AU2021201301B2

AU2021201301B2 - Low Headroom Jaw Crushing Facility

Info

Publication number: AU2021201301B2
Application number: AU2021201301A
Authority: AU
Inventors: Johan Albertus Luies; Bruno Ruggiero
Original assignee: Lycopodium Minerals Pty Ltd
Current assignee: Lycopodium Minerals Pty Ltd
Priority date: 2020-07-14
Filing date: 2021-02-27
Publication date: 2023-01-19
Anticipated expiration: 2041-02-27
Also published as: AU2022100178A4; AU2022100178B4; AU2021201301A1

Abstract

5 A low headroom jaw crushing facility comprising: a structure housing a Run of Mine (ROM) bin 54 for receiving ROM ore from either a dump truck 56 or front end loader (FEL), and a primary feeder 58 for conveying ROM ore 10 delivered to the ROM bin 54 to an adjacent crushing circuit 60. The crushing circuit 60 comprises: a jaw crusher 62 for crushing coarse oversize ore and, a discharge conveyor 64 for collecting dribble from the primary feeder 58 and discharge product from the jaw crusher 62, and transporting it to a next processing stage. 15 Drawing to accompany abstract: Figures 3 and 4 . ... .... ................. ..... ... ....... .... NAh .. . -... rt 7---'1 ..... ... . ...v..

Description

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ORIGINAL AUSTRALIA

Patents Act 1990

COMPLETE SPECIFICATION

Invention title:

"LOW HEADROOM JAW CRUSHING FACILITY"

Applicant:

LYCOPODIUM MINERALS PTY LTD

Associated Provisional Application No.: 2020902426

The following statement is a full description of the invention, including the best method of performing it known to me:

"LOW HEADROOM JAW CRUSHING FACILITY"

Field of the Invention

The present invention relates to an improved low headroom jaw crushing facility and relates particularly, though not exclusively, to such a jaw crushing facility for use in the mining industry.

Background to the Invention

A conventional or low headroom jaw crushing facility is typically rated to approximately 4-6 Mtpa maximum capacity (depending on numerous other factors, but not critical for the purposes of this discussion). Historically, should a crusher of greater capacity be required, a gyratory crusher would typically be used. Typically, the smallest gyratory crusher has a capacity of 6 8 Mtpa when selected on the same basis as the jaw crusher alluded to above.

There are two obvious gaps in the current approach to design. These are: (a) There is a void between the 4-6 and 6-8 Mtpa capacity range - the challenge is how to address this gap in the market offerings. (b) A gyratory crusher installation is significantly more capital- and schedule- intensive, and requires significantly more maintenance attention than an equivalent jaw crusher installation.

There is a further problem in that as the capacity of the crushing circuit increases the overall Run of Mine (ROM) height also typically increases. While a low headroom gyratory crusher facility already exists, the inherent characteristics of the gyratory crusher have not lead to the general acceptance of this style of design. The low headroom gyratory crusher design that results is compromised for a number of reasons, including: 1. Inability to evenly feed the gyratory crusher around its periphery (by virtue of having an apron feeder feeding the crusher), leading to preferential wear and wastage of the liners. Some vendors have tried to address this by introducing a means to rotate the concave segments. II. Inability to utilise the full capacity of the gyratory crusher due to inability to evenly feed the crusher around its periphery (by virtue of having an apron feeder feeding the crusher). III. Hydroset maintenance (from below the crusher) causes discharge product to fall a significant distance onto the receiving conveyor, thus posing a considerable, and more often than not unacceptable, risk to the ongoing operation. Some vendors have tried to address this by introducing what is termed a 'top service unit', whereby all maintenance is undertaken from above the crusher.

The present invention was developed with a view to providing an improved low headroom jaw crushing facility that has a ROM height significantly less than that of a conventional jaw crushing facility using the same design basis, but has an overall circuit capacity that is equivalent to that of a comparable gyratory crusher installation.

References to prior art in this specification are provided for illustrative purposes only and are not to be taken as an admission that such prior art is part of the common general knowledge in Australia or elsewhere.

Summary of the Invention

According to one aspect of the present invention there is provided a low headroom jaw crushing facility which is permanently fixed, the jaw crushing facility comprising:

a structure housing a ROM bin for receiving ROM ore from either a dump truck or front end loader (FEL), the structure comprising a concrete ROM foundation;

a primary feeder for conveying ROM ore delivered to the ROM bin to an adjacent crushing circuit supported on a concrete foundation, wherein the foundation of the crushing circuit and the ROM foundation are at substantially the same level, the crushing circuit comprising: a jaw crusher for crushing coarse oversize ore; and, a discharge conveyor for collecting dribble from the primary feeder and discharge product from the jaw crusher, and transporting it to a next processing stage.

Preferably the jaw crusher is independently supported on a steel structure. Typically the crushing circuit further comprises a vibrating grizzly for screening the ore ahead of the jaw crusher. Preferably the vibrating grizzly is also independently supported on a steel structure. Advantageously the discharge conveyor also collects undersize ore from the vibrating grizzly.

Typically the primary feeder is an apron feeder which is used to direct the ore onto the vibrating grizzly. Typically the apron feeder is inclined at 150 - 180 to the horizontal.

Preferably a dribble conveyor is provided to collect dribble from the primary feeder and transfer it via a dribble chute onto the discharge conveyor. Alternatively the discharge conveyor could be used for this purpose, albeit at the penalty of increased ROM height. In one embodiment the structure housing the ROM bin is a concrete vault. Alternatively a structural steel support system with retaining wall can be used in lieu of the concrete vault.

In another embodiment the primary feeder is one of two parallel primary feeders, which are used to direct the ore onto two respective parallel downstream crushing circuits.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Likewise the word "preferably" or variations such as "preferred", will be understood to imply that a stated integer or group of integers is desirable but not essential to the working of the invention.

Brief Description of the Drawings

The nature of the invention will be better understood from the following detailed description of several specific embodiments of the improved low headroom jaw crusher facility, given by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a side elevation of a conventional gyratory crushing facility;

Figure 2 is a side elevation of a conventional jaw crushing facility;

Figure 3 is a side elevation of a first embodiment of a low headroom jaw crushing facility according to the present invention;

Figure 4 is a plan view of a second embodiment of a low headroom jaw crushing facility according to the present invention; and,

Figure 5 is a plan view of a modified version of the low headroom jaw crushing facility of Figure 4.

Detailed Description of Preferred Embodiments

Conventional GyratorV Crusher

A conventional gyratory crushing facility is shown in Figure 1 and comprises a concrete vault 10 which is used to house the gyratory crushing facility, and which is buried within a run of mine (ROM) pad 12. A run of mine (ROM) dump hopper 14 which is used to receive the ROM ore from either a dump truck or a front end loader (FEL), and direct the ore into a gyratory crusher 16. A crusher discharge chamber 18 is provided, typically larger than the dump hopper 14, to ensure that the gyratory crusher 16 does not need to stop while packed with ore, and to service the gyratory crusher hydroset (at the bottom of the crusher 16).

A primary feeder 20, typically an apron feeder, is used to direct the ore onto a crusher discharge conveyor 22. The discharge conveyor 22 collects dribble from the apron feeder 20 and the primary feeder discharge, to transport the crushed ore to the next stage of processing. The discharge conveyor 22 typically which runs in a corrugated steel tunnel or similar until it daylights the ROM pad. Various chutes 24, to collect and direct the crushed ore between the various items of equipment, and various access platforms 26, etc. as required to service the gyratory crusher hydroset, are provided. Various steel platforms and stairs 28, etc. which are used to complete the installation and provide working areas and access ways to all of the contained equipment are also provided.

The conventional design can be modified to include: A rock-breaker 30 at the ROM hopper 14 as required. Maintenance cranage in the form of a bridge crane 32, which is used to service not only the crusher 16, but also all floors within the concrete vault 10.

The conventional gyratory crushing facility, arranged in the manner illustrated, exhibits a number of key physical characteristics, these being:

A. The concrete vault 10 to house the entire crushing plant, which eliminates the possibility of differential settlement between individual elements housed within the vault - which in poorer quality soils is always problematic. B. A ROM height of 'X1' m. Reducing the overall height of this facility is desirable because: a. This would generally lead to a reduction in the overall cost of the facility and its associated construction schedule. b. This would generally lead to a reduction in working at heights requirements, thus promoting a safer workplace, with significant intangible benefits.

c. This would generally lead to a reduction in magnitude of the ROM pad required, with resultant savings in cost and schedule. d. This would generally lead to a reduction in ore haulage costs, as the travel distance for the ore that will be processed is reduced.

Conventional Jaw Crusher

A conventional jaw crushing facility, as shown in Figure 2, comprises a concrete vault 36 which is used to house the jaw crushing facility. A run of mine (ROM) bin 38 is provided, which is used to receive the ROM ore from either a dump truck 40 or front end loader (FEL), and direct the ore onto a primary feeder 42. The primary feeder 42, typically an apron feeder, is used to direct the ore onto a vibrating grizzly 44. The primary feeder is typically inclined at 150 to 180 to the horizontal. The vibrating grizzly 44, is used to screen the ore ahead of a jaw crusher 46. The jaw crusher 46 is used to crush the coarse oversize ore from the grizzly 44.

A discharge conveyor 48 collects dribble from the apron feeder 42, the undersize ore from the vibrating grizzly 44, and the discharge product from the jaw crusher 46, and transports it to the next stage of processing. Various chutes 50, to collect and direct the crushed ore between the various items of equipment, and various steel platforms and stairs 51, etc. which are used to complete the installation and provide working areas and access ways to all of the contained equipment, are also provided.

The conventional design can be modified to include: A structural steel support system with retaining wall in lieu of the concrete vault 36. A rock breaker 30 at the ROM bin 38 and/or at the jaw crusher 46 as required. Maintenance cranage 32 in the form of either a bridge crane/ monorail or similar.

The conventional jaw crushing facility, arranged in the manner illustrated, exhibits a number of key physical characteristics, these being: A. The concrete vault 36 to house the entire crushing plant, which eliminates the possibility of differential settlement between individual elements housed within the vault - which in poorer quality soils is always problematic. B. A ROM height of 'X2' m. Reducing the overall height of this facility is desirable because: e. This would generally lead to a reduction in the overall cost of the facility and its associated construction schedule. f. This would generally lead to a reduction in working at heights requirements, thus promoting a safer workplace, with significant intangible benefits. g. This would generally lead to a reduction in magnitude of the ROM pad required, with result savings in cost and schedule. h. This would generally lead to a reduction in ore haulage costs, as the travel distance for the ore that will be processed is reduced.

Low Headroom Jaw Crushing Facility

A first embodiment of a low headroom jaw crushing facility according to the present invention will now be described with reference to Figure 3. The low headroom jaw crushing facility comprises a structure which is used to house a ROM bin 54. In this embodiment the structure is a concrete vault 52. The ROM bin 54 is used to receive the ROM ore from either a dump truck 56 or front end loader (FEL), and direct the ore onto a primary feeder 58. The primary feeder, typically an apron feeder 58, is used to direct the ore to an adjacent crushing circuit 60. The primary feeder 58 is inclined at 150 - 180 to the horizontal.

The crushing circuit 60 typically comprises a jaw crusher 62 for crushing coarse oversize ore, and a discharge conveyor 64 for collecting dribble from the primary feeder 58 and discharge product from the jaw crusher 62, and transporting it to a next processing stage.

Typically the crushing circuit 60 further comprises a vibrating grizzly 66 for screening the ore ahead of the jaw crusher 62. Preferably the vibrating grizzly 66 is independently supported on a steel support structure 68. The jaw crusher 62 is used to crush the coarse oversize ore from the grizzly 66, and is also independently supported on a steel support structure 70. Advantageously, both the steel support structures 68 and 70 can be mounted on a separate concrete foundation to the crusher vault 52. Because the concrete vault 52 housing the ROM bin 54 is independent of the adjacent crushing circuit 60, and the ROM pad is significantly reduced in height, overall settlement of the concrete vault 52 and crushing circuit 60 are both commensurately reduced (the ROM pad being the most significant load and greatest contributor to settlement). More specifically, the settlement of the concrete vault 52 and adjacent crushing circuit 60 is such that they do not impact each other.

Advantageously undersize ore from the grizzly 66 also reports to the discharge conveyor 64. Preferably a dribble conveyor 72 is provided to collect dribble from the apron feeder 58 and transfer it via a dribble chute 73 onto a discharge conveyor 64.

Various chutes 74, collect and direct the crushed ore between the various items of equipment, and various steel platforms and stairs 76, etc. are used to complete the installation and provide working areas and access ways to all of the contained equipment.

The design of the low headroom jaw crushing facility can be modified to include: A structural steel support system with retaining wall in lieu of the concrete vault 52. A rock-breaker 82 at the ROM bin 54 and/or the primary crusher 62 as required. Maintenance cranage in the form of either a bridge crane 78, monorail or similar.

The low headroom jaw crushing facility of Figure 3 exhibits a number of advantageous physical characteristics, these being: A. A concrete vault to house the ROM bin 54 and the primary feeder 58, which eliminates the possibility of differential settlement between these critical elements. B. A ROM height of approximately 'X3' m, where X3 is significantly less than X2 using the same design basis as that for the conventional jaw crushing facility. C. The vibrating grizzly and jaw crusher foundations can now be designed as mass concrete foundations using simple in-situ pouring techniques. D. The steel support structures 68, 70 for the jaw crusher 62 and vibrating grizzly 66 respectively can be modularised and delivered to site as prefabricated systems, with much reduced installation requirements.

Other benefits of the low headroom jaw crushing facility compared with the conventional jaw crushing facility are therefore: E. A significant reduction in the overall cost of the facility and its associated construction schedule. F. A significant reduction in working at heights requirements, thus promoting a safer workplace, with significant intangible benefits. G. A significant reduction in ore haulage costs.

A second embodiment of the low headroom jaw crushing facility according to the present invention will now be described with reference to Figures 3 and 4. The low headroom jaw crushing facility of Figure 4 is similar to the low headroom jaw crushing facility of Figure 3, and therefore the like parts will be identified with the same reference numerals, and will not necessarily be described again in detail. In side elevation the low headroom jaw crushing facility of Figure 4 looks substantially the same as that shown in Figure 3. As with the previous embodiment, it comprises a concrete vault 52 which is used to house the ROM bin 54. However in this embodiment a bifurcated ROM bin

54 is used to receive the ROM ore from either a dump truck 56 or front end loader (FEL), and direct the ore onto two primary feeders 58a and 58b arranged to operate in parallel. The two parallel primary feeders, typically apron feeders 58a and 58b, are used to direct the ore onto respective parallel downstream crushing circuits 60a and 60b.

The two parallel crushing circuits 60a and 60b, downstream of the primary feeders 58a and 58b, are substantially unchanged from that described for the low headroom jaw crushing facility of Figure 3, and therefore will not be described again here. Crusher discharge conveyors 64a and 64b can be designed to run independently to the next stage of processing, or combined onto a single conveyor to run to the next stage of processing.

The low headroom parallel circuit jaw crushing facility, illustrated in Figure 4, exhibits all of the characteristics described for the low headroom jaw crushing facility of Figure 3, whilst offering significant overall benefits when compared to two parallel conventional crushing circuits or a gyratory crushing facility, including the following: A. An overall circuit capacity that is equivalent to that of a comparable gyratory crusher. B. An extension in the range of application of a jaw crusher to typically twice that of a conventional jaw crushing facility and a circuit that is capable of better meeting the demand for circuits between that of a single jaw crusher to the smallest gyratory crusher, i.e. the extension of the range of application of the preferred crusher type. C. A redundant crushing circuit, which enables one of the jaw crushing circuits to operate while the other is being maintained, leading to an increase in availability and utilisation. The only time that both crushing circuits 60a and 60b must be shutdown is when the ROM bin 54 is down for maintenance, i.e. the ROM bin will be sized such that ROM ore can rill from either side of the ROM bin to the operating line. D. A significant reduction in the overall cost of the facility and its associated construction schedule.

E. A ROM height of approximately 'X4' m, where X4 is significantly less than X1 using the same design basis as that for the conventional gyratory crushing facility. F. A significant reduction in working at heights requirements during construction, thus promoting a safer workplace, with significant intangible benefits. G. A significant reduction in ore haulage costs. H. A facility which is significantly more cost and schedule effective when compared to a gyratory crushing installation or two parallel and independent jaw crushing facilities.

The low headroom parallel circuit jaw crushing facility can easily be designed with a structural steel support system with retaining wall in lieu of the concrete vault 52.

For the examples given above, X1 = >24m; X2 =18m, X3=12m, X4=13m. However, the main point is that for the purposes of comparison, on a like for like basis, X1>X2>X3 and X3 is approximately equal to X4, i.e. the low headroom jaw crushing facility of the present invention provides a significantly reduced overall ROM height compared to both the conventional gyratory crusher facility and the conventional jaw crusher facility.

A modified form of the low headroom parallel circuit jaw crushing facility is shown in Figure 5. This modified low headroom parallel circuit jaw crushing facility contains all of the features of that described with reference to Figures 4 and 3. However in this case the ROM bin 54 has been modified to allow dual tipping, by providing side approaches to the ROM bin for dump trucks 80a and 80b as shown. This facilitates a higher number of heavy vehicle movements on the ROM pad due to reduced queueing times at the ROM bin 54.

This may be considered advantageous in some situations where the selection of mining fleet, for whatever reason, results in a higher number of heavy vehicle movements which must be managed safely and efficiently on the ROM pad.

Now that preferred embodiments of the improved low headroom jaw crushing facility have been described in detail, it will be apparent that the described embodiments provide a number of advantages over the prior art, including the following:

(i) Significantly reduced overall ROM height compared to both the conventional gyratory crusher facility and the conventional jaw crusher facility (ii) A significant reduction in working at heights requirements during construction, thus promoting a safer workplace, with significant intangible benefits. (iii) A significant reduction in the overall cost of the facility and its associated construction schedule.

It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention. For example, in the illustrated embodiments the primary feeder in each case is an apron feeder. However it will be apparent that any suitable conveyer system could be employed. Therefore, it will be appreciated that the scope of the invention is not limited to the specific embodiments described.

Claims

The Claims defining the invention are as follows:

1. A low headroom jaw crushing facility which is permanently fixed, the jaw crushing facility comprising:

a structure housing a Run of Mine (ROM) bin for receiving ROM ore from either a dump truck or front end loader (FEL), the structure comprising a concrete ROM foundation;

a primary feeder for conveying ROM ore delivered to the ROM bin to an adjacent crushing circuit supported on a concrete foundation, wherein the foundation of the crushing circuit and the ROM foundation are at substantially the same level, the crushing circuit comprising:

a jaw crusher for crushing coarse oversize ore; and,

a discharge conveyor for collecting dribble from the primary feeder and discharge product from the jaw crusher, and transporting it to a next processing stage.

2. A low headroom jaw crushing facility as defined in claim 1, wherein the jaw crusher is independently supported on a steel structure.

3. A low headroom jaw crushing facility as defined in claim 1, wherein the crushing circuit further comprises a vibrating grizzly for screening the ore ahead of the jaw crusher.

4. A low headroom jaw crushing facility as defined in claim 3, wherein the vibrating grizzly is also independently supported on a steel structure.

5. A low headroom jaw crushing facility as defined in claim 3, wherein the discharge conveyor also collects undersize ore from the vibrating grizzly.

6. A low headroom jaw crushing facility as defined in claim 1, wherein the primary feeder is an apron feeder which is used to direct the ore onto the vibrating grizzly.

7. A low headroom jaw crushing facility as defined in claim 6, wherein the apron feeder is inclined at 150 - 180 to the horizontal.

8. A low headroom jaw crushing facility as defined in claim 1, further comprising a dribble conveyor to collect dribble from the primary feeder and transfer it via a dribble chute onto the discharge conveyor.

9. A low headroom jaw crushing facility as defined in claim 1, wherein the discharge conveyor is used to collect dribble from the primary feeder, albeit at the penalty of increased ROM height.

10. A low headroom jaw crushing facility as defined in claim 1, wherein the structure housing the ROM bin is a concrete vault.

11. A low headroom jaw crushing facility as defined in claim 1, wherein a structural steel support system with retaining wall is used as the structure housing the ROM bin.

12. A low headroom jaw crushing facility as defined in claim 1, wherein the primary feeder is one of two parallel primary feeders, which are used to direct the ore onto two respective parallel downstream crushing circuits.

Dated this 1st day of December 2022

Lycopodium Minerals Pty Ltd by its Patent Attorneys WRAYS