Crushing Plant for Large Open-Pit Mines
Graumann Design Aachen
Dipl.-Des. Kerstin Graumann
Augustastr. 40 - 42
52070 Aachen | Germany
Tel.: +49 (0) 241 - 54 28 58
Fax: +49 (0) 241 - 401 78 28
eMail: kontakt@graumann-design.de
Internet: www.graumann-design.de
ThyssenKrupp Fördertechnik GmbH
Essen | Germany
Volvo Construction Equipment
Volvo Fleet Under Ground - All Good Things Come From Above
Germany
Tudeshki, H. ; Xu, T.
Surface Mining and International Mining | Clausthal University
of Technology | Germany
von der Linden, E.
The most intelligent chapter in mining history was written by German Engineering
Debriv; Tudeshki, H.
NEUHEITEN & REPORTAGEN
Hot Success! Steelworks « Dillinger Hütte » & « Saarstahl »
ESCO GmbH
Stationary plants now become mobile thanks to interlinked plants! Kleemann demonstrates what is
possible today with process know-how and high-performance plants
KLEEMANN GMBH
New SURFACE MINER 4200 SM from Wirtgen: Maximum performance in large-scale opencast
mining!
WIRTGEN GMBH
METSO MINERALS Germany GmbH
Improved performance out in the open!
MB Crusher S.p.A
The new bucket crusher BF
AVANT TECNO Germany GmbH
PROGRAMMING INTERNET SITE
ATLAS COPCO
Surface Drilling Equipment, Tunnelling &
Mining Equipment
The Atlas Copco Simba W6 C rig available for new markets!
79pixel
Steffen Ottow, B.Sc.
Scharenbergstr. 24
38667 Bad Harzburg | Germany
Tel.: +49 (0) 53 22 - 8 19 38
eMail: steffen@79pixel.de
Internet: www.79pixel.de
Diamond scrap heap - Cat-machines process one of the world’s largest scrap metal stock piles in
Namibia!
CATERPILLAR INC.
EVENTS
The AMS Event Calendar 2009
THIS MAGAZINE IS SUPPORTED BY:
Bell Equipment
Continental/ContiTech
Metso Minerals
Sandvik Mining & Construction
Vermeer
Zeppelin
ISSUE DATES
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Issue 03 | 2009
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103

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