Mining and Materials Handling

Equipment and Systems

ThyssenKrupp

ThyssenKrupp Robins
2

Contents

Introduction 3

Materials Handling Equipment

Stacking, Reclaiming and Blending 4

Plant Conveyor Systems 7

Shiploaders and Unloaders 8

Service and Spare Parts 10

Mining Equipment

Bucket Wheel Excavators 12

Spreaders 14

Crushing Plants 16

Mine Conveyor Systems 18

Heap Leaching 20

Transport Crawlers 21
Introduction 3

ThyssenKrupp Robins. A long and well

established company in the field of mining and
materials handling equipment and systems.
With years of experience and a
World-wide list of installations, In the United States of America,
ThyssenKrupp Robins is fully the subsidiary of ThyssenKrupp
capable of offering reliable, Fördertechnik is ThyssenKrupp
efficient and economical Robins Inc., located in Denver,
equipment to meet the specific Colorado. Likewise in Canada,
requirements of the customer. the head office of Krupp Canada
Inc. is located in Calgary, Alberta.
The fields of activity are broad Together with ThyssenKrupp
and diversified encompassing: Robins, the two offices work to
provide cost effective solutions to
• Mining and extraction of raw satisfy the specific and varied
materials and minerals, such demands of the customer.
as coal and ore
• Movement of earth and Both offices have in-house
overburden engineering capabilities and
many years of experience backed
• Crushing, classifying, milling, up by extensive and diverse
drying and filtering of raw and reference lists. The close
processed materials relationship with the head offices
• Conveying, handling, lifting in Germany allow both
and transporting of bulk and companies to benefit from the
piece goods pool of knowledgeable and
• Storing, homogenizing and experienced engineers and
reclaiming of bulk materials technicians working world-wide
• Marine technology and within the ThyssenKrupp
logistics organization. The extensive
know-how, critical to the
Whatever the task, ThyssenKrupp satisfactory completion of any
has the machines, systems and project, is shared and enhanced
equipment to do the job. by the close working relationship.

The wide product range is due, With confidence and

in part, to the comprehensive dependability, both head offices
know-how that ThyssenKrupp in North America are capable of
has acquired and developed providing all the information
throughout many decades of specific to each customer’s
developing and designing tailor request. Whether the project be
made systems to meet the in the feasibility stage or final
particular demands specific to procurement and installation,
each project. ThyssenKrupp in North America
is able to meet the challenge.
The challenge for the future is the
continual improvement of The similarity in the structure of
products and services. Maximum the two offices and their close
effect and efficiency demand proximity to each other enables
customized solutions, a wide the staff to work as one body,
range of alternatives, continual better enabling them to serve the
product up-grades through customer.
effective development programs
and yet more innovative With representatives located
technology. across the North American
continent and in Mexico,
From planning and projecting ThyssenKrupp can assist in the
through engineering, manufac- development, management,
ture, installation and follow-up procurement, manufacture,
service, the employees of installation, commissioning and
ThyssenKrupp Robins are all after-sales service of the project.
aiming at the same goal. All for
the customers benefit. ThyssenKrupp in North America
is your contact for mining and
materials handling equipment
and systems. All for the
customers benefit.
4
Materials Handling Equipment

Stacking, Reclaiming & Blending

Above: Storeyards play an integral

The world’s largest covered Stackers are employed to form
circular stacker / reclaimer part in the layout and operation The equipment required is a
blending bed built by of most materials handling machine to stack, or form the pile the pile. They are either rail
ThyssenKrupp for a coal-fired systems. They serve as a and a machine to reclaim mounted or fixed on a central
power plant in New column. The operation of the
Brunswick.
storage area for raw or material from the pile. Piles can
Stacking capacity: 2,500 tph. processed materials, a buffer be formed either longitudinally or stacker will determine the extent
Reclaiming capacity: 1,200 area between the mine and in a circular fashion. The site of homogenization of material in
tph. processing facility, or to provide geometry, the required storage the pile.
Top Right: blending of two or more grades volume and the type of material
A large portal scraper with of material. influence the pile configuration.
two scraper booms in a
cement plant in Florida.
Overall capacity: 2,000 tph.

Bottom Right:
A-frame portal stacker /
reclaimer in Texas. Rail
gauge: 33.5 m.
Stacking capacity: 272 tph.
Reclaiming capacity: 272 tph.
5

Top Left:
Blending bed bridge-type
Reclaimers collect the material With hundreds of references, bucket wheel reclaimer used
from the pile and deposit it onto ThyssenKrupp has the storage in Australian coal handling.
the yard conveyor system. equipment for all applications. The bridge has two rakes to
allow reclaiming in either
Several types are available direction.
incorporating scraper chains, Capacity: 2,000 tph.
rotating drums and bucket
wheels. The method of Bottom Left:
A circular stacker / reclaimer
reclaiming will determine the in Florida.
amount of blending between the
various material grades in the Bottom Center:
Bucket wheel reclaimer
pile. handling coal at 6,000 tph.

Top Right:
Bucket wheel stacker /
reclaimer.

Bottom Right:
The circular stockpile installed
in a cement works has a
special loosening rake for wet
clay.
Capacity: 300 tph.
6

Stackers

Top Left: A major part of any

Crawler-mounted stacker with Rail-mounted, fully-automatic
mobile belt system. large-scale stockyard operation is Stackers are designed in a wide
A pre-requisite for building the stacker that deposits the bulk variety of configurations stackers are ideal for building up
large stockpiles. Shown here materials in pre-set patterns and depending upon the required stockpiles for blending beds.
is a stacker in South Africa. Crawler-mounted units with
Capacity: 1,600 tph.
systems. throughput, extent of mobility,
and ability to raise and lower the mobile belt systems are the
Bottom Left: stacking belt, whether single or natural choice for handling
Polar radial stacker in
twin booms are required, and large-volume stockpiles.
northern Quebec.
Boom length: 38 m. with semi or fully-automatic
Capacity: 2,500 tph. controls. Many other features
are also possible depending on
Top Right:
Traveling slewing and luffing the application.
stacker designed to handle
phosphate in Louisiana.
Boom length: 29.3 m.
Capacity: 3,000 tph.

Bottom Right:
Traveling stacker built for an
iron ore transshipment facility
in Quebec City.
Boom length: 40 m.
Capacity: 2,500 tph.
7

Plant Conveyor Systems

Conveyors are the common Top Left:

Part of the conveyor system
element in the mining, storing whether it be conventional structural system, all of the for a lead-zinc mine in Alaska
and processing phases of ore design, one that incorporates mechanical components, and the following commissioning.
handling. Generally, plant horizontal curves or one in the optimal layout of a curved The ore upgrading mill
contains seventeen
conveyor systems run on form of a pipe conveyor. conveyor system. conveyors.
prepared grades at the plant. Lengths: between 10 and
They are module type structures, In most instances, a large portion Making the best use of today’s 140 m.
mounted on foundations or en- of the project’s capital cost is set technology assures the customer Widths: Between 762 and
1372 mm.
closed in steel galleries when aside for the conveyor system. that the system will be fully Belt capacities: Between 100
elevated and inside the ThyssenKrupp utilizes the most utilized in tomorrow’s world. and 700 tph.
processing plant. Conveyors can up-to-date computer programs to
Bottom Left:
be straight or with horizontal model each conveyor in the ThyssenKrupp is your source for Pipe conveyor raising at 27
curves so that they avoid system and to optimize the conveyors to meet all the degrees from under a fluid
obstacles at the site. design and associated costs. demands of the project. bed dryer to the top of the
Programs are available to screening building. The plant
produces various sizes of
ThyssenKrupp has the ability to calculate the optimum required sand for sand blasting, grout
design and supply any type of power, the most economical mixes, glass making and
conveyor system imaginable, other uses.

Right:
Pipe conveyor in Hawaii
transporting coal from the
unloading facility 1-1/2 miles
to the power plant.
Capacity: 1,125 tph.
8

Shiploaders and Unloaders

Above: Shiploaders and unloaders

Shiploader located in Radial Type Shiploaders
Vancouver, British Columbia are the centerpieces of today’s Traveling Type Shiploaders
employed to load metallurgi- modern terminals. They ensure
cal and steam coal. accurate, reliable and sensitive Traveling shiploaders are The radial shiploader pivots at
Capacity: 7,000 tph. the tail end allowing the
Maximum ship size: 250,000
movement of materials such as mounted on rails that are parallel
DWT. coal, coke, ores, fertilizers, and to the ship. They are fed by a shiploader to access the entire
raw materials for the chemical conveyor belt incorporating a length of the ship. Rather than
industries. Our designs accept tripper that travels with the incorporating a shuttle conveyor,
bulk commodities as well as shiploader. They utilize a belt the entire upper structure travels
boxes of bananas and bags of conveyor on the boom and, in on the fixed lower bridge section
flour. most instances, a shuttle head to of the shiploader. The
provide complete coverage of the combination of bridge rotation
Generally, shipoloaders can be ship’s hold. The discharge spout and boom travel allows the
divided into two main types.: incorporates a rotating spoon operator to access all areas of
which allows the operator greater the ship’s hold.
flexibility when placing the
material.
9

Shipunloaders are also Top Left:

View of the ‘L’ type foot
Divided into two main groups, Continuous Type Shipunloader Each port has it’s own individual arrangement of a continuous
namely: site requirements, namely shipunloader designed to
The continuous shipunloader commodity, capacity and local handle a variety of
commodities ranging form
Grab Type Shipunloader incorporates a chain and bucket regulations which dictate the type coal to limestone, gypsum,
elevator system to provide of shiploader or shipunloader to sand and slag.
The grab type unloader is the continuous unloading of the hip. be employed. ThyssenKrupp has Capacity: 1,415 tph.
traditional method to unload a The machine travels alongside a wealth of experience, Maximum ship size: 65,000
DWT.
ship. It incorporates a bucket of the ship and the boom slews to knowledge and references such
appropriate size to satisfy the enable access to all areas of the that the equipment most Bottom Left:
capacity. These machines travel ship’s hold. Once the operator appropriate for the project can be A traveling slewing and luffing
shiploader handling limestone
alongside the ship. They remove sets the working limits, the PLC determined with the greatest of in Mexico.
the commodity and deposit it control system unloads the hold confidence. Capacity: 5,000 tph.
either in a hopper integral with in a smooth, dust free and near Maximum hsip size: 65,000
the shipunloader or on the land silent operation. Capacities are DWT.
behind the shipunloader. This lower with this type of design but Right:
style of shiopunloader is can reach 2,250 tph. Two radial shiploaders in
available in any capacity up to Indonesia load coal. The
terminal, with stockyard,
5,100 tph with payloads as great stacker and bucket wheel
as 85 tons. reclaimer, is laid out for a
handling capacity of 7 million
tons of coal a year.
Capacity: 4,200 tph.
Maximum ship size: 180,000
DWT.
10
Service and Spare Parts

Left: Plants and systems can only

Installation of semi-mobile Early detection of wear and minor
crushing plants in a copper perform as well as maintenance ThyssenKrupp’s after sales
mine in British Columbia. and service allow. You can rely service department provides damage provides the necessary
on ThyssenKrupp’s after sales assistance in inspection and information for preventative
Top Right:
specialists. They assist modernization of existing plants maintenance planning. On
Assembly of a large bucket
wheel. customers in a variety of tasks, and ensures the timely supply of request, ThyssenKrupp offers
from the planning phase through spare parts. inspections on precision parts,
Bottom Right: design. such as ball races, slew bearings
Servicing equipment in the and gear reducers.
field.

Next Page:
Manufacturing of a tubular
conveyor for a lead-zinc mine
in Alaska.
11
12 Mining Equipment

Bucket Wheel Excavators

Above: The ThyssenKrupp program

The massive Bucket Wheel Though compact excavators are
Excavator at work in the Encompasses a broad line of The compact excavator series
Rheinbraun Mine, Germany. bucket wheel excavator systems was developed to suit open pit traditionally suited for
designed to meet the specific mines and earthmoving applications where the material is
Top Right:
demands of each project. operations with small to medium soft to medium hard, special
Compact Bucket Wheel
Excavator Type S-100. Machines vary greatly in size and production rates. Modern considerations and modifications
capacity, from standard design computer aided design methods made during the design stage
Bottom Right: compact excavators operating at were employed to simplify the enable these machines to work in
View of a bucket wheel harder materials such as
excavator working in deep-cut 4,000 m3 per day to custom built operation of the machine,
mode. systems capable of handling as increase reliability and limestone.
much as 240,000 m3 per day. availability, reduce maintenance
requirements and increase the ThyssenKrupp compact
Large bucket wheel excavator lifetime of the components. excavator systems are
systems are custom built for the Standardization of components complimented by a a family of
specific operating conditions and and the development of a related equipment, such as
production rates for each open systematic fabrication process mobile transfer conveyors, belt
pit mine. In the world of combine to optimize delivery time conveyors, tripper cars and
technical giants, these machines and minimize capital investment. spreaders.
are capable of digging heights to
100 meters and weigh in excess
of 13,500 tons.
13

Top:
One of four bucket wheel
Depending upon the mine plan, Our bucket wheel excavators are excavators with connecting
ThyssenKrupp Bucket Wheel designed and constructed to bridge employed to reclaim oil
Excavators can be supplied as a withstand the rigors of twenty- sand in northern Alberta.
Capacity: 8,000 tph.
complete system with a four hour, year round operation
connecting conveyor bridge and under the difficult conditions and Bottom Left:
loading unit or as a single bucket extremes found in open pit mines Compact S-160 bucket wheel
wheel excavator with a discharge around the world. Whether in the excavator excavating gravel
and sand in a direct dumping
boom. In the latter case, a tropics, the desert, or the arctic, system. The transfer con-
mobile transfer conveyor is they are built to endure the veyor incorporates a screen-
usually employed between the climactic conditions and perform ing plant.
bucket wheel excavator and the to the peak of their design Capacity 720 m3 per hour.
belt conveyor to reduce the standards. Bottom Center:
frequency of shifting the bench View of a compact bucket
conveyor. wheel excavator working in a
chalk mine loading directly to
the mine conveyor system.

Bottom Right:
Another of the bucket wheel
excavators with a connecting
bridge reclaiming oil sand in
the difficult climatic extremes
of northern Alberta, Canada
14

Spreaders

Top: Spreaders are generally

Direct dumping system shows Where the mine plan permits,
two bucket wheel excavators Crawler mounted machines A belt conveyor system is
transferring overburden incorporating a conveyor system incorporated in the mine to XPS Cross Pit Spreader systems
material to an XPS spreader. mounted on the discharge boom. transfer material, via a rail or can be employed to direct dump
The spreader deposits the the waste and eliminate the need
waste on the far side of the
When transferring waste crawler mounted tripper, to the
mine, eliminating haulage. overburden to a dump, or when spreader. The entire system is for a conveyor system altogether.
stockpiling ore and raw material, shiftable so that the conveyor
Bottom Left : the spreader is the last machine moves along the working face of Overburden is excavated by
Spreader for overburden. bucket wheel excavators which
in the chain of equipment the waste dump.
Bottom Center : incorporated at the open pit feed the tail boom of the XPS
C-frame type spreader for mine. Depending on the size of the spreader. The long discharge
continuous dumping of boom of the XPS spreader, which
overburden. mine, the spreader can be fed
Capacity: 4,850 m3 per hour. ThyssenKrupp has built with one or more bucket wheel can exceed 200 meters in length,
spreaders of all capacities for excavators. Transfer conveyors spans the pit and deposits the
Bottom Right : facilities located throughout the can be used to extend the waste material on the far side of
Spreader system in a North the mine, thus eliminating the
American hard coal open pit
world. The service weight of the working range of the excavator
mine. equipment ranges from 70 tons and minimize traveling of the need for a conveyor system. As
Capacity; 6,800 m3 per hour. up to 5,400 tons, which spreader. the mine face progresses, the
corresponds to a machine with a SPS spreader backfills the mine
daily capacity of 240,000 m3. with waste, thus reclaiming the
site.
15

Above:
This XPS Cross Pit Spreader
The XPS Cross Pit Spreader System in Texas has a dis-
system also eliminates the need charge boom length of 207
for trucks at the mine to handle m.
overburden. The system is very Capacity: 3,000 m3 per hour.
efficient and reliable, providing a
continuous movement of waste
from the working face of the pit to
the mined-out side.
16

Crushing Plants

Left: In hard rock mining, belt

Aerial view of two semi-
mobile crushers used in a conveyor systems have an The ThyssenKrupp program can • Semi-mobile crushing plants
copper mine in British unquestionable advantage over be divided into three main are designed to rest on steel
Columbia. truck and rail transport. To allow categories of crushing plants: feet integral with the design.
Top Right :
mined material to be handled by Concrete footings are not
Mobile Crushing Plant with a conveyor, a crusher must be • Relocatable plants which are required as the plants rest on a
gyratory crusher, hydraulic installed in the system. generally anchored to concrete prepared gravel bed.
walking mechanism and
conveyor bridge on crawlers. footings. The plant would be Transport crawlers are usually
Capacity: 3,000 tph of ThyssenKrupp has been engaged dismantled into several large used to relocate the plants as
sandstone. in the design and supply of segments for relocation within the mine progresses.
crushing plants for over 35 the mine. In most instances,
Bottom Right :
One of two semi-mobile
years. The result is a broad the plants are not moved • Fully mobile crushing plants,
gyratory crushers located in a spectrum of reliable tried and within the first six years of supported on rubber tires or
copper mine in British proven designs to satisfy any operation. crawlers. These plants move
Columbia. crushing scenario.
Capacity: 6,000 tph. as the mine face develops and
very often incorporate transfer
conveyors prior to the main
conveyor.
17

Top Left:
Relocatable and semi-mobile Various types of crushers are One soon realizes that there are Semi-mobile gyratory
crushing plant with transport
crushing plants are generally available for incorporation in the many factors which dictate the crawler in Utah.
built into a slot in the mine bench crushing plant. They include type of crushing system to be Capacity: 9,000 tph of copper
and fed with haul trucks. They jaw, impactors, hammer, employed at any particular mine. ore.
are positioned at a strategic gyratory and double roll to name With our experience and broad
Bottom Left:
location in the mine to optimize a few. The size and abrasiveness knowledge, ThyssenKrupp has Semi-mobile crushing plant in
the haul distance. Depending on of the ore being mined, capacity the crushing systems to meet the Arizona incorporating a
demands of the industry. concrete dump pocket and
the mine plan, these crushers are of the system and the final horizontal apron feeder.
capable of up to 10,000 tph. product size are important factors Capacity: 4,500 tph of copper
in the selection of the correct ore.
Fully mobile crushers work on the type of crusher. Top Center:
pit floor and follow the mine face Semi-mobile crushing plant in
as it progresses. They are Crushing plants can be direct British Columbia being
usually fed with front end loaders truck dump design or they can relocated with a 288-wheel
trailer.
and, as a result, have lower incorporate a hopper with feeder Capacity: 3,600 tph of copper
capacities when compared to to better regulate the flow of ore ore.
crushers fed by haul trucks. to the crusher. The type of
Top Right:
crusher material being handled Mobile crusher on pneumatic
and the layout fo the conveyor tires in Texas.
system all influence the design of
the crushing plant. Bottom Right:
Mobile crushing plant on
pneumatic tires in California.
18

Mine Conveyor Systems

Left: The continuous belt conveyor

A 12 km overland conveyor The pipe conveyor system is an
transporting coal in northern system is the link between the The Conveyor system can be
Alberta. The route follows the crushing plant and the mill, when either for a fixed location or can effective and economical
owner’s right of way, traveling handling ore, and the waste be made shiftable. Shiftable alternative to conventional belt
through mountain valleys, conveyors. Both the top and
tunnels under a major logging
spreader, when handling waste. conveyors are mounted on
road and crosses the The conveyors can run in a sleepers and are relocated as the bottom strands of the belt are
Athabasca River. It is straight line following the natural mine expands. The conveyors rolled into a tube shape, totally
designed to withstand harsh contour of the land or they can are powered by electric drives enclosing the ore within the
climatic conditions with conveyor and eliminating the
temperatures between –40° C run through horizontal curves, mounted at the head and tail
and + 35° C. simplifying the layout. ends and ratings as high as 6 x need for covers.
Capacity: 700 tph. 2,000 kW per conveyor are
ThyssenKrupp has built hundreds possible. Important considerations when
Top Right :
Conveyor headstation built for of systems throughout the world laying out a pipe conveyor
an oil sand mine in northern with capacities as high as For conveyors running downhill, system are that the pipe
Alberta. It is one of several 40,000 tph and belt widths to it is possible to regenerate power conveyor can run at much
movable headstations at the
site. 3.0 meters. with the conveyor system. steeper inclined angles than a
Capacity: 9,000 mtph. Generated power is fed back into conventional system and it can
the power grid at the mine, thus include a multiple of horizontal
Bottom Right : and vertical curves. Relatively
Three overland curved belt reducing the associated
conveyor systems connecting operating costs. small radia eliminate the need
the open pit mine and the for transfer stations and reduce
power station are so-called the overall cost of the system.
“contour conveyors” with
horizontal, concave and
convex vertical curves. One
conveyor is 8.55 km while the
other two are 5.5 km each.
Capacity: 1,000 tph each.
19

This Pipe Conveyor

Was built in South Dakota.
The two kilometers from the
open pit mine to the new
crushing plant are managed
with ten horizontal curves.
Capacity: approx. 350 tph of
gold ore.
20

Heap Leaching

Left: The increased usage of large

The bridge stacker illustrating
the freestanding stacker heap leach pads for the recovery The stacker is capable of luffing
concept. of copper and gold over the last and rotating. Because of the
few years has permitted counterweighted design, the unit
Top Right :
Portable conveyors for a heap
ThyssenKrupp to use it’s own is free standing and the boom
leach mine in Chile. knowledge of large spreader does not need to be supported
Capacity: 3,000 tph. systems to develop a stacking on wheels. The ThyssenKrupp
system suitable for both bridge and stacker design has
Bottom Right :
Crawler mounted tripper with permanent and on-off pads. several advantages over
cross conveyor. traditionally designed stackers,
Portable conveyors transfer the namely:
ore from the overland conveyor
system to a large crawler • The crawlers only travel on a
mounted traveling bridge with small area of the pad, thus
integral radial stacker. The reducing compaction which
traveling bridge is supported by could reduce the flow of
two pairs of powered and leachate through the pile.
steerable crawlers. The
counterweight balanced stacker • The indexing bridge is 70
is mounted at the head end of meters long, reducing the
the bridge. frequency of conveyor
relocation.
• The system operates in both
the retreat and advance
modes, fully controlled by an
on-board PLC.
21

Transport Crawlers

The implementation of large Top Left:

Transport crawlers come in
shiftable conveyor systems and Several models of transport The ThysssenKrupp transport various sizes and can be
semi-mobile crushing plants led crawlers are available from crawler is the economical and utilized for moving
to the development of the ThyssenKrupp, the largest is efficient solution to meet the semi-mobile installations.
ThyssenKrupp transport crawler. capable of handling 1,200 tons. demands of the mining industry. Center Left:
These units are extremely robust A Frontal view showing the
and heavy duty. They are The modern mine plan calls for breadth of the crawler base.
designed to travel over uneven frequent shifting of conveyors
Bottom Left:
terrain and negotiate very steep and crushing plants in order to A transport crawler in action,
grades. minimize truck haulage. moving a large semi-mobile
crushing unit from one point
to another. Note the
hydraulic lift system which
supports the unit above the
crawler.

Right:
Transport crawler moving a
heavy conveyor drive station
weighing 700 tons.
TKRI MINING/MATERIALS HANDLING / 2004 / DEPT. 2300

ThyssenKrupp Robins Inc.

7730 East Belleview Ave. Suite 404
Greenwood Village, Colorado
80111-5820 U.S.A.

www.thyssenkrupprobins.com
Phone: 303-770-0808
Fax: 303-770-8233
E-mail: [email protected]