AngloGold Ashanti conveyor-crusher feed transfer station

Minerals processing plants and mining services company DRA in 2011 designed a conveyor-crusher feed transfer station, with four ore-flow routes, including the feed to a crusher unit, for major gold miner AngloGold Ashanti’s operation, in Ghana.

AngloGold Ashanti required a design with an initial conveyor transfer point feeding to either the crusher or a crusher bypass. Material flow to the crusher needed to move either through the crusher or out the crusher overflow, and then to either the crusher discharge conveyor or the discard stockpile.

The project required thorough design analysis, including the testing of virtual prototypes using EDEM BulkSim software simulations, to identify the optimal design.

DRA imported computer-aided design models into the software and used calibrated material models for ore and crushed material.

The virtual prototypes were then tested and various design options were evaluated, with particle flow simulations carried out on each model.

Using EDEM BulkSim simulation and analysis, material-flow velocities and areas of high impact were examined. Using this data, DRA established optimal locations for dead boxes to minimise impacts from large rocks and for selected suitable liner plates to protect areas of high wear.

Further predictions of mass flow into the crusher were used to estimate critical crusher choke feed and overflow capacities.

The simulations showed that design requirements would be met using a single transfer station, resulting in AngloGold Ashanti’s saving on costs of steelwork and services.

Virtual prototype testing ensured that material flow was free-running, even with high moisture content.

EDEM BulkSim prediction of particle velocities and impact forces enabled for accurate placement of dead boxes and liner plates, reducing impact and lowering overall plate-wear characteristics.

Predictions of mass flow to the crusher provided better operational data to improve crusher performance.

The simulation results gave DRA engineers the confidence to proceed with the final design, within the budget and timeframe.