Crushing Plants made by MAN TAKRAF

MAN TAKRAF Fördertechnik GmbH was formed by the merger of specialized engineering divisions of TAKRAF and MAN GHH. It has its headquarters in Leipzig and a factory in Lauchhammer, Germany.
The company has many decades of experience in the fields of project planning, design, fabrication and erection of plant facilities throughout the world. This experience enables the company to provide state
of the art equipment that is field proven with a high level of reliability.

MAN TAKRAF has many years of experience in the design of machines and systems to handle difficult materials including copper, gold, iron, etc., ores that are abrasive, sticky and with high impact factors.
Since 1957 MAN TAKRAF has been supplying crushing and screening machinery as an integral part of complete stockyard handling systems. Numerous laboratory (at MAN TAKRAF, Lauchhammer) and field tests, including comprehensive material tests, were carried out over the years.
This experience, facilitated MAN TAKRAF's successful introduction to the market. The crushing plants provided are comprehensive in design and optimally adapted to the prevailing site conditions.

MAN TAKRAF can supply a full line of crushing plants including stationary, semi-mobile or fully mobile plants with tire/track or hydraulic walking systems. The company is able to provide solutions incorporating primary crushing plants for very high volume applications to suit almost all site conditions.
The first large-scale relocatable primary crushing plant was supplied to Minera Escondida Limitada, a copper ore mine in Chile, in 1995. The crusher utilized was a 60-89 gyratory crusher.
Crushing plant and surge bin (after the discharge conveyor) were made of steel and since the rock around the plant was competent enough, allowed the elimination of retaining walls and other civil work expenses (Fig. 1).

Fig. 1 1995 Primary crushing plant supplied to Chile Mine:                  Escondida Crusher:            gyratory type 60-89 Throughput:       5750 t/h Service weight: 1670 t	Fig. 2 1996 Two primary crushing plants supplied to Chile Mine:                  Chuquicamata Crusher:            gyratory type 60-109 Throughput:       5750 t/h, each Service weight: 1410 t, each

In the following year, MAN TAKRAF received another large order from Chile for the supply of two semi mobile crushing plants installed in the very close proximity of and parallel to each other.
In contrast to the Escondida crushing plant, the plants were installed on fill, requiring a great deal of expenditure to erect the retaining walls. The scope of supply also included the crusher discharge conveyors and the surge bins (Fig. 2).

In 1997, MAN TAKRAF received an order for the supply of a relocatable crushing plant with the associated conveyor and stacking system in Sonora, Mexico. Unlike the plants already mentioned, the surge bin was arranged right underneath the crushing plant. MTF was responsible for the total project planning, technical development, design, supply erection and start up of the complete system.
The scope of supply covered the crushing plant, discharge belt feeder, overland conveyor system a tripper car and a spreader (Fig. 3).

Fig. 3 1997 Primary crushing plant supplied to Mexico Mine:                 Cananea Crusher:            gyratory type 60-89 Throughput:       3600 t/h Service weight: 850 t	Fig. 4 1997 Two primary crushing plants supplied to Russia Mine:                  Taldinsky Crusher:             twin-shaft type Throughput:       3600 t/h, each Service weight: 440 t, each

In the same year, MAN TAKRAF obtained another order for a semi-mobile crushing plant in Siberia, Russia. The scope of supply included two twin-shaft sizers, fed by an apron feeder for overburden and one spreader with related tripper car. This application was unusual and unique in that the plant must operate at temperatures as low as -40°C (Fig. 4).

In 2002, a new order for the Minera Escondida copper mine was placed with MAN TAKRAF.
As requested by the consultant, a surge bin was designed right underneath the crushing plant which also served as a foundation for the plant.
The poor stability of the rock required additional concrete work (Fig. 5).

Fig. 5 2002 Primary crushing plant supplied to Chile Mine:                  Escondida Crusher:            gyratory type 60-113 Throughput:       8800 t/h Service weight: 1190 t	Fig. 6 2002 Primary crushing plant supplied to Indonesia Mine:                 Grasberg Crusher:            gyratory type 60-113 Throughput:       5600 t/h Service weight: 1995 t

In the same year, another large scale crushing plant was supplied to P.T. Freeport Indonesia at their Grassberg Mine in Irian Jaya. It is also a plant with direct feeding. A steel surge bin was located underneath the crushing plant in a recess cut in the wall (Fig. 6).

A special challenge in the design of the crushing plant for the Collahuasi mine in 2003 was its location at an altitude of 4600 m above sea level. The elevation required a special design of the drives, hydraulic, lubricating and compressed-air systems. Very strict structural and seismic requirements were called for in the design of this plant. Site conditions and elevation made it a difficult situation for our start up and commissioning personnel. As with all plants previously supplied to Chile, potential earthquake and seismic conditions were of major consideration (Fig. 7).

Fig. 7 2003 Primary crushing plant supplied to Chile Mine:                 Collahuasi Crusher:            gyratory type 60-113 Throughput:       8500 t/h Service weight: 1360 t	Fig. 8 2003 Primary crushing plant supplied to Brazil Mine:                 Carajas Crusher:            jaw type Throughput:       5700 t/h Service weight: 460 t + 350 t

South America is an important and major market for the large-scale crushing plants produced by MAN TAKRAF. In addition to the projects described above in Chile and Mexico, the company has a contract for a large plant in Brazil. This crushing plant consists of three modules; namely, the dumping module, the crusher module and the crusher discharge conveyor. The design was performed in Germany and in Brazil. This project is being executed in collaboration with Brazilian partners. This crushing plant will be used for crushing iron ore and the material will be fed by an apron feeder. The crusher type applied in this case is a jaw crusher (Fig. 8).

Large-scale crushing plants are used in Europe/UK, as well. In the past year, an order was received from England from Cliff Hill Quarry. This crushing plant is of a semi-mobile design just as the majority of the above-mentioned plants.

Due to the prevailing climatic conditions, the dump hopper was completely enclosed. The service crane reaches all elements in the hopper area through a shutters door (Fig. 9).

The 12th large-scale crusher plant by MAN TAKRAF is designated for the “Escondida Norte” copper mine in Chile.
Both man and machinery face the challenge of assembling this plant at an altitude of 3,200 m above sea level, joined by the fact that it is situated in a zone 4 earthquake area (according to UBC 2001). This crusher plant was constructed as a "Semi-mobile crusher plant". This means that the entire crusher plant, with a service weight of some 1,300 tons, can be moved via a transport crawler or multi-wheel trailer to follow the progress of the mine.
The crusher plant fundamentally consists of two structures that are uncoupled from one another in operation. This uncoupling is performed for reasons of vibration. The loading hopper has a casing with dust extractor to reduce dust volumes. A personnel lift is located on the outside of the service tower, with a load-bearing capacity of 1,200 kg, covering a height of 29.3 m.

Fig. 9 2003 Primary crushing plant supplied to England Mine:                  Cliffe Hill Quarry Crusher:             gyratory type 54-77 Throughput:       2500 t/h Service weight: 865 t	Fig. 10 2004 Primary crushing plant supplied to Chile, under erection at present Mine:                 Escondida Norte crusher:            gyratory type 60-113 Throughput:       8800 t/h Service weight: 1300 t

Three-dimensional models of the crushing plants form the basis of the structural calculations and design work carried out by MAN TAKRAF. The workshop drawings are derived from the same model. The design is based on the results of the structural calculations and finite-element analysis of individual structural members taking into account both static and dynamic loads. Thus, comprehensive static and dynamic analyses can be carried out for all load cases that may occur during operation and/or relocation. Also, out-of-balance forces of the crusher and possible resulting vibrations can be analyzed in order to minimize their effects on the structure. The same applies to seismic loads which, particularly in Chile and Mexico, need to be taken into account to make sure full stability will be maintained even during earthquakes. The dynamic calculations are confirmed by the vibration tests taken during operation.

MAN TAKRAF understands the need to be competitive in international markets and the benefits of accessing regional resources for our fabrication needs. We do, however, also understand the benefits of taking advantage of our own workshop facilities in Lauchhammer when it is to our customer's advantage, technically and commercially. We will continue to fabricate critical subassemblies in our own shops to assure our clients state of the art quality assurance oversight and compliance with delivery schedules. In addition, our work at the Lauchhammer works provides vocational training for start up and commissioning personnel and validates design, constructability and safety issues before they are moved to the field.

MAN TAKRAF's goal is to supply field proven, reliable, state of the art mining and materials handling equipment that provides our client with the lowest cost per ton of material moved. We have the experience and capability to assist clients in assessing the various operating alternatives and in determining the most attractive technical and commercial solutions.

MTF/07.2005

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