CAT Rock Flow System

Markus Frenzel
Business Manager Rock Flow
May, 2014

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AGENDA
1. PL HRC
2.Mining Method - Block Caving
3.Case Study
4.Cat Rock Flow System
5.Development and Status to date
6.Q&A

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PL HRC

HRC & HRD: Location, Sourcing & Population

Luenen, Germany
HRC Products

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Total area: Shared with Longwall

Mining industry segments and Caterpillar Global

Mining product coverage
Mining
Soft Rock
Underground

Hard Rock
Surface

Surface

Articulated Trucks Hard rock vehicles

Longwall
Drills

Scrapers
Off Highway Trucks

Room & Pillar

Caterpillar Unit Rig Truck
Electric Rope Shovels

Highwall Miner

Belts

Tractors
Draglines
Hydraulic Shovels
Wheel Loaders

Underground

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WHAT IS BLOCK CAVING?

Block Caving I

Block Caving

Panel Caving

GRAVITY
MINING

The Cat continuous mass mining system

Rock Flow is applicable for both caving methods:

Main
principle
of
block caving is use of
gravity

Main Application: UG Hard Rock Block Caving Mines

Block caving is a large-scale underground mining method applicable to the extraction of low-grade, massive ore bodies

State of the art

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Main principle

Mining Sequences

Block Caving

System Specifications

CASE STUDY PERFORMANCE CONSIDERATIONS

Expected UG Hard Rock Mining Trends

Operating Block Caves & Greenfields

Trend goes from open pit to underground mining

Decrease of ore grade in Greenfield projects, mainly caused by increasing
depth of deposit.
infrastructural drawbacks for new projects
Trend to mega mines (Super Cave)
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Case Study - Performance Considerations

Exhausted

Active Panel/Exploitation Direction

Reapin
g

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Spreading

Reaping
Reaping rate
rate limited
limited to
to

Spreading
Spreading rate
rate limited
limited to
to

<< 0.7
0.7 tpd/m
tpd/m

<< 0.45
0.45 tpd/m
tpd/m

due
due to
to LHD
LHD performance
performance
and
traffic
and traffic
(
( Codelco:
Codelco: 10%
10% of
of an
an
active
active area
area are
are in
in active
active
production)
production)

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Mine Preparation

due
due to
to geomechanics,
geomechanics,
air
blast
air blast risks
risks

Challenge:
To increase the extraction rate
by balancing the different
phases of the mining sequence

Case Study - Performance Considerations

today
Reaping
Reaping rate
rate limited
limited to
to
<< 0.7
tpd/m
0.7 tpd/m

Spreading
Spreading rate
rate limited
limited to
to
<< 0.45
tpd/m
0.45 tpd/m

Super Cave
Optimum
Optimum Reaping
Reaping rate
rate
== 4.05
4.05 tpd/m
tpd/m
(1
block)
(1 block)

Mean
Mean Production
Production rate
rate
== 1.35
1.35 tpd/m
tpd/m
(reaping
+
spreading)
(reaping + spreading)

LHD
LHD is
is limited
limited
so
so how
how to
to get
get there?
there?
How
How to
to increase
increase Reaping
Reaping performance
performance significantly?
significantly?

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Basic consideration:
target production: 170.000 tpd
1,100 DP

Cat equipment in caving operations

REAPING
REAPING

127,750 tpd
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SPREADING
SPREADING

42,525 tpd

Cat equipment in caving operations

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Continuous production system

Cat Rock Feeder

Cat Rock Mover

Spreading
Spreading (3
(3 Blocks):
Blocks):
Drawpoints
Drawpoints in
in spreading:
spreading: 420
420
Operated
Operated by
by Rock
Rock Flow
Flow or
or
LHD
LHD
140 DP *15m *15m * 4.05tpd/m 420 DP *15m *15m * 0.45tpd/m
= 127,750 tpd (reaping)
= 42,525 tpd (spreading)
Production/Reaping
Production/Reaping (1
(1 Block):
Block):
Drawpoints
Drawpoints in
in active
active area:
area: 140
140
14
14 setups:
setups: 10
10 Feeder/1
Feeder/1 Mover
Mover

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170,000 tpd

total number of DP in operation :

CAT ROCK FLOW SYSTEM

Cat Rock Flow System Feeder and Mover

: Extraction
: Haulage

Cat Rock Feeder

Service drift

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Production drift

Cat Rock Mover

Rock Feeder and Rock Mover in a Continuous

Production System

Rock Flow - video

RFS@mining.cat.com

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Rock Feeder and Rock Mover in a Continuous

Production System

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Cat Rock Flow System

Cat Rock Flow Top Messages
Revolutionary continuous mass mining
production system

Rock Feeder (RF300):

High-performance continuous ore handling

system multiplies extraction rates

extraction rate: 300 t/h

Pushing Device

Highly automated system with real time draw

control
System Flexibility
High Level of Health, Safety and Sustainability

Moving Dozer Plate

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Cat Rock Flow System: - main components

Rock Feeder (RF300):
Performance: 300 t/h

Dozer Cylinder
Quantity: 4
Stroke:
1,350
mm
Cycle time:
112.5 sec.
Pressure: 4,021 kN

Rock Mover (RM900):

Load capacity: 900 t/h

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Specifications:
Type:
hard rock chain
conveyor
speed:
0.15
m/s
power:
2 x 90
kW
Line pan, width:
1,800
mm
Line pan, length :
3,000
mm
chain:
42 x

Cat Rock Flow System: Automation

Specifications
Control System
- One data world (EIP)
- Control and visualization of
other subsystem
- Load depended conveyor
control

surface

underground

Draw Control
- Selective extraction
- Flexible sequence / Mix of
qualities
- Easy Hang-up detection
Subsystem
- Communication with pumps,
conveyor and monitoring of
chain tension

Data Base
- Data storage in SQL database
- Real time data logging
State of the Art Automation due to highest level of Functionality and Flexibility
Remote control
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Draw Control

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Integration of
Subsystems

Data Storage

DEVELOPMENT AND STATUS TO DATE

CAT ROCK FLOW SYSTEM - OUTLOOK /

POTENTIAL

Cat Rock Flow System - Outlook / Potential

-

Increased safety and work

efficiency by remote supervised
autonomous system operation
- Multiplied extraction rates
up to 500% production increase
smaller active area

- Reduced ventilation efforts by

smaller production area and
missing diesel fumes
- increased HSE, lower specific
costs, higher production
rates, larger NPV
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QUESTIONS

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Thank you for your attention

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herein, are trademarks of Caterpillar and may not be used without permission.

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