Bulk materials handling in mining

Sandvik is a high-technology engineering group with world-leading positions in selected areas tools for metal working, advanced materials technology, and mining and construction. We employ more than 40 000 people and are represented in 130 countries. Sandvik Mining and Construction represents one third of the overall Sandvik Group and serves a broad range of customers in construction, mineral exploration, mining and bulk materials handling. Our construction expertise covers quarrying, tunneling, demolition and recycling, and other civil engineering applications. Our mining products and services support customers on the surface and under ground, including coal, copper and gold mining.

SANDVIK MINING AND CONSTRUCTION

WWW.SANDVIK.COM

Sandvik is a registered trademark of the Sandvik Group

2007 Sandvik

SFM-AB-M-1

Engineering and planning

Bulk materials handling expertise and competence

Nowhere is the breadth and depth of Sandviks expertise more apparent than in the handling of bulk materials. Since our 19th century roots, we have developed into a global industry leader. Wherever bulk material is handled, you will find Sandvik present. A focal area is the systems and needs surrounding the mining industry. You also find us in downstream operations, such as ports, power plants and mills, with an approach tailored for each application. Fabrication and inspection Excavation, transportation, sizing, stockyard storing, homogenization and reclamation are all part of the mining processes we support. Our offering includes consulting, systems design, engineering, procurement, erection and support, for turn-key projects, individual new equipment or upgrades and modernizations. Sandvik applies mining and automation technologies to help you best utilize your assets. We design and manufacture the full range of conveyor components used in materials handling equipment, whether for new systems or replacement parts to any existing equipment. Our goal is to make our customers more successful through long-term cooperation and partnerships. That success comes from efficient process design, innovative engineering and a dedication to reliability. The Sandvik brand has always stood for productivity and quality. Through the well developed Sandvik Mining and Construction organization, we also have the global parts logistics and local services to keep the continuous mining processes running.

Commissioning and on-site training

Maintenance and services

AROUND PIT SYSTEM - bucket wheel excavator, beltwagon, conveyors...

Continuous open pit soft rock mining systems

A continuous soft rock process starts with a bucket wheel excavator. The mined material, overburden or other material, such as lignite, is then transported from the pit on conveyors. Overburden material is typically dumped on the other side of the pit across from the mine face. Sandvik has a long history as a leading supplier of soft rock mining systems. We supply a multitude of different machines, with various purposes and capabilities to facilitate the continuous process. Our engineering and mining experts design the correct system for each specific mine, using one of the two following techniques. AROUND THE PIT SYSTEM In this technique, the conveyor system transports the material along three sides of the pit. Because each mine operation is unique, Sandviks engineering and mining experts design the correct system for each specific operation. The bucket wheel excavator, through an installed conveyor system, discharges overburden into the receiving chute of a hopper car. To minimize distance and height issues, a beltwagon can work as a mobile link to the mobile hopper offering greater flexibility. A conveyor system, specially adapted to the topographic conditions, transfers the material around the pit to a crawler-mounted spreader which discharges the waste material in the dumping area. Sandviks around the pit systems: Adapt to different mining and deposit conditions Provide shiftable or mobile conveyors Accommodate long distances between mines and dump areas CROSS PIT SYSTEM In this specialized system, to be used as an across the pit conveyor, the excavator extracts overburden material and feeds it via conveyors to a spreader. The spreader conveys the waste material directly across the open pit and onto the developing dumping area. Sandviks cross pit systems: Produce the shortest distance and time for conveying material Mines deeper reserves economically Meet requirements of certain geographical conditions at the dump site ...and spreader for continuous mining

CROSS PIT SYSTEM - bucket wheel excavator and spreader

Overall length of 350 m (1150 ft) installed by Sandvik in USA

In-pit crushing with fixed, semi-mobile and mobile plants

Continuous open pit hardrock mining systems

In a continuous hard rock process, drilling and blasting are still utilized. But unlike the traditional load and truck haul process, the materials transportation from the pit is continuous. The process includes in-pit crusher, a conveying system and spreader to dispose of waste material in a dumping area. Sandvik draws on a wealth of experience and expertise for designing and installing the most effective and economical systems in hard rock mining. These include three different processes which, using fixed, semi-mobile or fully mobile in-pit crushers, are tailored to your specific mine. Our offering covers drilling, in-pit crushing and all materials handling systems, with an extensive list of references demonstrating our competence and understanding of customer needs. Sandviks innovative systems have proven to reduce operating costs for transportation, manpower and maintenance. An additional benefit is the improved environment with electrically-powered material haulage. IN-PIT CRUSHING WITH FIXED AND SEMI-MOBILE PLANTS In this method, trucks are used to transport material from the mine face to the inpit crusher, often moving between levels when using semi-mobile plants. As mining advances, the hauling distance to the crusher increases, eventually requiring the crusher and conveyors to be relocated. IN-PIT CRUSHING WITH FULLY-MOBILE PLANTS In this method, without any trucks, a fully mobile crusher or sizer is positioned between the mine face and a conveyor. The crushing plant, typically crawler-mounted, continuously follows the mine face development. High-angle conveyors can be used to avoid overly long mine conveyors to transport material from the pit. Sandviks continuous mining technology and our understanding of process needs have meant improved results for our customers.

Shiftable track-mounted conveyors in Thailand

Spreader with tripper car for systematic dumping of overburden

BUCKET WHEEL EXCAVATORS - capacities 150 - 10 000 m3/h (196 - 13 100 yd3/h) - loose

Continuous open pit mining equipment

Sandvik specialized equipment for bulk materials handling support continuous mining processes for hard and soft rock. BUCKET WHEEL EXCAVATORS Sandvik bucket-wheel excavators are designed to strip overburden and mine coal, lignite and various soft minerals continuously. Controlled by state-of-the art PLC systems with extensive automation possibilities, they have ergonomic, user-friendly interfaces for operator comfort, quick familiarization and sustained high productivity. Since they are of modular construction and custom-built, our bucket wheel excavators are easy to optimize for different applications. BELTWAGONS (OR MOBILE TRANSFER CONVEYORS) Sandvik beltwagons, or mobile transfer conveyors, are designed to form a flexible, adjustable, synchronized bridge between the bucket wheel excavator and the bench conveyor in order to ensure a continuous, uninterrupted flow of material from open pit mining operations. SPREADERS The purpose of the spreader is to receive overburden from the haulage conveyor and dump it in an orderly and efficient manner. The extensive line of Sandvik spreaders ranges from 30 m (100 ft) to more than 350 m (1 150 ft) in length corresponding with machine service weights of, respectively, 50 to 4 000 metric tons. Rail or track-mounted tripper cars, usually part of the spreader package and also delivered from Sandvik, are used to transfer the material from the haulage conveyor to the spreader. TRANSPORT CRAWLERS AND AUXILLIARY EQUIPMENT Sandvik transport crawlers are special vehicles used to relocate heavy mine equipment and plants, such as conveyor drive stations and semi-moble crushing plants safely and economically over rough terrain and/or poor ground conditions. The load carrying capacities of our transport crawlers range from 150 to 1 500 metric tons.

BELTWAGONS - cost-effective link between excavator and conveyor

TRANSPORT CRAWLERS - transportation for heavy loads of mining equipment even in difficult conditions

SPREADERS - customized for each mine with a capacity to match the current range of Sandvik bucket wheel excavators

Overland conveyors in Nigeria

Transportation systems
Sandvik has a highly skilled projects division specializing in the design, manufacture, installation and commissioning of conveyor systems for a full range of applications. We also upgrade and modernize systems and supply a comprehensive range of quality components and spare parts. MINE CONVEYORS Our systems for open pit mines include shiftable, semi-mobile and fully mobile trackmounted conveyors, always tailored exactly to specialized needs. Based on a modular concept that greatly facilitates relocation or expansion as the mine develops, our system can expedite and optimize the process of material removal, redistribution and stacking. OVERLAND CONVEYORS Sandvik is recognized worldwide for its developments in long overland conveyors with both horizontal and vertical curves. Co-operating with the natural lay of the land, our long-distance systems provide a cost-efficient and more environmentally friendly alternative to trucking for transportation of bulk materials. Our innovative technology also reduces noise and dust emissions. Our overland conveyors have ranged from 1 to 13 km (0.6 to 8 miles) as a single flight, operating at belt speeds of 2.5 to 7 m/s (8.2 to 23 ft/s).

Overland conveyors in Brazil

Mine conveyors in Thailand

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Market leader in conveyor components

Conveyor components bulk materials transportation

Transportation systems depend on the consistant functioning of conveyor components. Sandviks complete conveyor offering includes components with an emphasis on performance and reliability, for light, medium and heavy-duty applications. Through innovation in design and manufacturing techniques, we provide operations and maintenance personnel with products that support modern mining practices, both as original components or as replacements in existing systems. HEAVY DUTY TRANSPORTATION Highly demanding conditions for rollers, frames or complete idlers (rollers and frames) are often encountered in stripping and handling of overburden material and in processing and transportation of coal, iron ore, and other mined materials. Individual conveyors often transport 20 000 tonnes per hour and overland conveyors can have up to 100 000 rollers in a single system. Sandviks component business has grown up in this environment; we understand the importance of reliability and the cost of failures. Thanks to our global strength, and close-to-customers manufacturing on several continents, our rollers and idlers are delivered to suit a range of differing standards and specifications including European, Australian, Asian, African and American standards and dimensions. Sandviks low-noise rollers support operations in sensitive environments. Pulleys must effectively and reliably transfer the drive motor load to the belt as well as provide support for changes in the belt direction. In-house design software, coupled with our dedicated research and development activities, ensure that we supply the optimum pulleys for each application. Sandvik supplies conveyor pulleys in diameters to over 2 000 mm (80 in) diameter, suitable for the most extreme operating tensions. These can be coupled with Sandviks takeup devices, both vertical or horizontal, that make it easy to maintain the pre-set belt tension for optimal load transportation with less slippage and reduced wear. HIGH SPEED CONVEYING High belt speeds bring additional challenges to rollers in bearing life, noise and power demands. Our latest commitment to lead in this field is the revolutionary HM150 formed roller, designed to operate in applications up to 11 m/s (36 ft/s) and capacities up to 52 000 tonnes per hours. Based on innovative and new design principles, formed rollers will operate longer, more quietly and will consume less energy than traditional high-speed rollers.

Pulleys for the toughest conditions Component activation for system reliability

Conveyor components mining focus

Heavy duty Rollers Formed rollers Idlers Frames Metric Imperial Metric Metric Imperial Metric Imperial Pulleys Metric HM140 HA140 HM150 HM240 HA240 HM340 HA340 HP130 HM220/HM230 HA220/HA230 HM320/HM330 HA320/HA330 HP110/HP120 Light/Medium duty HM120/HM130 HA120/HA130

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Conveyor components loading points

A poorly designed or integrated transfer point can lead to product spillage, impact damage on conveyor belts, dust emission and poor belt tracking. Sandviks design expertise and complete offering for loading points components provide a smooth transition from chute to belt. SPILLAGE REDUCTION Although difficult to calculate, waste of material is a cost that needs to be minimized. Sandvik loading sections, including a range of skirting systems, are designed to assist with the sealing of conveyor loading points to prevent spillage of material whether with or without a skirt (sealingless). CONVEYOR BELT STABILITY At high speeds and heavy usage, conveyors must be able to operate smoothly and well aligned. Sandviks belt centralizing idler starts centering the return belt immediately when the slightest deviation appears. Products such as our belt tracking roller or our range of positive action trainers are suitable for both the carry and return side of both single direction and reversing conveyors. IMPACT MANAGEMENT Heavy material can cause considerable damage dropping onto an unsupported conveyor belt. Our impact stations include impact slider beds, with or without center rollers, as well as heavy-duty impact roller cassettes to ensure the belt is adequately supporting when subjected to heavy impact loads. WEAR PRODUCTS Designed to extend the life of such equipment as chutes, hoppers and transfer points, sheet rubber products and rubber wear panels also help reduce noise. These can be bonded or bolted to the chute or hopper walls to provide significantly increased wear life.

Dust free loading points Consistent alignment

Durable wear protection

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Dust suppression de-activated

Dust suppression activated

Conveyor components safety and the environment

Protection of personnel, equipment and environment are issues that are themselves important, but also affect operations and productivity. Conveyors can create a lot of dust, cause spillage, and intensify noise. With a variety of thoughtful products, Sandvik addresses these concerns. DUST SUPPRESSION The HX410 is an electrostatic dust suppression system which is an economical, effective and low-maintenance alternative to traditional suction and filter or water spray systems. Sandviks HX410 is installed directly after the transfer point, above the conveyor belt. As the material and dust are conveyed through the HX410, the dust is ionized causing it to be attracted to the inside of the housing. A vibration motor on top of the housing then returns the dust to the material flow. The design is modular to fit a range of belt widths and speeds. Contributing to a safer working environment Primary belt cleaner BELT CLEANING Sandvik manufactures a comprehensive range of primary and secondary cleaners with both tungsten tips and polyurethane blades. Suitable for dry powdery applications as well as sticky materials, our belt cleaners keep belts running efficiently, reducing the amount of material spillage. A Sandvik belt turnover system turns the belt upside down, keeping material that has adhered to the belt from dropping along the length of the conveyor. SAFETY DEVICES In collaboration with the conveyor industry, Sandvik has developed a range of safety devices for both new and existing conveyors, including electrical safety devices such as pull-wire emergency switches, belt rotation detectors, belt misalignment switches and blocked chute switches. Safety guards and a belt rip detention system can be fitted to reduce or restrict conveyor access. Return belt plough

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Life cycle services for your equipment

A first objective of Sandviks life cycle services is to ensure maximum availability and productivity of equipment and plants, throughout their planned lifetimes. A second objective is to increase the expected lifetime by appropriate preventative maintenance and by timely investments in modernizations. Sandvik offers supervisors and specialists for regular inspections, condition monitoring and maintenance, provides spare parts and assists in major replacements or overhauls. WARRANTY When you partner with Sandvik, you know that we will stand behind our products, with a dedication that goes beyond a standard guarantee. MAINTENANCE Sandvik offers scheduled inspections or complete maintenance contracts. We also provide complete maintenance management systems utilizing electronic on-line condition monitoring systems. The maintenance management systems can discover irregularities and consequently minimize costs resulting from unscheduled downtime and failure repairs. SPARE PARTS Our international market strength shows our ability to source and ship material and components anywhere. This also translates into highly effective spare parts support, which is further strengthened with the global Sandvik logistics organization. We can provide all wear and spare parts to keep your equipment and plant in good condition. MODERNIZATION You can be assured that Sandvik will take all possible steps to modernize your equipment and processes, enhancing your productivity. Introducing new monitoring systems, improving serviceability, and upgrading training are just some examples of how Sandvik can update our offering to you. REPLACEMENT BY NEW MACHINERY At the end of a life cycle, Sandvik can provide recommendations for replacement with a new plant or piece of machinery, utilizing the newest technology for improved productivity and cost efficiency.

Materials Handling in Action

Sandvik has the long term experience to design, manufacture and install virtually any kind of bulk materials handling system. From continuous openpit mining systems to integrated stacking and reclaiming systems for mines, terminals, power plants and port facilities, we offer total solutions and turnkey installations. We also offer a wide range of individual equipment and quality components for plants, as well as upgrading and modernization services.

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