Tenova Metals India Private Limited Andheri East, Mumbai, Maharashtra

TAKRAF delivered the machine as a turn-key project. The MTC is equipped with two booms, which are independently either liftable and slewable.

Transport crawlers are heavy-duty mining machines developed for transport and relocation of heavy and big units of mining and processing plant equipment like head or tail stations of belt conveyors, segments of conveyor structure, semi-mobile crushing plants, apron or belt feeders, surge bins and counterweights. TAKRAF started to build transport crawlers in the beginning of the 1990’s – a fact that guarantees highest performance, safety and convenient maintenance today. Our transport crawlers are especially engineered for client’s purposes. The geometry, payload, travelling performance and optional equipment on board can be chosen by the client. Our product range includes machines with a payload from 200 t to 1,200 t. Our crawlers may be equipped with or without an operator’s cabin. Special equipment and devices for safety, condition monitoring and convenience like a remote control, fire-fighting equipment, TAKRAF PLC, sensors of many kinds, GPS or design acc. to clientcountry-specific standards are buyer-selected. Our transport crawlers are fully assembled and tested in factory resulting in quick on-site commissioning.

The spreader was designed to dump a massive leach pad in the irregular deep valleys close to the Toquepala pit. The upstream feeding equipment consists of an extendable and relocateable belt conveyor with a mobile head station on crawlers, a 60 m wheel driven Grasshopper and a 150 m long mobile conveyor bridge. The spreaders total length of 160 m guarantees a wide range of dumping before the upstream equipment needs to be relocated. The spreaders superstructure can be leveled against the crawler undercarriage to dump steep ramps. The 95 m long spreader intermediate bridge is supported on the spreaders superstructure and on a second double crawler for a total independent operation of the spreader.

Tenova offers a fully integrated range of high quality products, technologies and services for the steel making route, from iron and ferroalloy ores and scrap up to secondary metallurgy and liquid steel. Tenova is strongly focused towards the global market combining process automation and metallurgical know-how to enhance the value delivered to the customer. Tenova is a combination of several competences and business units able to supply worldwide direct reduction plants, electric arc furnaces with the unique continuous preheating and charging Consteel®, secondary metallurgy equipment as ladle furnaces and vacuum degassing systems including the refining equipment for the oxygen route and all relevant accessories and ancillaries. Tenova represents a one stop shop for the requirements of melting and electric steelmaking industry and their upstream suppliers.

Spreaders are mobile continuous operating dumping machines receiving the material from the shiftable dump bench conveyor via a tripper car or from mobile transfer conveyors. The main parts of a spreader are the receiving boom with or without support crawler track, the superstructure, the sub-structure with crawler tracks and the discharge boom. Determined by operational requirements the discharge boom can be fixed, liftable or slewable. The spreader is able to dump a low cast, which will be the travel plateau for one of the following dumping blocks, and a high cast on the other side of the shiftable dump bench conveyor. The main design criterion is the length of the discharge boom, determined by the required dumping height and block width as well as by the material properties meeting safety requirements (stability of the dump itself, safety of the equipment on dump). TAKRAF offers spreaders of compact design or large spreaders with long discharge booms for high and safe dumps. The capacity ranges up to 20,000 m³h. The length of the discharge boom can reach 195 m as built for a cross pit spreader for Russia. Cross pit spreaders are part of a highly efficient direct dumping system. They receive the material directly from a bucket wheelchain excavator. The discharge boom of those spreaders reaches over the open pit and transfers the material directly onto the dump site.

TAKRAF delivered the shifting head as part of a complete crushing, conveying and dumping system for the open-pit mine Vostochny in Kazakhstan. The shifting head has a special design for cold climate conditions and can be operated at temperatures down to -43 °C. The shifting head is adapted to the rail type R 65 according to Russian GOST standard.

The transport crawler was designed for a payload of 500 tons with an eccentricity of the load of 500 millimeters. One special feature of the project was the low geometry caused by an extremely narrow access opening required by the client. So the challenge was to design a very compact machine. In compliance with local and client-specific safety standards, an automatic fire-detection system was installed.

TAKRAF supplied a complete waste rock conveyor system including a spreader for waste dump. Special features of the conveyor system are an extendable conveyor CV-75 with belt storage and crawler-mounted head drive station and the shiftable dump conveyor CV-76 with crawler-mounted tripper car.

Bench conveyors which are operated together with mining and dumping machines have a shiftable design. Since such conveyors need to be moved into a new position from time to time, the conveyor modules are equipped with steel sleepers and rails to allow easy shifting. The shifting procedure is done by shifting vehicles which travel up and down the conveyor line and move the conveyor in small steps into the new position. The shifting vehicle has a special attachment for rail clamping, the shifting head. Our product range covers also shifting head fabrication and testing in our own workshop. Shifting heads are adapted to the specific rail type and the shifting vehicles used in the mine.

Highlights of this semi-mobile plant are: Semi-mobile design with truck bridges Building above crushing plant Material fed by heavy duty TAKRAF apron feeder Crusher designed and manufactured by TAKRAF Extremely cold weather design Dust collection system

Highlights of this semi-mobile plant are: Semi-mobile design with diamond shaped truck dump hopper Dump truck bridges avoiding retaining wall Building above crushing plant Material discharge with heavy duty vibrating feeder

This primary crushing plant in Sierra Gorda, Chile, is equipped with a hydraulic slewing crane designed and manufactured in TAKRAF's own workshop. Further innovative features include: Frequency controlled variable speed heavy duty TAKRAF apron feeder Earthquake proof design · Belt reel station (for stock pile feed conveyor) Dedusting systems

Rail mounted service vehicle for idler change at steep inclined belt conveyors. On-board belt lifting crane and idler handling tool.

Primary crushing plants can be equipped with gyratory crushers, jaw crushers, twin-shaft sizers, double-roll crushers, impact crushers or hammer crushers, depending on material properties and required throughputs. We are able to provide mobile, semi-mobile or stationary plants and work together with our clients to choose the most suitable machine type depending on the mineral deposit, mine plan and mining method. TAKRAF supplies fully mobile crushing plants equipped with crawlers, wheels or walking mechanisms. Fully mobile crushing plants are directly fed by shovel or wheel loader and no haulage trucks are required. A considerable number of mines around the world opt for a semi-mobile crushing plant. These plants are designed in such a manner that they can be relocated through the use of transport crawlers andor multi-wheel trailers. Having the flexibility to relocate the crushing plant enables travel distances for haulage trucks and belt conveyors to be optimized during the life of the mine; all with a view to providing increased efficiency to the mine operator. Choosing the optimal crushing plant location is an essential criteria for the reduction in the number of haulage trucks required. For mines or quarries boasting mineral deposits with smaller extensions andor with short haul distances between bench and plant, a stationary crushing plant is usually the most optimal solution. Variations in production can easily be matched by increasing or decreasing the number of haulage trucks.

Tenova is a leading company in the design and supply of high-capacity electric furnaces (ac, dc), submerged-arc smelting furnaces and complete smelting plants for the production of ferroalloys, base metals, slag cleaning and alloy refining. We are industry specialists in solid liquid separation and mineral processing applications for the minerals, chemical and industrial markets offering flotation, sedimentation, filtration, screening and gravity separation systems. With a long and successful history in the ferroalloy industry Tenova also designs and supplies equipment for material handling and pre-treatment, alloy conversion and refining, granulation of metal, matte and slag, furnace off-gas fume collection and treatment, treatment of hazardous dusts and wastes.

TAKRAF's MTCs are designed to handle a wide range of capacities of various bulk material. The crawler-mounted machines improve the performance of any mining operation and function as flexible links between mining machines and bench conveyors. In this manner, they are thus able to increase the shifting width of the system. Our machines are all specifically designed to our client's requirements and incorporate various solutions according to their specific application. Our machines can be equipped with separate receiving and discharge conveyors or one single conveyor. A MTC with a single conveyor is a common solution without having a material transfer point in the center of the machine. The receiving and discharge sections of the conveyor can be lifted to adjust to various transfer points and a slew bearing between the machine's undercarriage and superstructure allows for a slewing movement of the superstructure. However, MTCs are also often employed to bridge different bench level heights and thus many machine designs include two independent boom conveyors. A MTC with separately liftable booms and a material transfer point in the center of the machine allows for a greater luffing range as compared to single-boom machines. Another solution providing maximum flexibility is a MTC with separately liftable and separately slewable booms. Further to a slew bearing between undercarriage and superstructure, a second slew movement between the receiving boom and the discharge boom is also provided for. In order to guarantee machine stability at any slew or luffing position, the receiving boom is thus equipped with a counterweight and consequently, the service weight of such a machine is higher than of other machines.

Mobile Stacking Bridges (MSBs) are designed for fast advancing dumps with small dumping heights for deep and high cast operations. MSBs consist of several, up to 100 m long, straight connected bridge segments with separate single or double crawlers and a single bridge belt conveyor. The material is dumped by a short, slewable and, if required, liftable discharge boom which is integrated in a tripper car traveling across the entire bridge length. MSBs are able to dump circle-shaped dumps in a slewing mode operation or rectangle-shaped dumps in a parallel mode operation. With a retractable discharge boom it is possible to dump both a low (max. height per geotechnical and safety requirements) and high cast (up to 8 m high) at the same time.

TAKRAF designs and develops MCBs as mobile link conveyors between other mining equipment. The crawler-mounted machines are "multi-use" machines mainly consisting of one conveyor bridge segment supported on two crawler undercarriages. MCBs operate as flexible links between mining machines and bench conveyors and increase the operating range of the system. Additionally, MCBs can be used to bridge different height levels of benches. Our machines are all specifically designed to our client's requirements and incorporate various solutions according to their specific application, including actual site conditions. We have supplied MCBs with belt widths from 1,400 mm to 1,829 mm and with effective bridge lengths of up to 150 m. If necessary, machines can be equipped with leveling devices so as to avoid conveyor cross inclination. We are able to meet the most diverse demands for the operation of MCBs.

Conveyor belts are supported across their length by idlers or rollers; and on long overland conveyor systems, these idlers can run into the thousands. Worn or damaged idlers need to be changed as soon as possible in order to increase efficiency and reduce operating costs of the system; as well as to avoid the risk of any further damage to equipment or even the potential outbreak of fire. Conducting maintenance on belt conveyors – especially in tunnels or on elevated structures – is a challenge for all parties involved on site. The belt needs to be lifted and the idler(s), with a single part weight of about 50 kg or more, replaced. The issue of space really becomes critical in tunnels where space is very limited and the work has to be conducted manually. Enlarging a tunnel’s size in order to more effectively conduct maintenance, as well as for greater safety and access reasons, is almost impossible due to the significant costs to be incurred and an intelligent new solution had to be found.

The application of mobile stacking bridges (MSB) is not restricted to operate on ON-OFF heap leach systems. The biggest advantage of the crawler mounted mobile stacking bridge is the continuous operation without interruptions (downtimes) to shift or relocate. MSBs are designed with a minimized number of bridge segments with the advantages of: less crawler units, less maintenance, less complex equipment control (leveling), reduced operating expenses, more reliable structural design according to fatigue loads (bolted instead of welded). A retractable tripper stacker conveyor allows dumping on both sides of the bridge (low and high cast operation).

The machine is in use for excavating overburden in a coal mine in Chinese Inner Mongolia. Due to the extreme conditions with temperatures down to minus 40° C this type of bucket wheel excavator has a special design of mechanical and electrical parts. The excavator serves as the key member of a complete TAKRAF overburden system with four conveyors and a spreader in the waste dump area.

The machine has a special design for overburden excavation as it is the case in the Drmno coal (lignite) mine in Serbia. The excavator serves as the key member of an overburden system including four conveyors and a spreader in the waste dump area. The bucket wheel head consisting of a 2 x 670 kW bucket wheel gearbox, a single-web bucket wheel, a bucket wheel shaft and a dual diaphragm support was entirely manufactured in the TAKRAF Lauchhammer workshop.

AKRAF supplied the copper ore leaching system consisting of the agglomeration plant, the onoff leach pad, as well as the waste disposal facility. The Mobile Stacking Bridge (MSB) forms part of the stacking and reclaiming system for the onoff heap leach pad. The application of MSBs is not only restricted to operating across onoff heap leach systems and the technology can be applied across a wide range of areas. The most significant advantage of the crawler mounted MSB is its ability to operate continuously without interruption and do not require any downtime to shift or relocate. MSBs are designed with a reduced number of bridge segments which provide the following advantages:

Sustainable fume treatment and intelligent off gas management will play an important role in future steelmaking business. Tenova provides developments and products in the field of heat recovery and cogeneration systems, minimized off gas volume strategies, modern filter and dedusting equipment as well as latest analyzing technologies to meet future requirements and environmental regulations.