Best of Germany 2014

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Mining Equipment and Technology BEST OF GERMANY 2014

A supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age China, Coal Age Russia, Coal Age India, Coal Age Indonesia, The ASIA Miner and Mining & Technology Australia

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Foreword:

Welcome to the 2014 edition of Best of Germany, highlighting the expertise of companies that sup- Germanply equipment andMining services to theTechnology exploration, mining and Serves mineral-processing the Global industries worldwide, VDMA and are members of the German Engineering Federation (VDMA). Expertise in engineering is not easily achieved; it requires dedication and a long-term vision. Many of these companies have histories that date back to the 19th century, and they understand the cyclic nature of commodity markets. The situation in the mining sector has changed in the last 18 months. Prices for most mined commodities have softened and mining companies have tabled ambitious future plans. Even though the level of investment for new projects has declined for the moment, miners will still produce significant amounts of gold, copper, iron ore, nickel, potash, coal, oil sands and more. The difference today is that they are looking to optimize processes to not only improve profit margins, but to also compensate for a lack of skilled labor and a growing regulatory burden. Through innovation and continued investment in research and development, German equipment and service providers are meeting the needs of today’s miners. This edition of Best of Germany focuses on work being done by VDMA mining branch member companies to increase efficiencies, optimize operating costs, and improve safety underground, on the surface and at the mill. We hope that you find value in this publication, wherever you are in the world.

Glückauf!

Dr. Paul Rheinländer President of the VDMA-Mining Equipment Association

VDMA, the German Engineering Federation, Mining Equipment Association Lyoner Strasse 18 D-60528 Frankfurt Germany

Table of Contents:

A Special Supplement to Your Contacts in the Mining Equipment Association (MEA) ...... 2 Engineering & Mining Journal (E&MJ) Produced by Mining Media International Miners Looking to Optimize Operations Can Rely on German Engineering Expertise ...... 4 11555 Central Parkway, Suite 401 Jacksonville, FL 32224, USA Surface Mining: Increasing Productivity and Reliability ...... 6 Tel: +1-904-721-2925 Fax: +1-904-721-2930 Underground Mining: Longwalls Mine Safely at Low Cost Per Ton ...... 12 www.mining-media.com Copyright 2014 Mining Media Int’l Customized System Solutions for Bulk Materials ...... 25 Mineral Processing: Magnetic Separators Reduce Energy Consumption for Iron Ore Recovery ...... 30

Sponsor: German Engineering Federation Innovations: Modern Storage and Reclamation...... 38 Verband Deutscher Maschinen- und Anlagenbau (VDMA) e.V. Energy Efficient Pumps Help RWE Save Energy ...... 48 Lyoner Str. 18, D-60528 Frankfurt/Main Tel: +49-6966-031262 Safety: De-dusting Technology for Underground Mining ...... 52 Fax: +49-6966-032262 www.vdma.org Vendor Matrix and Buyers Guide ...... 54

Articles in this publication were researched and written by Steve Fiscor, editor-in-chief of Engineering & Mining Journal (E&MJ) and Coal Age. For additional information about the articles or the manufacturers highlighted here, please contact Mining Media International ([email protected]).

Published by Mining Media Int’l in cooperation with the VDMA EQUIPOEQUIPO | INGENIERÍAINGENIERÍA | TTECNOLOGÍAECNOLOGÍA

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Your Contacts in the VDMA Mining Equipment Association

Joachim Schmid Klaus Stöckmann Managing Director Deputy Managing Director Phone: + 49 69 6603-1261 Economy and statistics, trade fairs, Fax: + 49 69 6603-2261 markets Asia and Australia Email: [email protected] Phone: + 49 69 6603-1270 Fax: + 49 69 6603-2270 Email: [email protected]

Helmut Schgeiner Monika Bind Director Manager Markets Technology, standardization and research, CIS and Russia markets Europe, Africa, USA and Canada Phone: + 49 69 6603-1262 Phone: + 49 69 6603-1680 Fax: + 49 69 6603-2262 Fax: + 49 69 6603-2680 Email: [email protected] Email: [email protected]

Alessandro Colucci Yvonne Golle Director Markets Assistance Latin America Phone: + 49 69 6603-1577 Phone: + 49 69 6603-1254 Fax: + 49 69 6603-2577 Fax: + 49 69 6603-2254 [email protected] Email: [email protected]

Alexandra Landgraf Rajesh Nath Assistance Chief Representative Phone: + 49 69 6603-1577 VDMA Representative Office India Fax: + 49 69 6603-2577 Phone: + 91 33 2321-9522/7391 Email: [email protected] Fax: + 91 33 2321-7073 Email: [email protected]

Stephanie Heydolph Thomas Junqueira Chief Representative Ayres Ulbrich VDMA Representative Office China Chief Representative Phone: + 86 10 87730212-808 VDMA Representative Office Brazil Fax: + 86 10 877302-09 Phone: + 55 11 430580-42/-43 Email: [email protected] Fax: +55 11 3078 4335 Email: [email protected]

Volkmar Clauß Holger Wittich Chief Representative Chief Representative VDMA Representative Office Russia VDMA Representative Office Japan Phone: + 7 499 41803-71 Phone: + 81 3 3363-6632 Fax: + 7 499 41803-72 Fax: + 81 3 3363-7582 Email: [email protected] Email: [email protected]

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Miners Looking to Optimize VDMA Operations Can Rely on German Engineering Expertise

Business plans among mine operators worldwide have changed. Cost control is benefiting small- and medium-sized compa- Instead of bringing as much capacity online as quickly as possi- nies in other ways, particularly for mine and plant construction ble, their attention has now turned to improving the bottom line. projects. “We see more mining companies refusing to purchase And, that might be a good thing for German mining equipment through ‘bundled contracts,’ where an engineering firm selects suppliers and service providers. This was one of the messages all of the equipment from a small group of providers,” Dr. Paul Rhinelander, president of the German Engineering Rhinelander said. “By opening these contracts to competitive Federation’s mining branch (VDMA), presented at a press confer- bids, the mining companies are essentially unbundling the pur- ence held during the branch’s annual meeting at the Zollverein chasing decisions for equipment, each of which could be worth mine in Essen during late November. many millions of euros. These smaller lots are more attractive for Similar to all equipment and service providers, the 130 or so medium-sized companies. This makes it possible for our medi- members of VDMA’s mining branch benefited from the mining um-sized companies to actively participate, which we could not super cycle that has recently stalled. “Looking back at an unri- do in the past. This approach has resulted in orders, which is a valed history of success, we nearly tripled our revenues during positive development for our branch.” the past 10 years. In the past year alone [2012], we have grown 28% to €6.2 billion [$8.5 billion],” Rhinelander said. “For the Regional Markets current year [2013], we expect, based on the figures of the first In Europe, Germany is by far the largest market, but that pales nine months, further low single-digit growth, maybe a 1% to 2% in comparison to the groups’ exports. For 2013, the VDMA was increase to about €6.3 billion [$8.6 billion].” At that point, expecting a decrease of revenues for the European market of Rhinelander believes their group has reached the peak of a cycle. about 4% to €430 million ($589 million). Revenues related to He has predicted a two-digit percentage decrease for 2014 surface mining remain relatively constant and the group expects before business stabilizes or rebounds in 2015. a similar outcome in 2014, an additional decline of 4% with While this forecast for immediate business seems a bit dire, total revenues dropping to €400 and €430 million. one has to consider the context; this small group of mostly pri- “A large portion of future revenue will be affected by vately held, medium-sized companies actually performed quite Germany’s new energy law and how the government will handle well compared to its peers during the last five years. The mining this,” Rhinelander said. “Lignite-fired power plants are running sector felt the impact of the recession brought about by the U.S. at full capacity and coal consumption has decreased. Mine real estate meltdown and European debt crisis, but it recovered operators in the region are looking at different ways to cut costs quickly. Unlike the manufacturing and construction industries, and save money. In addition to that, the few hard-coal mines that which are still waiting for a recovery, the mining industry is look- are still operating will soon disappear. RAG is slowing down ing toward the future with confidence. “The demand of raw investments continuously and in 2018, we will see it finally materials will increase during the medium and long term, per- end. Companies that relied on sales to these mines will be forced haps significantly,” Rhinelander said. “Our machines and to react to that situation.” To compensate for this decrease of rev- knowledge will play a pivotal role in satisfying this demand.” enues, the VDMA members will export a large share of its equipment and expertise. Returning to an RoI Approach For 2013, the VDMA expected to report an increase of export Another important reason for the VDMA’s confidence is a trend revenues of about 2% to €5.83 billion ($8 billion). This year, they see taking place. Because prices for mined-commodities, Rhinelander is predicting a double-digit percentage decrease. such as gold, iron ore and potash have dipped, mining com- “We have reached the peak of the economic cycle for mining,” panies are looking more closely at production costs. “Mining Rhinelander said. “We have seen swings both up and down for companies are again making massive calculations to deter- commodity markets. This will impact the mining branch of the mine a reasonable return on investments [RoI],” Rhinelander VDMA, but we know the situation will not last forever. Demand said. “Today more mining companies are making purchasing will again increase—under some circumstances very quickly.” decisions based on life-cycle cost rather than solely on the Meanwhile, this group of medium-sized companies dedicat- initial purchase price. German equipment suppliers could not ed to mining will explore opportunities in new markets with the compete with much of the low-priced equipment. When mines support of the VDMA. Results show that they have been very suc- factor total life-cycle costs into the equation, the ‘Made in cessful with this approach, especially in Latin America. “Latin Germany’ logo now becomes much more competitive. We are America is becoming a more and more important market for us,” leaders in low total life-cycle costs in many sectors.” The situ- Rhinelander said. “The share of exports to this region was 7% in ation only improves, Rhinelander explained, when the mining 2012 and it has grown to 9% in 2013.” company is looking at more sophisticated technology or safety With a market share of 14%, the U.S. was the biggest export improvements. market for the VDMA in 2013. With more stringent environmental

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regulations and a shale gas boom, many coal-fired power plants in the U.S. have either switched to natural gas or are strongly considering it, Rhinelander explained. Growth of coal stocks have spilled over to coal export markets mainly to Europe. The situation has placed downward pressure on coal prices. The weak pricing structure will lead to further mergers and acquisi- tions. “As this rationalization process evolves, we should benefit from this situation with our high-quality machines,” Rhinelander said. “Nevertheless, regarding the upcoming year, we expect a decrease of revenues.” Russia is the VDMA’s second most important trading partner, representing 12% of the total market share. The Russia economy, however, can best be described as erratic, Rhinelander explained, between stagnation and recession for some time now. “The state income generated from raw materials and sale of natural gas has collapsed,” Rhinelander said. “The mines are under increasing pressure to cut costs to improve profits. Once again, high-quality German equipment and machines should become part of the solutions. But, knowing that about 70% of all investments in mining are coming from the state and that the economic situation of Russia will worsen, we expect for 2014 more or less a decrease of revenues.” Business for the VDMA has been brisk in China and at 11% market share it represents the VDMA’s third biggest trading partner. “The Chinese buy strong and highly efficient machinery,” Rhinelander said. “The demand for high-tech, especially when it comes to automation, is still very high. Most of the other supporting machinery is produced by the Chinese themselves.” For 2014, the market opportunities in China are unclear, as the number of Chinese suppliers just keeps increasing. “Although there is an overcapacity already, the number of ven- dors is still increasing,” Rhinelander said. “The support that many of the companies receive from the Chinese government works against equipment importers.” The VDMA also expects to see revenues related to China decrease in 2014.

Technical Innovation When it comes to technical innovation, the Germans see themselves as the leaders. However, the Chinese are constantly improving. As an example with underground coal mining equipment, Rhinelander explained, they stand nearly eye-to-eye with equipment manufacturers in the Western Hemisphere and that will certainly be the case soon when it comes to materials handling products. Rhinelander concluded his remarks with a brief discussion about industrial espionage. At the time, former U.S. National Security Agency (NSA) contractor Edward Snowden had revealed that the agency was spying on officials from the German government. Rhinelander said that his employer (Eickhoff) had uncovered evidence of industrial espionage. “The problems with security breaches and the theft of intellectual property is real,” Rhinelander said. “The ability of small scale companies, such as the VDMA members, to protect themselves are limited. We nearly have no chance to defend ourselves. Firewalls offer only limited protection. In the meantime, organized crime becomes more sophisticated. These clans have learned to make more money with stolen know-how and product piracy.” This is where the medium-sized companies in the VDMA hold an advantage over larger companies. Most of the knowledge for these companies, Rhinelander explained, resides in the brains of our people, not in computer hard drives.

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Surface Mining: Increasing VDMA Productivity and Reliability

Liebherr’s Mining Division supplies some of the largest machines for The T 264’s AC drive system delivers up to 3,300 kW the surface mining sector. The company’s line of loading equipment (4,425 hp) of electric dynamic braking, reducing engine loading and consists of eight large hydraulic excavators with service weights from fuel consumption. The T 264 is designed to operate for approximately 100 to 800 metric tons (mt), rated power outputs up to 3,000 kW and 24 hours without refueling, depending on the application. loading capacities of up to 47.5 m3. Liebherr also builds some of the An integrated electronic system monitors, records, and outputs best trucks in the mining business. Powered by a diesel-electric drive- vital truck health and performance data. Data is stored and available line, payloads range from 220 mt to 360 mt. for download to perform detailed analysis. This system supports pre- “Our high-performance machines for open-cast mining must have dictive maintenance strategies to minimize unscheduled downtime. round-the-clock availability,” said Dr. Jörg Lukowski, executive vice The 350-mt R 9400 mining excavator can be used to load a fleet president, Liebherr-Mining Equipment Colmar SAS. “For this reason, of mining trucks in the 130- to 150-mt category. This excavator is after-sales service has an absolutely crucial role to play. We invest reg- equipped in standard configuration with a backhoe or face shovel ularly in extensions to our service network in the form of company- bucket of 22 m3. With either electric- or diesel-powered drive sys- owned subsidiaries, in spare parts supply, component remanufactur- tems, this machine is a versatile option for a very wide range of mining, and the qualifications and training of our service staff. Our aim in ing applications. all cases is to be a trustworthy partner for our clients directly on-site.” With more than 40 of these machines already operating in four In the past five years, Liebherr’s Mining Division has introduced countries, Liebherr believes these mining excavators achieve new more than one new development to the market every year. Last year at peak values in terms of tons per hour in this service weight category. bauma 2013, the new Liebherr R 9400 hydraulic excavator with a More recently, Liebherr’s Components Division explained how it 22-m3 bottom-dump bucket matched with a 220-mt truck was the continues to advance technology. “For years, we have been carrying central focus of the outdoor exhibit. The company’s new bucket tooth out research and development projects in the areas of energy effi- system for the R 9100 to R 9400 was also on display. ciency and hybridizing machines,” said Gebhard Schwarz, managing To synergize with its line of hydraulic mining excavators, Lukowski director, Liebherr-Component Technologies. explained that Liebherr has returned to the 220-mt (240-ton) class The group developed a drive system for a hybrid excavator con- with the T 264 haul truck. “This fuel-efficient truck is built for safety cept, which was presented at bauma 2013. The concept makes it pos- and reliability, and is sized to match the Liebherr R 996 B and R 9800 sible to unite the advances of electric and hydraulic systems, Schwarz hydraulic excavators,” Lukowski said. explained. “In addition to hydraulic pressure accumulators, storage The T 264 combines Liebherr’s Litronic Plus AC drive system and systems that have been developed in-house with supercaps are used a 2,000-kW (2,700-hp) engine to yield higher speeds on grade. The for the storage of electric energy,” Schwarz said. T 264’s hydraulic system offers efficient dump hoist performance that “Our focus is increasingly being placed on the design of complete promotes fast cycle times. machine systems and the optimization of the corresponding components,” Schwarz said. “As a result, we have developed the complete drive system for Liebherr's mining trucks over the past few years— from current generators, electric motors and wheel drives to complete control technology with power stacks (frequency converters) and drivetrain regulation. Additional diesel-electric systems are being pre- pared for various machines. “We are also working with new drive systems, which combine the advantages of a hydrostatic drive with mechanical drives, the so- called power split gearboxes (CVT gearboxes),” Schwarz said. “We see great opportunities for these drives in all applications where load col- lectives require the advantages of both systems, for example with wheel loaders.” Liebherr also supplies tailor-made tools for the maintenance of mining excavators, replacing hydraulic pumps and cylinders, travel drives or track pads. The unit assures optimal working conditions despite the size of these components. The service tools include a pin puller, a hydraulic pump lifting tool, a monitoring system for crawler tracks and their components, and a jacking system. The new jacking system developed by Liebherr is a straightfor- ward, cost-efficient method of raising the mining excavator’s superstructure for necessary maintenance or replacement of the slewing ring. This jacking-up principle is a safe, efficient alternative to complex lifting work with a crane. Liebherr’s 220-mt T 264 haul truck combines a Litronic Plus AC drive sys- The system has four synchronized hydraulic supports with an inte- tem with a 2,000-kW engine for higher speeds on grade. gral power stage and mechanical locking, the lifting frame, and a

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roller unit on which the working equipment is supported. These ele- examined under the most stringent tolerance criteria and finally a ments work smoothly together and lift the load safely with optimal decision is made on whether it is suitable for reuse. In the processes weight distribution. that follow, different mechanical processing methods are used to As soon as the cylinder pins have been removed, the lifting frame restore the as-new condition of the component. VDMA has been installed and the bolts securing the slewing ring have been After undergoing repeated quality checks, the individual parts unscrewed, jacking up can be carried out by one person. In only can then be stored for later use or immediately used in the refitting of 15 minutes, the superstructure reaches the maximum height needed a “reman component.” Before it reaches a mine site, each component to run the undercarriage out from beneath it. An ergonomically is tested at state-of-the-art test benches, which are identical to those designed wireless remote control permits unrestricted movement, and used by the series manufacturer. “To guarantee the quality, the com- an integral LCD display enables the user to monitor the system while ponents are also then subjected to the new-component test protocol,” the superstructure is being lifted. During October, Liebherr showcased its remanufacturing compe- tence center in Ettlingen. While the company has always taken great pride in its high-quality manufacturing standards, it also understands the economical importance of remanufacturing, explained Kurt Schoellenberger, managing director, Liebherr-Ettlingen GmbH. “The aim of remanufacturing is to create the quality of a new product from material that has already been used, according to industrial standards,” Schoellenberger said. “Ideally, this means that as much as possible of a complete drive component, such as a diesel engine, is reassembled from previously used and reconditioned parts. A requirement for this is the suitability of the individual parts, which are subjected to stringent checks without exception. Wear parts, such as sealing materials and bearings, are not considered for reuse for quality reasons.” After a component is delivered to the Ettlingen facility, it passes through a high-pressure pre-cleaning process to remove the coarsest dirt. It is then completely disassembled and any wear parts that can obviously no longer be used are sorted and disposed of. The remaining material is then cleaned thoroughly, any paint is removed and The 350-mt Liebherr R 9400 excavator can be configured as a backhoe or detailed diagnostics are run. At this stage, each individual part is a face shovel with a 22-m3 bucket.

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Schoellenberger said. “We therefore provide the same guarantee for all reman components as for new components.” Remanufacturing is beneficial both economically and VDMA environmentally: In comparison with the production of a new component, reconditioned components require up to 75% less energy and raw materials by the time they are delivered, Schoellenberger explained. “As an original manufacturer, we also have the ability to access all the required parts quickly or to produce them according to demand without great expense,” Schoellenberger said. “The latter applies particularly to older models, which are no longer series produced, so that our series production operations can outsource this work to us if needed. This production method has clear time and cost benefits for the customer. Having the option of various processing steps enables the customer to find the perfect solution for machines of any age, according to their requirements.” With diesel and gas engines; hydraulic pumps, engines and cylinders; travel, slewing and swivelling drives; splitter boxes and rope winches, the majority of Liebherr on-site production is already con- tained in the reman program today. Reacting to customer preferences, Liebherr now offers three dif- Liebherr’s reman program is expanding to other regions. ferent processing levels for its reman program: Exchange components, general overhaul and also classic repairs. 50% of the guarantee for new components—not only for the replaced As-new reman exchange components are ideally ordered preven- parts but also for the entire component, which distinguishes us from tively. The used component is only disassembled as soon as the the common market practice.” exchange unit is delivered. The replacement is carried out within Since 2006, Liebherr-Ettlingen GmbH has been able to quadruple 24 hours, to ensure minimal downtime. The second option involves a its total turnover. Currently, hydraulic components contribute around general overhaul of the customer’s component. The component is 25% of component sales. Travel and swivelling drives have been the extracted, sent to Ettlingen and then processed according to the same second largest product group processed. Diesel engines are currently quality criteria. The price of a general overhaul is approximately 50% their best-selling product, making up 65% of all components sold. of a new component. However, the customer must accept a downtime Seeing large future growth potential, Liebherr has invested of between three and 10 days, depending on the complexity of the unit approximately €500,000 (US$679,000) per year in production and the mine’s location. resources and it is currently in the process of further expanding For older machines that are only used for a few operating hours Ettlingen’s capacity. Due to lengthy transport times and customs and each year, purchasing an exchange component or carrying out a gen- export barriers, it has become necessary to establish other continen- eral overhaul is not always profitable. Whereas replacement parts and tal reman operations based on the Ettlingen model. Sites currently general overhauls have fixed prices, for classic repairs the extent of under development include Burlington, Canada, and Nizhny Novgorod, the damage is assessed first and then a price is quoted accordingly. Russia. These will be able to take on production within the existing The similarity to remanufacturing comes from the fact that recondi- manufacturing companies as departments of Liebherr-Ettlingen tioned individual parts are also used where possible for repairs. “The GmbH by mid-2014 at the latest. To do this, they are orienting them- guarantee is another feature,” Schoellenberger said. “It amounts to selves closely with the processes in Ettlingen, which is being supported through employee exchanges and the appropriate training courses.

Exporting Surface Mining Experience With a foundation built on 60 years of in-house experience in continuous mining, RWE Power International (RE GmbH) provides expertise in the design and operation of large-scale open-cast and open-pit materials handling systems. “We feel that there is a movement toward continuous operations within the mining industry,” said Dr. Martin Schmid, head of business development for RE GmbH. “However, for continuous mining to be successful, it needs careful planning and operational experience, which is what RE can provide.” According to his colleague, RE’s head of mining, geology and hydrogeology, Stefan Blunck, providing experience-based operational assistance is an area that the company is now focusing on specifically. “RE is a planning partner for surface mining,” he said, “and we can bring expertise in areas such as maintenance as well as operations to companies that are evaluating new continuous mining projects around the world.” A new jacking system developed by Liebherr raises the excavator’s super- RE is now looking to transfer in-pit crushing and conveying solu- structure for maintenance. tions (IPCC) from its traditional soft-rock homeland further into hard-

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rock territory, with primary crushing with mobile or semi-mobile to a significant extent by the success of the mining companies. The crushers being used only to size run-of-mine rock for conveyor trans- mining industry is the key driver of economic growth. port. The company also sees great potential in countries such as Conventional mining methods involving drilling and blasting VDMA Australia and Chile, where mines are being expanded and existing were dominant until recently; since 2007, however, one of the long-distance conveyors will need duplicating as the tonnages being continent’s largest iron ore producers has been banking on the handled increase. innovative technology offered by the Wirtgen surface miners. The One area in RE’s portfolio that is experiencing increasing demand mines operated by Fortescue Metals Group (FMG) are Australia’s first is in the training of technicians and engineers. During tailor-made large-scale project that uses surface mining as the main mining training sessions in RWE’s German operations, they acquire the local method. As many as 43 Wirtgen surface miners have become vital know-how in conveying technology, for example. The aim is not only keys to the economically efficient mining of high-quality materials to ensure reliable and highly available operation of existing plant in FMG’s iron ore mines. and equipment at home, the participants also learn to evaluate key FMG’s iron ore deposits are located in the Pilbara region in parameters such as product quality and configuration, so that they Western Australia, less than two hours’ flight north of Perth. In can optimally design new plants in their own operations. The targets: this region, FMG holds the mining rights to an area covering lower maintenance, reduced downtimes and higher profitability. 71,400 km2. A special hallmark of the mines presently opened up by Aside from the operational side, RE also remains deeply involved FMG is the flat-lying nature of the iron ore deposits. in setting standards for the surface mining sector, in areas such as In such an environment, the advantages offered by the surface conveyor suitability and durability. The company has its own testing mining technology are most obvious: “Wirtgen surface miners allow facilities, available to customers worldwide, where it can perform high-quality products to be mined with economic efficiency even from standard DIN tests as well as those of its own design, from which it technically challenging mineral deposits,” said Bernhard Schimm, can then make recommendations on the quality and suitability of spe- manager of the Wirtgen Mining Division. In comparative studies that cific belts. were performed as part of the selection process to determine the most suitable main mining method, surface mining was able to win out Selective Mining Lowers Costs over all other mining methods. The Australian continent offers a wealth of mineral resources that is truly unique in the world. As a raw material supplier of, for example, Commissioning a Fully Mobile Crushing coal, iron ore, bauxite or nickel, Australia holds a prominent position Plant in Inner Mongolia in the world market. The economy of the fifth continent is determined During 2013, Baiyinhua Coal Corp. held the official ceremony of putting into operation the first of four fully mobile crushing systems at Baiyinhua coalfield. This first system is used to remove overburden with a nominal capacity of 6,000 tons per hour (t/h) and consists of a crawler-mounted crusher MC 6000, a mobile conveyor bridge and a hopper car with cable reel car. The equipment is designed to operate under extreme climatic conditions—temperatures fall to 40°C below in winter. A large shovel with a capacity of 50 m3 feeds the hopper of the crushing plant, which is equipped with a double-roll crusher. After crushing, the material is continuously transported with belt conveyors, eliminating the need for conventional truck transport. “Application of this advanced mining equipment shall generate a As many as 43 Wirtgen surface miners have become vital to economically long-term economic benefit for Baiyinhua Coal, promoting the devel- efficient mining at Fortescue’s iron ore mines in Australia. opment of coal production,” said Liu Yi, deputy general manager of Mengdong Energy, during his remarks at the ceremony. The other three crushing systems will be put into operation before 2015. Two of them will also be used to remove overburden with a capacity of 6,000 t/h, each. And one crushing system with a capacity of 3,000 t/h will be used for coal mining. ThyssenKrupp is responsible for the design, engineering and construction of all four crushing systems. Demand for fully mobile in-pit crushing systems is growing in large open-pit mining operations around the world. The mining business at ThyssenKrupp Resource Technologies developed these plants for combined use with power shovels. Fully mobile crushers are powered exclusively by electricity. In the present case annual carbon diox- ide emissions can be cut by up to 100,000 mt.

Roll Crusher Advancements in Brazilian Iron Ore Engineers in the Cologne area are designing and building some of the ThyssenKrupp supplied this mobile crushing system to a coal mine in largest roll crushers for a continuous mining system at Vale’s S11D China’s Inner Mongolia province. project. While the company’s expertise spans roll crushers, sizers and

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double-roll crushers (hybrids), Sandvik Materials Handling GmbH has been focused on semi-mobile applications for in-pit crushing and conveying (IPCC) systems more recently. “We do more than design and build machines. We also get involved with mining companies, engineering plants and mining systems,” said Thomas Jabs, managing director, Sandvik Materials Handling GmbH. “The miners want us to get our heads wrapped around their business. They need us to understand what they crush and process. Yes, they are buying a crusher, but more importantly, they are investing in a properly sized product.” Jabs singled out three trends taking place in the area of semi- mobile crushing stations: a tremendous push for safety, especially in the area of ease of maintenance; total cost of ownership (reliability and availability); and placing the crushers closer to the face. “Miners are increasingly trying to close the gap on the length of the haul for mining trucks,” Jabs said. “We are in a great position to support them at the mine planning phase. We can calculate the break-even points and determine whether the mine plan should be trucks only, a combination of a semi-mobile system and trucks, or doing away with trucks completely.” This was the experience with Vale and the S11D iron ore project. Vale wanted a fully mobile system working directly with rope shovels and no trucks, Jabs explained. Sandvik Materials Handling will engineer, design and build four IPCC lines for moving overburden at S11D. The company has already shipped two systems and the third unit was under construction during E&MJ ’s visit. “These are the biggest hybrid crushers ever built for iron ore applications,” Jabs said. “They are designed for a capacity of 11,500 mt/h. The rolls are 1.8-m diameter and 4-m long. There are bigger units [14,000 mt/d], which are operating in the oil sands, but that’s nameplate capacity only. In some cases, sand flows freely through those machines at times.” Vale will have four P&H 4100 shovels moving overburden on four different levels. They will operate in concert with Sandvik’s PF200 fully mobile crushing stations, which use a CI10 double-roll crusher. Sandvik will supply the entire system, the fully mobile crushing station, the belt wagon, face conveyors, the belt out of the pit and the belts to the spreaders, and the spreaders. The S11D mine is expected to reach full-scale commercial production by Q3 2014. “It’s a massive installation for a massive project,” Jabs said. “Sandvik has already supplied two 18,000-mt/h shiploaders. We will be supplying more. Sandvik can now go from the harbor all the way to the face.” To take advantage of economies of scale, mining projects seem to be getting bigger and these companies expect more capacity and higher reliability, explained Manuel Noss, vice president, crushing and screening, Sandvik Materials Handling GmbH. “The mines are looking for better wear materials and ways to incorporate more automation, and we are working on some development projects in those areas. This is where we will concentrate our efforts for the next few years.” The Sandvik Materials Handling team recently completed a tran- sition. “In the past, we focused on customized machines,” Noss said. “Today we provide standardized machines and we are engineering customized solutions for the mines. The miners appreciate this strategy and we are selling more and more machines into mining.” Sandvik has narrowed a very wide product range down to 20 different roll crushers, 10 sizers and 10 hybrids. “By doing away with the trucks or at least shortening the hauls, especially with long-term mass mining, mine operators can expect to lower costs,” Noss said. “With less equipment moving more material, there is also improved safety and environmental benefits.”

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Underground Mining: Longwalls VDMA Mine Safely at Low Cost Per Ton

Companies competing in today’s global markets need to focus on lowering costs, and this holds especially true for underground coal operators. With 150 years of experience as a premium manufacturer of underground mining machinery, Eickhoff understands these principles. Not only do they have highest possible installed power ratings, which assure high productivity, Eickhoff also says its shearer loaders and continuous miners feature a well-balanced combination of maximum machine availability and reliability. These products provide optimum benefits for miners by pairing ease of maintenance with long service life resulting in an increase of as much as 20% in production output when compared to the Eickhoff’s CMZ continuous miner has lower bearing pressure and improved competition, according to Eickhoff. traction for soft under-foot conditions. These mining machines enable mine operators to safely extract even the most difficult deposits with cutting-edge communication Eickhoff’s shearer range consists of five models: the SL 300, and automation technology, delivering field-proven equipment that SL 500, SL 750, SL 900 and SL 1000. works without compromise. The SL 300 comes with two 480-kW cutter motors and two 90- Flexible and customized machine solutions are backed by the kW AC haulage motors, giving increased cutting and travel capa- company’s service assistance, which is considered legendary in the bilities while producing more than 600,000 mt/month at operations industry, according to Eickhoff. in Australia and the U.S. From the remote regions of Vorkuta in Russia to excavating The SL 750, introduced in 2006, built on the success of the potash in Belarus—requiring very specialized, high-powered slightly smaller SL 300 and SL 500 machines, has significantly machines—to Anhui and Shanxi provinces in China with deep more cutting power. The shearer is designed for seams 1.8- to 4.5- mines and challenging mining conditions, Eickhoff’s coal-cutting m high, with 1.9 MW of total installed power. machines are operating in almost all major mining regions. The SL 900 combines the compact dimensions of the SL 750 Eickhoff’s SL series shearer loaders hold several unrivaled with the power of the larger SL 1000, and although it is of similar world production records. The first monthly record of 1 million met- size to the SL 750, its weight is around 25 mt heavier—a conse- ric tons (mt) was achieved at the Shangwan mine in China in 2003, quence of its higher machine body stiffness and rigidity. The being equaled in 2007 by SL 750-equipped Oaky Creek in Australia, installed power of 2.35 MW enables the SL 900 to produce in seams working in a mere 3-m face height. In the U.S., an Eickhoff shear- ranging from 2.1 to 5.5 m in height. er helps CONSOL Energy’s Bailey mine maintain its position as one With what it claims is the world’s most powerful shearer load- of the country’s top longwall producers. er, Eickhoff commissioned the first SL 1000 at a Shenhua mine in China in 2007. The machine is designed to achieve peak performance in giant seams of more than 7.1-m thickness, although it can be adapted to work at medium seam heights down to 3 m. Turning to continuous miners, Eickhoff recommends the hydraulic driven version of its CM2 for better traction in wet and muddy floor conditions. The CM2 series provides low ground pressure and high tramming speeds. A 1.2-m-diameter cutting drum is fitted as standard, with 360 kW of total installed cutting power. Looking ahead, Eickhoff’s engineers are already working on the next generation of mining machinery. Its online computer support combined with onboard maintenance systems and intelligent automation options help to make underground coal mining safer and more efficient. With the help of the latest computer-aided design and simulation processes, and using the latest foundry and manufacturing technology in its own facilities, Eickhoff is continuing to push the envelope of underground cutting technology.

Innovative Underground Mining Equipment In recent years, the core product range of Deilmann-Haniel Mining Systems GmbH—drill rigs, loaders, excavators and shaft sinking equipment—has been continuously extended as a result of technical innovation. The company introduced a new family of roadhead- Eickhoff longwall shearing machines hold several world records for production. ers in 2010 for roadway development: dh R60t, dh R75 and dh R75t

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fit. These roadheaders are achieving outstanding daily advance rates, according to dh Mining Systems. The main characteristics of the roadheaders include: VDMA • low-height design; • telescopic cutting boom; • onboard drilling and bolting rig; • unique water mist spray system; • automatic balancing system for stability during cutting; • low ground pressure due to large crawler pads; • radio-remote controls for cutting and bolting functions; • automatic profile control system; and • online monitoring and data analysis system. “The robustness and the integrated design features combine to make these roadheaders an ideal system for coal mine development, especially in extreme conditions,” said Michael Maas, global marketing manager, dh Mining Systems. After the machine was introduced, units went to work in the Czech Republic and Russia. The latest machine was recently assembled at Bogdanka, a coal mine in Poland. “It’s a new road- The R75 from dh Mining Systems has been created for development work way driving concept for a Polish coal mine,” Maas said. “It’s in soft rock. assembled and has starting cutting. We’re expecting good results and we think we can sell a few more of these units to and 25 metric tons (mt). Bucket sizes range from 0.3-m3 to the 2- coal operators.” m3-capacity bucket carried by the dh L2000 loader. The roadheader has a specially designed water spray system to A quick coupling allows rapid attachment of various tools and protect against ignitions. “We have an external spraying system use of the basic unit for loading, dinting, blasthole drilling, bolting, that uses compressed air and less water than conventional sys- cutting and further applications is achieved. The new quick-coupling tems,” Maas said. “Water consumption is down to 20 l/min only. device means much shorter attachment changeover times, while the Conventional systems use 60 to 80 l/min. We are mixing water and use of a basic carrier vehicle for multiple tasks represents a flexible air and the mist is covering the entire cutter-head so it cools the and cost-effective solution for roadway driving and roadway-mainte- picks and prevents against an ignition. It’s very effective.” nance operations, especially when working in confined spaces. The spray system only needs 12 to 15 m3/min of compressed These machines were presented for the first time at bauma air. It can be operated without an additional booster pump. The 2013 in Munich. The dh L600 dinter loaders with bucket volumes of diameter of the nozzles is large enough that it can be used with 0.6 m3 (side-dump bucket) and 0.3 m3 (box-type bucket) is a prime unfiltered mine water. example of the new quick-coupling concept for underground load- Reviewing the activities that take place underground, dh ers. In the meantime, it has been successfully introduced to sever- Mining Systems recognized a growing demand for multifunctional al coal mines. Besides multifunctional applications, the dh L600 equipment. “One of our ideas to help reduce costs for miners is to was designed with a special focus on high loading/dinting perfor- have multiple purpose machines,” Maas said. “Some miners are mance and simple maintenance. asking for a dinter loader with a few attachment tools for doing The hydraulic control system allows for the use of hydraulic drive roadwork. You could say the same with our excavator business.” power to full extent when operating with the various attachments. The company’s line of crawler-mounted side-dump (dinting) The ergonomic control stand offers very quick and precise handling loaders are a well-known, useful tool for roadway development. and greatly enhances operator comfort. A long-hole driling attach- Currently dh Mining Systems produces five different types of load- ment is also available for methane drainage (150 to 200 m), or with ers at its Dortmund plant, with machine weights of between 6.5 the auger attachment miners can drill 250 m into the seam. The EQ200 compact underground excavator can carry a whole range of tools on its boom, allowing it to be used with different buckets up to a volume of 0.3 m3 for loading, as a drilling/bolting machine, with hydraulic hammer for scaling, or with a service platform and several other attachment tools. Basically designed for multifunction use during shaft sinking, the excavator can also be used effectively for underground infrastructure work. Due to optimized transport and slinging dimensions, the excavator can be brought into operation at shaft bottoms in a very short time. The compact design allows dh EQ200 to operate with its attachments in very confined spaces. The attachable drilling/bolting device with the hydraulic dh DP15 drifter (15 kW impact power) guarantees efficient drilling/bolting cycles. The drifters’ very short length has a beneficial effect on the ratio between effective drill depth and total drill Recognizing a need for underground miners, dh Mining System offers feed length, which is an important factor for drilling/bolting oper- multifunctional equipment. ations in confined spaces.

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A Simpler, Smoother Design Increases Hydraulic Flow for Longwall Operations In the last four years, Kamat completely redesigned all of its plunger pumps from 80 to 400 kW. The objects of the redesign was to reduce vibration and noise emission and to allow vertical and horizontal installation. At the same time, the advantages of the Kamat design would be retained: ease of service, wide interchangeability of spare parts, long lifetimes, superior VFD regulating range, and service only from top for a small footprint. Changing the pump head design was not an option. The gear ends were redesigned, but the wear parts of the new gearboxes are identical to those of the old design. For a mine that still runs the old pumps, the wear parts they stock will not become obsolete even if the pumps in operation are updat- ed. As the general principles of the gearboxes have been kept, the general advantages could be kept: bearings free of axial forces (longer bearing lifetime, less heat), service without draining the oil, service from top, and a small footprint. The new Kamat gear ends (K8000M-3G to K40000M-3G) run so smooth; a coin placed vertically on the pump head will not fall while the pump is running, according to Kamat. This extremely low vibration level emits substantially less noise and allows noise reduction by the softest possible suspension of the pump’s drivetrain. Moreover, in modernizing the existing pump range, Kamat extended its pump range substantially in two directions. The pressure range of the standard Kamat pump range has been extended in the last few years to a reliable 3,500-bar pressure basically for cleaning and cutting applications. This is 10 times higher than what is needed for longwall hydraulics. Longwall pumps are Kamat’s low-pressure pumps, but big longwalls with fast cutting shearers require increasingly greater flows. To satisfy that need, Kamat launched two quintuplex pumps rated at 530 kW (max.) and 800 kW (max.), the K50000M-5G and K80000M-5G, respectively. These two pumps extended the range of the Kamat pumps from 12 to 14 available power ratings doubling the max available power input for a single gearbox from 400 kW to 800 kW. When Kamat decided to double the power input of its pump designs, the whole production process had to be adapted for a new pump size. The old manufacturing machines could not machine the bigger pump heads and gearbox housings. The company built a second factory with bigger CNC centers, with automated handling systems and CAD/CAM installations. In the main Kamat factory, the paint shop was redesigned to accept the 800-kW pumps. The test bed has been equipped with 1-MW power supplies. Joint research with German universities showed clearly that a triplex pump arrangement would not be able to deliver large flows

Kamat pioneered big flow pumps and introduced VFDs for longwall pumps.

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Kamat changed the gear ends for its longwall pumps, but left thew wear parts the same.

(K80000 = max. 3,482 l/min) at an acceptable net positive suction head required (NPSHR) level. To eliminate cavitation, Kamat opted for a quintuplex design and it has proved to be so reliable that the company says it is now able to supply units that can pump more than 600 l/min without the need of a booster. Low inlet valve pressure losses and low acceleration losses have eliminated the need for booster pumps. This is a big advantage for longwall mines. Removing booster pumps, their power supplies, switches, fuses, piping, base frames, etc., and relying on one pump system and its power supply simplifies the entire process. For longwall mines cutting coal, the K50000M-5G can deliver 641 l/min at 420 bar or 7,63 l/min at 360 bar. The K80000M-5G can deliver 1,185 l/min at 420 bar or 1,360 l/min at 375 bar. This means that a whole longwall can easily be powered with a single pump. For more than a year now, U.K. Coal’s Kellingley colliery has operated its longwall on a single K50055M delivering 641 l/min with a VFD drive. This is the simplest and easiest way to run a longwall. A K80000M-5G can easily handle any longwall application, according to Kamat. Big fluid flows, however, are more complicated to control than smaller flows. So Kamat also launched a new range of fail-safe smooth acting unloading valves for flows up to 1,500 l/min per pump at 500 bar (max.). Design engineers again focused on service and the interchangeability of spare parts. The check valve and 2/2-way valve in the Kamat unloaders are fully interchangeable. Mechanical and electro-hydraulic versions are available. The mechanical pilot valve may be fitted with only four bolts onto an electro-hydraulic unloading valve if the electronic control system is down. This assures superior availability of the pump system. An unloading valve has to act quickly to control the line pressure to the face reliably. This means that certain pressure shocks will remain—increasingly with bigger flows. Kamat pioneered big flow pumps in coal mines and introduced VFDs for longwall pumps underground. Several installations proved that a VFD-driven longwall pump increases service intervals and availability impressive- ly. The VFD eliminates pressure shocks by simply changing the pumps drive speed if the longwall changes its flow demand. This is also reflected in a much more stable pressure as the VFD reacts to even 1 bar change in pressure. Pumps controlled by unloader valves will only react if the pressure drops or rises out of its scan. VFDs eliminate the unloading action completely. The pump is running smoother and the entire network—the hoses, pipes, flanges, etc.—is facing much less stress. The overall reliability of such a system improves significantly. In one of its installations, Kamat claims the VFD-controlled pump hasn’t been repaired for 4.5 years.

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In these arrangements, Kamat only uses one VFD per pump system—no matter how many pumps are installed—due to the wide regulating range of its gearboxes. Using one VFD per system also holds costs down. Flow requirements for longwalls seem to constantly increase. Adding more unloading-valve-controlled pumps with boosters was becoming complicated and the systems were struggling to control pressure. Modern Kamat systems are equipped with one to three big pumps (no boosters) controlled by a single VFD.

Giving Miners What They Want For more than 20 years, miners have relied on the MinCa, short for mining car, as a dependable form of transportation underground. Manufactured by Emsbueren-based Hermann Paus Maschinenfabrik, it is a front-steered, all-wheel-drive vehicle for transporting miners and materials (payloads up to 4 metric tons). It features a number of add-on cassettes, such as passenger cab- ins, crane platforms, and tank and service units, to meet specific customer requirements. While its robust design and relatively low service weight (7 mt) are important features, the MinCa can also transport up to 18 people when used as a sole passenger vehicle. The ultra-compact vehicle measures 5.8- x 2- x 2.1-m (L x W x H) and it can make a 90° turn with an entry width of only 4.3 m or less. A further reduction in the turning radius is possible with an optional four-wheel steering system. The MinCa is powered by a 90-kW Deutz engine, classified as COM II and IIIa in terms of exhaust emissions, with which it can achieve speeds of 33 km/h. The hydrostatic drive is a plus for inclines where it can reach high speeds with optimum efficiency without the need to change gear. The Paus MinCa’s climbing ability is around 60%. A hinged driver’s cab can be tilted forward using a manual pump to provide ease of access to the engine and hydraulic components for repair. Even though Paus has been building this type of chassis for 10 years, the company believes it has now made an additional leap forward with the new chassis for the MinCa. Both the steering axle as well as the rear axle are oscillating (±12°), by which two trailing arms and wishbone arms are suspended on the vehicle chassis, the result is all tires remain in contact with the ground even with poor under-foot conditions. Impacts to the chassis and cabin are atten- uated by springs and shock absorbers. The springs are tensioned at the ends of the axles between the axle and the chassis and shock absorbers are fitted between these springs and also between the axle and the chassis. Further features of the chassis include the end position stop, catch ropes and rubber buffer for the cab mount.

The MinCa can carry 18 underground miners to work and back.

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Before its launch, the MinCa with its new and innovative chas- al is conveyed from the concrete pump to the spray nozzle through sis was extensively tested and comprehensive measurements were a hose and sprayed with the aid of compressed air. taken on the ATP test track for off-road vehicles in Papenburg. A The concrete spray machine BSG 8 is equipped with a Deutz VDMA video is available at: www.paus.de. diesel engine with an output of 115 kW at 2,300 rpm. The speed of This is a prime example of their motto: listening to the cus- the vehicle can be infinitely adjusted in both directions (0-12 km/h) tomer and providing them with exactly what they need, explained by means of a hydrostatic drive. Franz-Josef Paus, managing director, Hermann Paus The core of the spraying train is the concrete spray manipulator Maschinenfabrik. “Some mines are having more difficulties than consisting of a rotating column, a telescopic boom and a spray others maintaining profitability and controlling costs,” Paus said. manipulator. The rotating column is positioned on a pivot table and “We provide equipment engineered for their conditions, their expec- can be hydraulically pivoted laterally together with the telescopic tations, and their way of working, rather than a standard product, boom and manipulator alongside the catenary. The rotating column which is not optimized for the application.” at the front end of the machine operates hydraulically, permitting As an example, Paus offered a hypothetical situation where an 360° rotation and worm drive. A three-stage telescopic boom (2.9-m underground mine needed a fleet of dumpers. The standard 20-ton telescopic length) is attached at the upper end of the rotating col- units are too big. The standard 10-ton units work, but the cycle times umn, which can be extended, raised and lowered with the aid of a are inefficient. “In that case, Paus would build a fleet of 15-ton hydraulic cylinder. The manipulator, with a spray capacity of 7.5 m,” dumpers for that mine,” Paus said. “The custom machines would consists of two hydraulic pivoting drives, which move the spray noz- probably be a little more expensive than the standard units, but there zle into the required position. The nozzle has a pivoting range of would be other benefits in terms of cycle times and fuel savings.” 360° along its longitudinal axis and 240° around its transverse axis. Many mines demand the latest technology, such as electroni- The hydraulically driven rotary vane compressor with an air flow cally controlled engines, while others do not. “Some regions do not of 7.5 m3 per minute (operating pressure 8 bar) ensures that the have the maintenance skills or the fuel quality for electronic con- concrete is sprayed by compressed air from the nozzle to the rock trols, and we can supply equipment for those mines,” Paus said. face. An adjustable liquid metering system enables a range of dif- Increasingly, Paus cautions, it’s becoming more difficult to find ferent additives, such as curing accelerators, to be used. What is components with low levels of electronic parts. more, the BSG 8 has an accelerator tank for liquid additives with a Engine and pump manufacturers do not always supply two volume of around 100 liters. The degree of liquidity of the concrete types of components. “This is one of the areas where we excel— can be adjusted by the 24-volt electric pump. knowing what miners from different regions want and understand- The BSG 8’s integral cleaning system consists of a hydraulical- ing the variety of components available, as well as the legal issues ly driven high-pressure cleaning unit with an output of 200 bar and surrounding their use,” Paus said. a tank that holds 200 liters of water. To improve its stability, the Next year, Paus will launch a new smaller utility vehicle at BTG’s pivot table can be supported by hydraulic supports on the Expomin in Santiago, Chile. “We recently overhauled our PFL8 load- floor adjacent to the track vehicle or between the rails. er,” Paus said. “We introduced Canbus systems. It’s not a new The concrete mixer and concrete pump are positioned on the development, just continuous improvement of an existing product trailer. The concrete mixer, with a drum volume of 5 m3, works by along with a new z-linkage and engine.” the post-mixing method, whereby finished concrete is kept mixed. Paus employs 300 craftsmen and they have a wide range of The mixing drum is hydrostatically driven by the spray machine’s competencies. When it comes to providing solutions, they also ben- diesel engine. The stationary drum is charged through the upper efit from cross pollination by applying technology or components manhole and the closing lid plate is opened to unload. they use on the construction side for mining and vice versa. The concrete pump is located underneath the reopening plate “Miners approach us with a situation and oftentimes we can pro- and works as a piston pump, which is also hydraulically driven by vide a tailored solution,” Paus said. the spray machine’s diesel engine. A concrete hose connects the One example is the company’s new concrete spraying train. The spray nozzle to the spray manipulator. The rail vehicle’s mixing rail-mounted vehicle consists of a concrete sprayer with diesel- drum can also be charged by a mobile concrete mixer truck, by driv- powered concrete spray machine (BSG 8) and a concrete mixer ing the mobile mixer to the concrete pump and transferring con- trailer (BTG 4) fixed to the spray machine. A concrete mixer and a crete into the concrete pump. concrete pump are fitted on the concrete mixer trailer. The materi- The quality of the machine components makes the vehicle ideal for use in extremely damp and seriously wet environments. The rail vehicle is equipped with an open and comfortable cab located in the center of the concrete spray vehicle. All steering and control equipment is clearly arranged in the cab. Convenient access is possible from both sides and a cushioned driver’s seat and comfortable and easily reachable controls continue to win over users.

Engineering Heavy-duty Hoisting Systems As a system provider of mechanical and electrical mining applications for heavy-duty hoisting systems, Siemag Tecberg is an international market leader in total integration solutions to the industry. When he thinks of the crowning achievements, Detlef Scheppe, executive vice president-hoisting technology mining, points to The Paus PFL8 now operates with Canbus, a z-linkage and a new engine. engineering feats such as the recent challenge of the largest

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integrated Koepe hoist. This 9-megwatt hoisting system with a 50- metric-ton skip payload will be installed at Yitai Coal in China’s Inner Mongolia region. It will have a 15-million-mt/y production capacity when commissioned in 2014-2015. VDMA “With this type of drive technology, the motor is integrated into the friction hoist drum assembly,” Scheppe said. “The compact construction provides a cost-effective solution in the product as well as hoist floor and foundation arrangements.” The stator and rotor elements on the integrated hoist are acces- sible through special openings in the side walls, which are closed during operations. Cooling air to the motor as well as input power cable supply are routed via the ventilation hubs, which are installed on the fixed axle complete with the roller bearing assemblies. The fixed axle supports symmetric foundation loads for both tower- and Siemag Tecberg’s 1- to 6-rope friction winch has a tractive force of 1,800 kN. floor-mounted arrangements, and hence hoist deflections and associated design criteria are simplified in the layout. cost-effective applications and the benefit of substitution of man- While Scheppe is quick to point out that Siemag Tecberg pro- ual labor with technology providing compliance to the Health and vides Koepe multi-rope specialized equipment unique to the chal- Safety Mining Regulations. lenges of deep-level mining and high-shaft compartment loads; The ability to create slack rope in the large multi-rope Koepe the world’s largest multi-rope Friction Winch rated at 185 mt has applications where high compartment loads dictate limitations to been supplied to Oyu Tolgoi in the Inner Mongolia region. maintenance activities, the use of the Siemag Tecberg Clamping Mobile Friction Winches can handle one to six ropes simultane- and Lifting Device (CLD) significantly simplifies the reliance on ously to or from the Koepe hoist rope handling activity. The prima- labor intensive and higher risk rope attachment adjustments. ry benefits of the specialized equipment enables speed of operation The CLD can clamp all of the ropes of a hoisting compartment and time efficiencies particular to minimizing shaft and hoisting simultaneously without any major work being required beforehand, downtime, while providing suitable technology to the challenges of and can hold the ropes in place, lift or lower them under maximum the deep-level mining requirements and the subsequent large com- load. The total lifting distance is determined by cyclic movements partment loads generated in the shaft. of the clamping beam. Considering that the mine can change multiple ropes at any “The rope system can be opened fast, simple, but mainly safe given time, the economics associated with the technology provide by use of the CLD,” said Michael Krenzer, project manager-hoist-

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ing systems, Siemag Tecberg. “Depending on the design, the CLD When it comes to the U.S., marco has been involved with some can move the ropes up to 4 m per minute during the loaded important installations beginning with the first Westfalia face at stroke.” CLDs supplied by Siemag Tecberg are designed until Pinnacle No. 50. They worked with Joy for a brief period and were VDMA approximately 250 mt rope load using four main hydraulic cylin- heavily involved with DBT through its relationship with RAG. “After ders with the product positioned under the main head sheave those alliances, it was difficult to return to the U.S. market, but we assemblies in the headgear. are now working with United Mining Equipment in Pittsburgh,” “After the ropes are provided by the CLD, the Friction Winch is Kutsch said. “We recently supplied new systems to Murray Energy in used to spool out the ropes of the shaft,” said Krenzer. “Ropes are the U.S. These systems have no ram transducer. Instead, it uses an reeled off with the Rope Reelers arranged behind the Friction ultrasound sensor for measuring the distance between the roof sup- Winch.” Siemag Tecberg recently sold a complete rope handling port and the AFC. They have done away with the reed transducers in system for the Impala No. 16 Shaft in South Africa. Impala pur- the advancing ram that normally measures the position of the AFC.” chased a Friction Winch, two CLD’s, the Rope Reelers and the This is new technology for the U.S. that was tested first in required steelwork. “We provided the whole system as well as the Chinese longwall mines. “We supply an ultrasound sensor mount- rope up support from the engineering and automation team in ed near the leg and we calculate from the ultrasound signal the Germany and Siemag Tecberg South Africa,” Krenzer said. distance between the roof support and a target on the AFC,” “The Friction Winch can raise or lower all six ropes, for a hoist- Kutsch said. Murray Energy is using the system at the New Era and ing depth close to 2,000 m, in shaft depth simultaneously in less Century mines. than three hours. The tractive forces occurring can be 180-200 mt. A small company based in Dachau near Munich, marco builds The chassis mounted equipment due to the design provides the 50 longwall systems per year. They are supplying ZMJ, Kopex, Fazos, ability to utilize the rope handling application on multiple shaft etc. “We have a lead time of six weeks per longwall,” Kutsch said. footprints in and around the shafts and mine complex offering “We do everything in house. When we can’t do it, we look for com- maximum utility to the asset on the mine.” panies that can supply the right equipment. As an example, a company in the Black Forest supplies the main blocks. They supply Applying Industrial Standards hydraulic blocks to a number of equipment manufacturers and they to Longwall Mining have the CNC machines and they buy the highest quality steels.” Marco is more than an electro-hydraulic control supplier for long- For the valve cartridges, they work with companies that supply wall mining. The company strives to offer installation, system and BMW, which must meet ISO standards, and they must mass-pro- product solutions tailored to meet a mining company’s needs. It duce high-quality parts at a relatively low price. has developed a module-based concept for shield control for floor Dr. Kutsch explained how marco is always looking to develop (base lift), roof (stabilizing cylinder with inclinometer) and mining new technology for longwall miners. Marco’s Digital Mining is the on gradient. A multi-sensor with integrated ultrasound technology direct result of that approach. “At any time, a number of machines for measuring armored face conveyor (AFC) distance and an incli- are running near the longwall,” Kutsch said. “Miners were asking nometer with infrared sensors for determining the position of the if we could integrate those systems—the high-pressure pumps, shearer have been recently commissioned. the stageloader, communications, etc.—and help get that data to Today, the bulk of marco’s sales take place in China. “Most of the surface. Marco responded with a control system that includes the Chinese longwall mines use systems developed by marco,” said the integrated face control (IFC) system.” Dr. Stefan Kutsch, sales director, marco. “We sell 25 to 40 longwall The Digital Mining system integrates roof supports, the AFC, systems to China annually. Our Beijing office has about 50 people the cutting system and peripherals, such as pumps, drives, supporting this business. While the roof supports are made in switchgear and stageloaders, into one system to provide control China, the miners want sophisticated control systems similar to and visualization within the mine network. This, Kutsch believes, the U.S. and Australia.” will be the basis for an overall optimization process. Marco also works with mines in Siberia (Kuzbass). “SUEK has A network, marco Back Bone, connects underground computers purchased a number of systems in the last few years to automate with 22-in. screens, video cameras, and underground switches their longwalls,” Kutsch said. “We have another branch in Vorkuta, covering all interface and protocol types. where we service five longwalls.” The Digital Mining system uses a lot of visual information starting with maps and moving to the IFC. The IFC window shows the shearer and shield as well as roof support information. Detailed information can be called up in extra windows, such as leg pressure analysis and a single support view. A camera system provides video feeds of the shearer roof and floor cutting along with supports advancing after the cut. “A camera needs to transmit a lot of data,” Kutsch said. “We made a cable connection for the controller, allowing 100 Mbps. That’s a standard Ethernet rate, but it’s not an Ethernet cable. It’s a 4-wire neighbor cable. A camera is connected every fifth or 10th shield. They switch on as the shearer passes by.” Marco has three of these systems running in China and hopes to install one soon in Poland. They are seeking approvals from regulators in the U.S. and Australia. Marco has developed the Integrated Face Control (IFC) system for longwall Kutsch explained marco’s modular approach. “We offer our cus- mining, which plays a key role in its Digital Mining platform. tomers a modular list of equipment for roof supports rather than a

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hydraulic parts list,” Kutsch. “We view the shield legs as a module. There are two legs and sometimes there is a base lift system. The customer wants to lift the base during advance. We analyzed the situation and connected a leg valve to the base. When the shield is VDMA lowered, the base is lifted by the lowering force of the leg. The valve closes and the shield moves forward. If this is not done properly, the hydraulic power is insufficient to keep the base up while the shield advances. In soft bottom conditions, the pontoons will dig into the floor.” The company has also developed algorithms to predict danger based on leg pressure data. “It doesn’t tell the longwall operator precisely when a bump will happen, but it lets them know that stress is building and maybe they can take some corrective action. Other companies are working on this too, but it is already built into GHH’s LHDs are optimized for aggressive applications. the marco system,” Kutsch said. Marco wants to make industrial standards available for under- tions, yet easy to maintain. They can also supply high-tech LHDs, ground mining. Mining machinery is very complex and the com- which have some of the highest performance standards. pany believes the miners should have access to all of the avail- Mortimer Glinz, managing director for GHH, explained that the able information. company focuses on improving three areas when it designs equipment: ergonomics, drivetrains and automation. “A better ergonom- Improving the Interaction with the ically designed machine will post better results as far as higher Operator Underground efficiencies and less damage,” Glinz said. “We are constantly GHH Fahrzeuge designs and manufactures equipment for under- improving the space within our cabs.” ground mining. The company prides itself on durability and The backbone of the high-tech product line is the efficient drive believes that this approach will yield a low total cost of ownership. system (EDS). A hydrostatic driveline offers flexible power distribu- The company’s product range consists of LHDs with payloads from tion, high breakout forces and increased tramming speeds. “The 3 to 20 tons, dumpers with payloads up to 55 tons, drilling and units have a second pedal (throttle) that is used in combination bolting rigs, and specialty vehicles such as scalers. with the hydrostatic drivetrain, which improves the operator inter- GHH works with the miners to supply what they need. They can action with the machine,”Glinz said. “Similar to an iPhone or any supply plain LHDs, which are optimized for aggressive applica- other machine, we feel it’s really important to facilitate the

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interaction between the operator and the machine to improve progress of 20,000 metric tons (mt) per day. It needed a powerful efficiencies.” The computerized drivetrain control also improves high-pressure pump station to deliver the appropriate hydraulic traction, improving brake and tire wear. pressure and volume. VDMA Automation keeps the operator out of harm’s way. The GHH In addition to these demanding pressure requirements, the LHDs can be equipped with assisted control where the operator mine also set high standards as far as water quality for its long- presses a button as the machine enters the muck and it automat- wall equipment. Clean and saline free water is important to the ically crowds the bucket according to the load. “This helps improve mine as it guarantees the longevity of the equipment and secures the productivity inexperienced and experienced operators alike,” the company’s capital investment. Glinz said. “It improves bucket fill factors and reduces the wear These were the key factors that needed to be considered in the and tear on the machines.” If the operator enters too aggressively, development and the design of the pump station. The result is one tire wear becomes an issue. A weak approach usually translates of the most modern longwall pump stations ever built by Hauhinco. into a poor fill factor. The entire high-pressure system consists of eight individual In 2012, GHH landed a major deal with Codelco to supply LHDs stations that result in one intelligent high-pressure system: to the El Teniente copper mine in Chile. They have been filling that First, the mine water runs through a pre-water cleaning sta- order throughout 2013 and, in doing so, they established a new tion. In this station, a hydrocyclone separates all solids out of the service and repair center near Santiago. “This project is going water. A three-stage filtration process with automatic duplex back well and it reflects nicely on GHH,” Glinz said. “It was our first flush filters in 100 micron (µm), 50 µm, 25 µm follows. A HFA-bag experience working in Chile on a large scale project and we gained return filter with a filter mesh of 50 µm is also stored on this sta- a lot of valuable experience. The GHH team in Santiago grew with tion, cleaning the Water-HFA-Emulsion returning from the face the project and the Chilean miners see that we are committed to before it is led back to the tank. the region.” After the three-stage filtration process, the water enters the The company has similar activities taking place in other parts water treatment system. This water treatment technology was of the world. GHH has upgraded its facilities in Russia. They are designed by Hauhinco in 2010. In this station, 1,000 l/hr of clean seeing constant growth in that region. “We will have two or three and saline free water is produced at a feed-in pressure of 15 bar. sites where we employ people for fix service points close to the After this treatment process, the water has a conductivity of only mines,” Glinz said. approximately 30 microSiemens (µS) and is practically saline free. GHH is currently entering Australia, allthough business has The clean water is enriched with concentrate in the automatic slowed in the region. “From a short-term perspective it might not emulsion mixing system. Afterward, the Water-HFA-Emulsion is led be the ideal time to enter the market, but if they are looking to to the main tank of the pump station. This stainless steel tank has save costs sustainably, we believe we can make a substantial dif- a total capacity of 6,000 l, which are separated in 5,000-l Water- ference,” Glinz said. GHH has shipped a test machine to Australia HFA-Emulsion and 1,000-l HFA-concentrate. In addition to the and they are negotiating to place it at a mine with a major mining automatic emulsion mixing system, the tank is equipped with ana- company. The company has its headquarters in Perth and is log level measuring instruments in the Water-HFA-Emulsion and in already linked up with service partners in Mount Isa and other the emulsion compartment. Both segments are additionally pro- areas in Australia. tected against falling rocks and other effects with stainless steel GHH recently announced a new partner in Canada, Wajax. They covers. A transmitted light refractometer with a bi-prism is also are looking for partners in the U.S. and forming a relationship with used at the tank to monitor the HFA-Water-Emulsion. The main tank a Mexican equipment dealer. “Our hardrock machines are success- is connected with an additional 6,000-l stainless steel tank that is ful around the world,” Glinz said. “And, GHH is becoming a truly mainly used for volume changes (pendulum volume). international mining equipment supplier.” A total of three EHP-5K 400 (five plunger high-pressure pumps), each run with a 400-kW electric motor, are installed in the Kirowa’s High-pressure Pumping Station pump station and provide the shield supports with enough power. Hauhinco has developed, manufactured and commissioned the Each EHP-5K 400 delivers a maximum flow rate of 635 l/min and a largest volume high-pressure pump station in its history for SUEK’s maximum pressure of 360 bar. The pumps, which were specifically Kirowa mine in Russia. designed for underground mining, are designed as flange type. The pump station has been specifically designed for the needs Each pump is equipped with a U504-pressure relief valve, a DN40 of the mine’s high-performance longwall. The longwall has a total PN420 bypass valve, a transmission oil pressure and temperature length of 300 m and a seam height of about 3 m with a mining control as an integrated transmission oil cooler. The generated pressure and volume is fed to a collecting block at the accumulator and filter station. From the collecting block the water enters two automatic high-pressure duplex back flush filters and is filtered once again. Two 32l PN400 accumulators are also stored on this station, to reduce any possible pressure spikes or shock. The emulsion then runs through a distribution block and is fed to the hydraulic shield supports on the face.

A total of three EHP-5K 400 (five plunger high-pressure pumps), each run with a 400-kW electric motor, are installed in the pump station and provide the shield supports with enough power.

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The Kirowa pump station was commissioned at the end of 2013. The management of the mine has been very satisfied with the installed equipment, according to Hauhinco. They believe the improved water conditions will preserve its longwall investments. VDMA

Intelligent Drive Technology for Underground Coal Mining Bartec Sicherheits-Schaltanlagen GmbH, headquartered at Menden, Germany, is best known for making underground equip- The Dynavert is an AC voltage converter with power up to 500 kW for four- ment in compression-proof enclosures for hard coal mines. In addi- quadrant use. tion to solutions for electrifying mining machines, such as longwall shearers and continuous miners, energy distribution stations and be used due to bad quality, water-water or water-air cooling sys- power transformers, Bartec has evolved into a specialist that deliv- tems are used. ers intelligent drive technology to the mines. It is important to have an optimized torque balance at multiple Bartec delivers several different types of electronic frequency drives or drive-groups. To achieve that, converters are coordinated converters, tailor-made solutions for different jobs, such as con- in a master-slave relation by a high-level assembly control system veyor drives, chain feeders, pumps or crushers. Indirect Voltage on IPC base. The converters themselves are equipped with intelli- link (AC) converters with power up to 90 kW, 315 kW and 630 kW gent small control systems, which communicate by a profibus-con- for two-quadrant-use (VSD), as well as frequency converters up to nection with the IPC. 500 kW for four-quadrant-use (Dynavert), have been integrated To realize a conveyor-connection between two mines in the into these applications. Czech Republic in 2013, two Dynavert converters were connected at The converters have been chosen and dimensioned appropriate the main and at the sub-drive (in TT technique) to drive groups (in to the drive solution needed. Especially when it comes to belt- each mine). Each group consisted of three 250-kW motors. This conveyors in a downward conveying direction, Dynavert frequency conveyor had a capacity of 1,500 mt/h within the connected mines. converters are used for a real four-quadrant mode; drive by The material was transported by two speed-controlled feeders to engine/break by generator; drive-engine-turn right or left. This delivery belts. At the skip, the material went to two bunkers. In application feeds energy back to the grid, when in use in the gen- addition to converters and drives for the main conveyor belt, Bartec erator mode. also supplied power transformers, motors for the feeders and The converters are water-cooled to remove heat efficiently bunker-extractors, converters for these, as well as needed cooling from the enclosure. In such cases, where water of the mine cannot systems and automation systems for the converters.

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For decades, electro-hydraulic side tipping loaders with crawler track assembly and telescopic booms have been used as standard loading machines for drilling and blasting in headings in deep VDMA German coal mining operations. The technique has been rarely applied elsewhere. The company has three loaders: H-L 600, H-L 1000 and H-L 1500. Due to its extremely compact design, the H-L 600 is especially suited for loading in the coal face/drift end and as loading device for drifting short galleries and special underground work- ings. For roadway drivage, the H-L 1000 is used for excavated cross sections of up to 16 m2, while the H-L 1500 is applied as a loading device for cross sections of more than 16 m2. In conventional roadway driving operations, electro-hydraulically driven drilling jumbos on crawler tracks can be used in connection with the side tipping loaders for preparing blastholes. The converters are water-cooled to remove heat efficiently from the enclosure. These drilling jumbos may optionally be fitted with combined feed units that permit anchor bolting and the installation of resin bolts. Bartec also demonstrated the advantage of its frequency con- In spite of its extremely compact design, the H-D1 single-boom verters in a set of downhill conveyors in the Kuzbass region in drilling jumbo can cover with its parallel automatic drilling range Russia. Drives, situated at the tail of the belt, controlled the belt all cross sections found in underground coal mining and—in con- speed, which is actually driven by the weight of load. Braking is nection with the respectively required type of side tipping loader— done electrically; mechanical brakes are used as a repair brake. it may be maneuvered on site without any problems. The system uses 1,140-volt Dynavert converters, which are typ- High-performance hydraulic drills achieve penetration rates of ical for Russia. The installed power of motors is 2 x 500 kW. up to 2.5 m/min. For compressive strengths of 80 MPa and less, a Because of the converters in four-quadrants-mode, all loading rotary drill drive is applied. For harder rock, a drifter is required. cases can be managed. The drilling equipment can also be connected to the H-L 1500. The At a potash mining operation in the Ural Mountains, the main weight of the carrier device (roughly 12 mt) provides nearly the conveyor facilities are equipped with special double-converters for same stability as the H-D1. The system is referred to as a H-MF controlling the drive. There are two VSD converters in an enclosure, 1500 (MF for multifunctional). specially developed for this application. The project also includes Hazemag Mining is currently developing a platform for two min- measurement of load condition of the belt with ultrasonic devices ers operating hydraulic bolting devices, which could also be used as (sensors) and the control of speed depending on the load. Targeting attachment for the H-L 1500. The machine’s hydraulics would power the final stage of extension, all main conveyor systems shall be inte- the Perforator roof bolters. The feeding lines are installed on the grated into the control system in order to achieve less consumption machine and on the basket and are connected via the quick-cou- of energy as well as less wear of the belt-conveyor. Since 2008, Bartec pling system. The operators on the platform are protected against has installed more than 20 conveyors systems for this operation. rock fall by a canopy and against falling by holding ropes. Since 2007, Bartec has equipped three mining faces in the This side-tipping technique relies on a chain conveyor in the Russian region of Vorkuta with frequency converter systems. The roadway, which are often integrated impact roll crushers. The com- drives are mounted at the face-conveyor. The faces are between pany has two types of crawler-mounted conveying systems 250 and 280 m each. At the shortest face are three drives with 500 equipped with impact roll crushers or feeder breakers. kW each installed; at the both longer faces there are 3 x 630 kW. The 27-m H-MC 27 (MC for mobile crusher) is designed as a The voltage is 1,140 volts. VDS converters control the start-up of gate-end loader between road heading machines and the down- the conveyor. By this control, the mechanical system, especially the stream belts and may be realigned by a lateral telescopic crawler chain and the gearbox, are prevented from damage without aban- track. The H-MC 45 is designed for hard rock applications. The 350- doning the braking-torque. Further possibilities of automation like mt/h conveying system is 45-m long and the unit weighs 63 mt. speed-control of the chain-conveyor relating to load or direction of drive of the shearer are realized.

Side Tipping Loader on Crawler Track Assembly Hazemag Mining offers efficient, modern system solutions for dinting, heading and drilling technology. Its business is based mainly on the former activities of companies its has acquired, such as EPR and includes the loading and dinting technology of the HausHerr and Salzgitter brands, the heading machines of the Salzgitter brand, as well as Turmag’s long hole and large hole drilling machines. The company also manages the international sales of the Perforator handheld drilling machines. The entire product portfolio for Hazemag Mining has been adapted to meet current market requirements and modernized and enlarged to meet new fields of mining. A miner dumps ore onto a chain conveyor with a side-tipping loader.

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Customized System Solutions for Bulk Materials VDMA

The ever-increasing technical demands in the bulk materials indus- company’s belt conveyors enable companies to transport large try are reflected in the particular expectations of the user. quantities of bulk material from the mine to the port as cost effec- Manufacturers who can supply all of the equipment and bring a pro- tively and as quickly as possible. Conveyors hold distinct advan- ject from concept to completion are in high demand. The Beckum- tages over trucks. Road building is expensive, and as production based Beumer Group with affiliations around the globe develops grows so does truck traffic. Added to this are the operating costs customized system solutions for conveying and loading systems. and emissions caused by the fleet—both with regard to fuel con- Beumer also acts as the main contractor on behalf of its cus- sumption and personnel costs as well as noise and dust. tomers. “A significant trend is that more and more clients want to Belt conveyors usually traverse a direct route, delivering mate- commission their systems in a turnkey state,” said Dr. Gerd rials much more quickly. They can be operated with significantly Oberheuser, head of system technology for the Beumer Group, fewer personnel. Depending on the project, belt conveying systems regarding the increased market requirements. “EPCM [engineering, need up to 90% less primary energy than comparable truck trans- procurement and construction management] is more than a buzz- portation, which reduces the operation’s carbon footprint. word. It’s an enhanced form of project management. And, this trend Belt conveyors can overcome long distances, steep gradients can be seen in many parts of the bulk materials industry, especial- and tight curves, and can be individually matched to the particu- ly open-cast mining.” lar task and topography. Use is made of durable, tension-resistant “For a quotation to be accepted, contracts are often only placed conveyor belts. In doing so, Beumer uses various calculation pro- on an EPCM basis,” said Dr. Oberheuser. This means that, as well as grams to determine the optimum belt design. These enable tensile supplying the equipment, Beumer is responsible for the whole pro- forces to be analyzed and also forces that occur due to acceleration cess. This includes the design of the entire system, the installation, and deceleration—always taking into account the intrinsic weight the commissioning and the instruction of subcontractors. Not only of the belt and the transported material. They are also used to does a high availability of machines and systems play a decisive role, determine possible curve radii. but also optimum support. For this reason, Beumer has set up com- Beumer can provide advance feasibility studies. In addition, petence centers in the Czech Republic, in Austria, at its headquarters the belt position is calculated in advance with the appropriate in Beckum, and in North America. These take care of research and curve radius for the empty and loaded states. With their slender development, sales, project management and purchasing. lines, belt conveyors overcome broken terrain and other obstacles With its solutions, the Beumer Group helps users to work more such as rivers, roads, buildings or rail tracks. Horizontal and verti- cost effectively and in a more environmentally friendly manner. The cal curves in the routing can also be overlapped. Depending on the

Belt conveyors traverse a direct route and are much more competitive than truck transportation.

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requirement, Beumer offers open troughed belt conveyors for high- year, ABB Germany equipped the 65th shovel with such a proven er throughputs and larger mass flows as well as larger curve radii, drive solution. and enclosed pipe conveyors for products, which need to be pro- Another example of one of the cost-saving developments of ABB VDMA tected against the effects of the environment. in materials handling is the new direct drive solution for conveyors. At the port of Callao in Peru, Beumer will be installing pipe con- The so-called gearless conveyor drive (GCD) solution can work veyors with a length of around 3 km for transporting copper, lead without the maintenance-intensive gearboxes and enables much and zinc concentrates for completion in 2014. higher torque and power ratings at the drive pulley. This allows “Depending on the landscape and environmental conditions, longer transport lines with less transfer stations, which in turn is we can install overland conveyors with horizontal curves with cutting the capex as well as the opex. lengths of up to 20 km,” said Oberheuser. Gradients of up to 15° Also the innovative stockyard management system (SMS) is a can be realized depending on the characteristics of the materials shining example where comprehensive knowledge and experi- to be conveyed. After planning, installation and commissioning, ence is combined in a total system automation solution to reach maintenance and service are no more laborious than with a highest efficiency. The control and automation provided by ABB straight conveyor. On average, the annual maintenance costs are contributes to a continuous and seamless operation with mini- only around 2% of the investment sum. mized down-time, and maximized production. The SMS is cross- In Canada, Beumer is currently installing a conveyor with a ing the different control levels in the plant. Because of the length of 3.48 km for a large mining operation. This will convey up experience with stackers and reclaimers, ABB delivers a fully to 6,000 metric tons (mt) of iron ore per hour. This large-area con- automated stockpile that includes train or ship loading/unload- veyor system must withstand extreme temperatures of down to - ing as well as intelligent stacking for optimized usage of the 40° and heavy snowfalls. Beumer has designed all mechanical and stockpile area. This system provides a job controlled operation of structural elements for the extremely low temperatures. For exam- a complete stockyard. An interface offers information of the ple, the system is fitted with a feed conveyor and an unloading sys- batches on the material quantity and quality from an ERP system with tripper car. tem e.g., like SAP or by manual input. The SMS is looking for the As the main contractor, Beumer has equipped a new distribu- right place, checking possible transport lines over the inner tion center off the shore of Malaysia with 17 trough belt conveyors stockyard conveyors and starts the unloading with afterward with a total length of 12 km for a large iron ore exporter. The con- transport and stacking. veyors ensure swift transport of iron ore from super-size freighters Through a material tracking function, the system knows where to the mainland. Beumer delivered and installed the conveyors, put which mass/volume with which material quality is located even if them into operation and took full charge of engineering, all accord- it is on the pile, the conveyor or in a surge bin. This knowledge in ing to a strict timetable. combination with an automated routing enables optimized operational procedures that can save energy and time by a pooled han- Efficiency Meets Reliability for Materials dling of the material in a job. For example, it is possible to mix dif- Handling Solutions ferent material qualities on a single pile. Therefore, a computer Mine operators worldwide are confronted with ever growing chal- calculated model is tracking the bulk materials’ movements in lenges, declining ore grades, increasingly remote locations and the real-time and delivers a 3-D stockpile visualization. In addition, need to maintain the same output, which increases energy costs. laser scanners are detecting the pile to get a real-life adjustment The demand for efficient operation solutions is high. To stay com- to the calculated model. This way one can move in an exact 3-D petitive, the mining operators aim to lower the cost per ton and Model where they have a real-time inventory overview. increase the life cycle of the mining machines at the same time. A laser alignment enables the industry to reach a new grade of Higher reliability qualifies the capex and optimizes the return on excellence in materials handling. By detecting the pile surface, it is investment. To help meet these ambitions, ABB develops and deliv- possible to stack the material on a flat pile, which allows storing ers efficiency raising electrical and integration solutions (E&IS) for more in the same footprint and enables a more continuous reclaim- automation in materials handling. ing performance without air digging. Located in Cottbus, ABB’s main technology center for open-pit Another benefit is the possibility to choose alternative routes mining has its roots in the local lignite-mining industry, which still and/or stockpiles, e.g., if a part of the transport system is in ser- plays an important role in German power generation. The center is vice, the ABB stockyard manager changes the root to fully auto- part of ABB’s mining business, which serves the mining and min- mated and minimizes the downtime of the complete stockyard. erals-processing industry worldwide with electric and automation Besides this, the system optimizes the operational procedures and systems, and mining-specific products. In addition to providing reduces longitudinal traveling significantly (up to 90%), which is life-cycle services to the local industry, its focus is as a sub-sup- cutting the opex. plier to mining-equipment manufacturers such as Tenova Takraf, With all these solutions for all out reliability, low maintenance Joy Global, Sandvik, ThyssenKrupp and FAM. and highest possible efficiency in operation, it is clear that ABB To reduce operational costs, ABB has developed several solu- with the main technology center in Cottbus (Germany) will be one tions for the different components and levels in automated materi- of the top players for E&IS automation solutions in mining in the als handling systems. For instance, AC drives for mining on elec- future. tric shovels enable higher performance at lower energy consumption levels. The possibility to switch faster between the motion The Conveyor Connection inverter drives allows shorter loading periods by eliminating stops; Hese Maschinenfabrik GmbH, headquartered in Gelsenkirchen, is this is saving time and improving the performance. Moreover, these one of the leading manufacturers of custom conveyor systems drives have a so-called mining duty shock and vibration design including intermediate drive technology for underground conveyor that ensures the reliability and extends their entire life cycles. This systems. Last year, the company won a contract for an underground

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VDMA

Hese will deliver 69 conveyor drives to Minera Escondida in Chile.

conveying system for two mines, Karvina and Darkov, in the Czech sioned an underground conveyor connection between the two Republic. Hese designed, manufactured, assembled, and commis- mines; the company now services it too.

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parameters of the plant can be followed in the pithead control room. Hese supplied a turnkey system. Since August, the entire belt conveyor system has delivered at VDMA peak power, according to Hese. At present, 4,000 to 7,000 mt of raw coal flow through the plant. The underground connection between Karvina and Darkov is not only a significant step for Czech coal miner OKD, but also for the entire region. The move allowed OKD to close the old Karvina prep plant. At the same time, the company could fully utilize the modern and highly mechanized Darkov prep plant, which was a major environmental improvement for the whole region. Similar to the the OKD project, Hese said it’s focus is on sus- tainability and product quality. As an example, the company cites a new installation at the Garlyk potash mine in Turkmenistan, which was also completed in 2013. Hese supplied shaft decking devices Hese supplies large diameter pulleys for high-horsepower applications. for a service shaft as well as the conveyor for the loading of the skip of the production shaft. The bunker discharge conveyor, which is For the underground connection, Hese delivered six 1,400-mm- located beneath the large storage bunker and was designed and wide belt conveyors and three bunker discharge conveyors, which manufactured for the production shaft, loads the belt conveyor that will ensure even loading. At a speed of 2.5 m/s and power ratings fills the measuring pouches close to the shaft with the material at from 100 kW up to 1,500 kW per belt, the 3-km-long network is a constant speed. The handling capacity is 2,000 mt/h. designed for handling a capacity of 1,500 metric tons per hour Garlyk’s service shaft—an extendable shaft—the transport via (mt/h). For belt No. 3, a belt with a length of 1,750 m, a special tech- cage-story to the floor level is carried out through winches. For this, nical solution was applied. Here, a three-drum-TT-intermediate drive the necessary vibration platforms and safety locks were designed was inserted. This intermediate drive technology makes it possible and manufactured by Hese. With a length of 2,000 mm and a width to relieve the main drive and to reach the required security by using of 3,000 mm, the vibration platforms as well as the shaft locks 250 kW-units and a belt strength of 2500 N/mm. Main and interme- were designed for the available cars. They are operated by electro- diate drives are operated by variable frequency drives (VFDs), which hydraulic adjuster. The access occurs at the pit bank (open cast) guarantee a gentle start-up and an even dispersion of load. from southwest and underground at stop -306.9 m from north- Owing to the fact that the transport of the personnel is carried east, each through one of these electro-hydraulic operated vibra- out at this belt, a high level of safety needs to be guaranteed. The tion platforms. Before the vibration platform is fitted, the protrud- conveying speed can be adjusted by the VFDs, with which the dis- ing cage is determined underground by means of a cage fixture. charge conveyor is equipped. The integrated belt scale ensures a To secure the shaft, there is an electro-hydraulic shaft lock constant surveillance of the loading. Consequently, all desired used at both stops, which keeps the car within the frame. The

The Voith 866 TPKL fluid coupling (pictures here in China) permits smooth conveyor start ups.

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underground shaft bottom frame possesses a cage fixture, which state of the belt, start-up times of up to three minutes are possi- keeps the cage for the charging at the head frame on both sides. ble. Thanks to stand by cooling of the operating oil, the 866 TPKL By means of the winder control, the cage fixture must be blocked fluid coupling also permits multiple conveyor start-ups in succes- for the free ride of the catches. sion, even when the belt is loaded. VDMA This spring, Hese started the delivery of 69 belt conveyor pul- The mine operator is very satisfied with the performance of the leys for the Chilean mining company Minera Escondida, which 866 TPKL, according to Voith. In contrast to other solutions, the operates two major copper mines near Antofagasta. The pulleys compact fluid coupling can withstand extreme environmental con- diameters varied from 800 mm to 1,800 mm (weights from 5 to 35 ditions such as dust, dirt, moisture, heat or cold. mt). Hese described its pulleys as long life, high use and low main- As in every hydrodynamic coupling, power transmission in the tenance. The company produces and exports approximately 1,000 866 TPKL is virtually wear-free. For the operator, this translates into pulleys annually. Hese’s extensive range of high-quality goods lower maintenance and repair costs for the coupling. In addition, ensures high reliability and low costs for miners worldwide. motors start up independent of the machine load, and through sequenced starting of the motors, the fluid coupling reduces the Chinese Select Fluid Couplings for a Large load on the power supply circuit. Conveyor Drive An additional benefit of the 866 TPKL is its ability to operate When high reliability and power are needed, the Xishan Jinxing with reduced filling to drive an empty conveyor at a reduced speed. Energy Co. Ltd. relies on Voith fluid couplings. A total of three are During the creep speed operation, less power is transmitted and used underground in the 4.8-megawatt (MW) drive for the main belt the belt runs more slowly. This function is useful for the visual conveyor at the Xiegou No. 12 coal mine in Shanxi Province, China. inspection of the belt and splices. In the Xiegou No. 12 coal mine, Three 1,600-kW (1,900 hp) drives power the 1,900-m (6,200-ft) the fluid couplings were operated in the partially filled mode dur- long main inclined belt conveyor. This conveyor transports 3,800 ing commissioning to be sure that the belt was tracking properly. metric tons per hour (mt/h) of coal. Powerful and reliable couplings With the fluid couplings operating in the partially filled mode, the were required and, for the mine operator, the fill-controlled 866 belt speed could be reduced to 1.2-1.7 meters per second (m/s) TPKL fluid coupling from Voith is the best solution on the market. instead of operating at the rated speed of 4.5 m/s. Through controlled application of torque, the fluid coupling pre- Until now, the coal mine has been operating at the initially tensions the belt slowly and permits smooth conveyor start-up. This planned production capacity of 15 million mt/y. The operator plans controlled soft start protects the belt and driveline components and to increase production capacity in the next one to two years. This extends their lifetime. As a result, the Voith fluid coupling reduces will require the main belt conveyor to be upgraded with a fourth unplanned downtime—the operator benefits from lower mainte- drive. For this, the operator plans on installing an additional 866 nance costs and continuous production. Regardless of the load TPKL fluid coupling.

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Mineral Processing: Magnetic VDMA Separators Reduce Energy Consumption for Iron Ore Recovery

In summer 2013, MBE Coal & Minerals Technology GmbH delivered After crushing and milling, the iron ore pulp with a top particle two newly redesigned Jones process/wet high intensity magnetic size of 1 mm is fed to low intensity magnetic separators (LIMS) for separators (WHIMS) for Rana Gruber’s Gullsmedvik iron ore pro- magnetite recovery. The non-magnetic fraction, i.e., paramagnetic cessing plant in Mo I Rana, Norway. “These new machines repre- hematite ore, is further transferred into the Jones WHIMS rougher sented an enormous research and development program carried stage. In total, six of those units are processing 750 mt/h of out by MBE-CMT Cologne during the past three years,” said Mario hematite with a grade of approximately 30%-36% Fe. The yield is Gerards, Jones WHIMS sales and product manager, MBE-CMT. in the range of 50%-55%, respectively. The concentrate is collect- “Compared to conventional designs, significant improvements ed and pumped at 400 mt/h to the cleaner stage, where four Jones were implemented within the electrical coils, the rotors, the yokes, WHIMS magnetic separators upgrade the feed to 60%-62% Fe. The the matrix grooved plates, and the electrical devices to increase the tailings (containing less than 20% Fe) are fed back to the rougher total capacity and to reduce energy consumption.” The project stage and processed again. Deposited rougher stage tailings con- itself represented an investment of €2.7 million (US$3.7 million), tain less than 10% Fe. Gerards explained, and increased the feed capacity by 180 metric The magnetic intensity and the necessary energy consumption tons per hour (mt/h) to the rougher stage of magnetic separation are key parameters that determine the economics for the magnetic section. separation process. The rougher stage machines are currently oper- Subsequently, MBE-CMT Cologne will revamp all existing old ating with an intensity of 8,500 Gauss and the cleaner stage Jones machines at Rana Gruber by upgrading them into the new machines are running at 7,500 Gauss. Generating the magnetic “high-flow” version. The Norwegian iron ore miner purchased 14 intensity with electrical coils represents about 50% of the total Jones WHIMS DP 317’s in 1981 when the first magnetic separation energy consumption. plant was built and erected. Today, 11 of these old machines are To meet modern production requirements, reduce the specific still operating profitably and efficiently. power consumption, and increase and secure plant productivity,

The two new Jones DP 317 HFR units installed at Rana Gruber AS.

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toring and interlocking of coil temperature and wash water volume and pressure. The two units were successfully installed and commissioned. The plant increased throughput by 180 mt/h; it was hoping for a VDMA 120 mt/h improvement. Energy consumption was reduced by 30%. The system runs more efficiently thanks to a better matrix design, Gerards explained. The plant is currently seeing lower specific costs per ton of feed and a faster return of investment than origi- nally expected. A reduced number of machines resulted in less capital expense. “The new machines are fully integrated into the normal production of the processing plant and they are working without any problems,” Gerards said. “Product grade is equal to or better than the yield on conventional machines.” Rana Gruber plans to start revamping the conventional machines in 2014 and 2015.

X-ray Ore Sorting Lightens the Load on the Mill Long recognized as a market leader in magnetic separation, Steinert has also branched into sensor-based sorting systems. The company supplies electromagnet drums, eddy current separators and induction, and X-ray and near-infrared (NIR) sorting systems. The company recently supplied an X-ray sorting system to the Conventional matrix grooved plates (above) have been changed to a new Wolfram Camp mine in northern Queensland, which produces tung- design that increases the machine’s effective area by 50%. sten, molybdenum and bismuth concentrates. In 2008, open-cut mining and ore processing through a new concentrator commenced Rana Gruber in 2012 purcased two newly designed Jones WHIMS DP operation; however, the plant operated for less than three months 317 HFR units to be implemented into the existing building. The when technical difficulties coupled with a shortage of working cap- scope of supply for MBE also included upgrading the 11 older units using as many standardized parts as possible. The two new machines were developed by the MBE product spe- cialists working in cooperation with Rana Gruber. The design of the new machine follows the conventional design closely, as far as general operations and overall dimensions. Rana Gruber wanted to implement these machines into its existing processing plant. The magnetic coils were enhanced in an extra efficient arrangement with less space between the coils and coil boxes. This allowed higher magnetic fields or equal field intensity with less energy consumption. The new design has more ampere windings per coil and the increased coil power generates higher magnetic fields (up to 15,000 Gauss) possible with lower temperature losses. The new coil system can be used in the conventional machines. The magnetic field is independently adjustable for each rotor. The conventional rotor disks can be revamped and used for the new matrix grooved plates design. The edges of the yokes can be dis- sembled to achieve higher magnetic fields. The width of magnetic poles are adjustable. As far as improvements to the matrix grooved plates, a new trapezoidal design for the entire matrix box was conceived by Rune Johansen, Gullsmedvik plant manager, and designed by MBE-CMT senior construction engineer Sergej Podkow. “It increased the number of gaps per box by 50%. The effective area per box grew by 62% and the effective matrix area per machine is now 50% greater,” Gerards said. “By using distance plates instead of wedges, there is now less blind area, which generates a more efficient material flow into the matrix box.” The new machines have a new state-of-the-art control cabinet with touch screen panel. Technicians can monitor machine performance via a secured Internet connection. VFDs allow rotor speeds to vary between 3-6 rpm possible. The system offers moni-

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ital, further compounded by the global financial crisis, resulted in The process plant was designed to treat ore from an open-pit a suspension of operations. Wolfram Camp Mining Pty Ltd. was mine at a rate of 150,000 metric tons per year (mt/y), through a acquired by the current owners in 2011 and they embarked on a process comprising: VDMA plant modification and expansion program. • Two-stage crushing; • Ball-mill grinding in closed circuit with a screen; • Bulk sulphide flotation, followed by selective flotation of molyb- denite into a concentrate; and • Flotation tailings treated in a gravity circuit comprising centrifugal jigs and shaking tables producing a +60% wolframite concentrate. The plant modification program improved ball mill screening; added cyclones, spirals and shaking tables; and removed centrifugal jigs, drying, and magnetic and electrostatic separation. Limited test work had been carried out by the previous owners into X-ray ore sorting and indications were that a high proportion of barren material could be rejected with minimum loss of valuable minerals. This offered a process route to increase annual tonnage treatment by rejecting a significant amount of waste ahead of the grinding and downstream process plant. Pilot ore sorting was carried out at the site, which confirmed earlier findings, then an arrangement was entered into with Steinert to lease a commercial capacity ore sorter for on-site trials that further confirmed the amenability to X-Ray ore sorting and culminated in acquisition of a new unit that was commissioned in March 2013 and incorporated into the Wolfram Camp Process. Now a sub-standard grade ROM material is upgraded to economic grades. With all the improvements implemented successfully, the plant doubled its capacity to 300,000 mt/y. The X-ray sorting technology was developed in Germany, and Steinert in Cologne and its field offices in Australia, South Africa, Brazil and the U.S. are helping mining operations by applying this technology. “The system at Wolfram Camp uses a flat conveyor to feed material in a single particle layer to the X-ray scanners,” said Johan van Zyl, product manager-mining for Steinert Australia. “The conveyor runs at about 2.5 m/s through the X-ray system, which scans each individual particle and determines if it is a wanted or unwanted. It makes that decision by measuring the average atom- ic density of the particles, which is a function of the mineral. A Steinert’s X-ray ore sorter eliminates waste rock ahead of the liberation process. computer subjects each particle to an algorithm. The particles follow the normal arcing trajectory over the end of the conveyor. Under the particle stream, a series of air jets, which are controlled by the computer, locate the individual wolframite particles and blast them out of the stream with a compressed air pulse.” From a health and safety standpoint, the X-ray system is no different than those used for security screening airports, van Zyl explained. “It’s a very low dose of X-ray radiation,” van Zyl said. “The machine is screened using mild steel and lead in such a way that there is no leakage. Most countries do, however, require the units to be registered with the relevant health and safety authorities. The mining company also needs to have a radiation officer on site.” This technology has been available for 30 years or more, but advances as far as microprocessors enable the processing to happen at a speed that allows decent throughput, van Zyl explained. “There also has been several advances mechanically with air valve technology,” van Zyl said. “When the technology was first tested, the throughput was so low that the system was not economical.” This technology lends itself to high-value base and precious metals, such as tungsten, nickel sulphides, gold, platinum, dia- A flowsheet shows how Wolfram includes the X-ray ore sorter in its process. monds and other gem stones. Steinert has recently tested the X-ray

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sorting system on diamonds. “We can separate the kimberlite from anything else we have tested.” Before testing TungStuds, mainte- waste rock and reduce the size of the stream being processed,” van nance crews used tempered steel sheets to protect wear-intensive Zyl said. “The technology does not necessarily need to target the parts, which had to be renewed frequently. The first use of TungStuds VDMA final product. We can do a pre-concentration to make the down- has already increased the maintenance interval by 16 times. stream process smaller and more economical.” Eliminating the waste rock ahead of the liberation process lightens the load on the Improving the Efficiency of mill and all of the downstream processes. Solid-liquid Separation Decanter centrifuges are an effective means of separating solid- TungStuds Increase Average Maintenance liquid mixtures. Similar to most areas, constant improvements Intervals Dramatically have consistently increased the performance of these decanters. New Zealand’s biggest open-pit coal mine—the Stockton mine— The GEA Westfalia Separator Group builds decanters for the mining has been using BETEK TungStuds for more than a year now. They business. Some of it largest machines can process 200 m3/h. The were first installed on shovels and dozers. Testing started with company has recently identified and implemented technological two machines and now the entire fleet of 14 shovels is supported changes that will help it reduce energy consumption on these by TungStuds. machines by as much as 30%. TungStuds protected these machines so well that they are now The decanter mainly consists of a bowl with a scroll. Both ends being used to protect a large rotary breaker from abrasion. All parts of the bowl are supported by roller bearings. The scroll rotates at a of the machine, which is made by McLanahan, that are exposed to lower speed relative to the bowl, conveying the solids to the dis- abrasive wear have been lined with 9,000 BTS08 TungStuds. This charge ports. The liquid is discharged through holes in the bearing wear protection has quickly proved its value. Another 5,000 BTS08 hub. In addition to supplying idling power, a primary motor, con- studs are welded to the machine running in parallel during normal nected to a rotor by a V-belt, supplies the power to discharge the maintenance intervals. clarified liquid in a traditional arrangement. A secondary motor BTS8 TungStud were introduced at bauma 2013 as an innova- drives the scroll. tive development of a “heavy duty” line to complete the wear pro- GEA performed a power study on its machines. They determined tection series. They are for the harsh conditions found at the that the ejection power of the clarified liquid is the most significant Stockton mine. TungStuds have a dome-shaped carbide. The exter- element, representing 45% of the machine’s total power require- nal steel jacket can be welded easily. Even if the jacket wears away ment. Idling consumed 26% of the power. The power to transport during operation, the remaining stud provides long-lasting wear solids was 7%. The losses through the frequency converter and the protection because it’s made completely from carbide. gearing amounted to 30%. Stockton’s maintenance manager, Henny Klopper, is very satis- To improve this situation, GEA developed the summation- fied with BETEK tools: “We tried many variations of wear protection drive concept. The power for conveying the solids is provided by in the past,” Klopper said. “TungStuds BTS08 are lasting longer than the secondary motor. A frequency converter is used to control the

GEA Westfalia’s decanter centrifuges have been used successfully to Maintenance crews used TungStuds (inset) to protect a high-wear zone on remove the crud formed by the foam during the extraction phase of the a rotary breaker. SX/EW process.

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secondary motor, which means the speed of the motor can be var- cessing, GEA Westfalia Separator Group. “We combined the old sys- ied between 1 and 25 rpm. If a higher differential speed is required, tem, which used two gearboxes, into one system with three steps a hollow shaft connected to the scroll may be driven by the prima- of planetary gearing. Through optimization, we have improved the ry motor by a belt. The differential speed range is shifted to 25 to energy balance of the machine and reduced energy consumption by VDMA 50 rpm. By using a different set of pulleys, the differential speed at least 10%.” The summationdrive system speed drive is designed could be further increased to 70 rpm. with an above-average safety factor for high torques even in cases “This is one of the biggest improvements we have made in this of high differential speeds. With a rugged, robust and reliable field in 20 years and we are referring to the new product line as the design, the decanter centrifuge has several improved features, CF line,” said Tore Hartmann, senior product manager-mineral pro- such as a flattened cone, an external gear, an enhanced solid

Gearbox

Main motor

Secondary motor

This illustration shows the summationdrive and two operating modes.

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output diameter and a special scroll design for the highest solid throughput and highest dryness. Hartmann specializes in solid-liquid separation equipment and VDMA he said that GEA has identified many areas for these decanters in the mineral processing sector. “Many of these machines can be found working in the industrial minerals sector, processing kaolin, talc, bentonite, calcium carbonate and lithium carbonate,” Hartmann said. “These machines have also been used to treat the crud formed by the foam during the extraction phase of the SX/EW process. We have developed machines with Hastelloy C276 specifically for this segment.” GEA has already sold and commissioned several different sizes of these machines worldwide.

Performance in Motion Joest produces some of the world’s largest screening machines. The company’s screens, feeders and sorting systems are based on some of the most advanced vibrating technology. Headquartered in Joest recently supplied this 60-mt screen to Rio Tinto. The isolating frame northern Germany, the company manufactures equipment in for the 4,500-mm screen reduces the vibrations transmitted to the foun- Australia, China, France, North America, India and South Africa. It dation to a minimum. also makes its own exciter drives. This is especially important for the mining sector as the heavy-duty drives used for the large In 2012, Joest supplied equipment for the first phase of this screening machines need to operate safely for long periods of time. project: Cape Lambert Port A project. Joest Australia Pty Ltd. recently signed a second agreement The Cape Lambert Port B project will provide an additional with Rio Tinto to deliver six additional vibrating screens and feed- 123 million metric tons per year (mt/y) in iron ore shipping capac- ers to the miner’s iron ore projects in the Pilbara. The contract ity, increasing Rio Tinto’s total port capacity from 237 million mt/y extends to the Cape Lambert Port B expansion, which will include to 360 million mt/y. Cape Lambert Port B is being delivered in two 13 large vibrating screens and feeders. overlapping phases of 53 million mt/y and 70 million mt/y. The first Under the new contract, Joest will manufacture screens and major milestone for the project (290 million mt/y) was achieved feeders in Welshpool, Western Australia, for the second phase of during the third quarter 2013 and it expects to achieve 360 million the Cape Lambert Port project. mt/y in 2015.

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VDMA SUPPLEMENT PROFILE VDMA PAID ADVERTISEMENT

HAZEMAG GROUP TODAY

Headquartered in Dülmen, Germany, mineral processing. Its acquisition of allminer- crushing technology for a famous diamond Hazemag & EPR GmbH has a long track al has brought expertise in coal and ore bene- manufacturer that significantly reduces stress record as a provider of outstanding engi- ficiation technologies to the group, while the on the diamonds during ore crushing and, as neering and class-leading products, with a integration into Hazemag of the long-estab- a result, minimizes losses during subsequent history dating back to 1842. lished engineering firm Saarmag, has given processing. During the last years, the company was it the ability to offer systems for transporting, Underground and open-pit coal processing transformed from being a specialized crusher stacking, reclaiming and stockpiling bulk is also an important market area for the group: supplier, mainly for the cement and aggregates materials. The capabilities of Hazemag’s crushing and industries, into the Hazemag Group—a solutions As an example of its capabilities, Hazemag mine-development equipment are renowned in provider for minerals processing, supported by recently installed a complete primary-to-tertiary longwall applications; and allmineral’s wet and its newly-created business development center. crushing plant at one of South Africa’s largest dry jigs are widely used in coal beneficiation. The Hazemag Group can now offer a com- iron ore mines. In the plant, a primary gyratory Hazemag has also built on its success in sup- plete range of crushing technologies: Building followed by two secondary gyratory crushers plying open-pit mobile and semi-mobile crush- on years of experience in crushing with and four tertiary cone crushers, reduce the ore ers, with units recently commissioned in China impactors and hammer mills, Hazemag now down to minus 30 mm. Hazemag followed this and south east Europe. offer hard-rock gyratory, cone, and jaw-crusher by supplying a complete processing plant Finally, Hazemag’s impact crusher tech- technology, through its South African sub- based on allmineral’s jigging technology, nology continues to provide a reliable crushing sidiary IMS Engineering, and the acquisition of employing 24 alljigs, and creating the world’s solution for the cement and aggregates in- MinPro brought impact roll crushers and feed- biggest iron-ore beneficiation plant. dustries, with the company providing cus- er-breakers to its portfolio. Hazemag has also been active in supply- tomized solutions, including complete pro- The company has also increased its ability ing new crushing concepts to the diamond cessing plants, to address customers’ specific to supply customers with turnkey projects in industry. After extensive testing, it designed requirements.

THE WORLD OF CRUSHING TECHNOLOGY

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Innovations: Modern Storage VDMA and Reclamation

In addition to the feeder and conveyor systems offered by its parent System Simulation for Mining and Aumund, Schade builds compatible products for the automated Processing Equipment storage and reclaim of stockpiled materials. The company was one Today, maximum safety and reliability of equipment and machinery, of the first to offer the chain scraper concept to reclaim coal and while maintaining efficient operation, are essential. At the same other minerals from storage and has since extensively developed time, quality requirements, such as high functionality and fail-safe this model and introduced the circular storage concept, which forms design with as little vibrational behavior and wear as possible, the core of many coal-fired power plants, particularly in China with must be met even under growing financial constraints. “These more than 50 units so far commissioned in the country alone. challenges raise many engineering-related questions, which can Traditionally, the chain scraper design is limited to reclaim be answered efficiently by means of system simulation,” said Joerg rates of around 2,000 metric tons per hour (mt/h) per boom. The Arloth, sales manager, ITI GmbH. “Such software helps to numeri- 120-m circular buildings can store 180,000 mt of coal. In China, cally assess various approaches early on in the development pro- one unit sufficiently handles enough coal for a 600-megawatt cess and to check feasibility and potential room for improvements power plant receiving seaborne deliveries from small cape size before an actual layout.” SimulationX developed by ITI, a firm (140,000 dwt) vessels. However, the market is moving onward and located in Dresden, Germany, is such a simulation tool. upward with ever larger vessels and 2 x 600-MW power plants on a Mastering the growing complexity of integrated devices and single site now being the norm demanding two 120-m diameter machinery efficiently both during the development and later on dur- storage facilities to satisfy coal demand. Recognizing the chal- ing real operation involves increasingly dynamic interactions lenges of such developments, Schade has conceived a new twin- between many sources, including mechanical, control engineering- boom design with opposing balanced stacker and reclaim booms related, electronic, electrical, magnetic, hydraulic, pneumatic and with a diameter extended to 150 m, and the possibility of storing thermal systems. “Apart from solving specific simulation tasks, the up to 400,000 mt under a single dome enclosure at handling rates modeling approach of such tools is an excellent basis for engineers to 6,000 mt/h with both booms running simultaneously. to broaden their knowledge of system behavior,” Arloth said.

Schade circular storage and blending bed at Dotternhausen.

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SimulationX is a comprehensive computer-aided engineering face. The typical truck hauls 8-10 hours a day. It’s a tough grind, (CAE) solution for modeling, simulating and analyzing physical but the reward is well worth it—the mine’s primary product is gold effects in machines. It provides several simulation and analysis with silver and copper byproducts. Due to these tough work condi- VDMA methods, which can be used within one model. They include simu- tions, mine haul trucks can’t last forever. When the Small Mine lations in the time and frequency domains as well as failure simu- Development Co. (SMD) determined it was time to give one of their lations (FTA, FMEA). Further analysis options consist of order anal- trucks an overhaul, they contracted MTU distributor Smith Power yses and analyses of transfer behavior, spectrums and eigenfre- Products to help. Their 1998 Atlas Copco MT436 haul truck had quencies. “The analysis of eigenfrequencies also includes mode endured more than 10 years on the job. It was time to rebuild and shapes and the corresponding energy distribution in a system, repower the vehicle. such as powertrains,” Arloth said. “This is a possible starting point “Since it had seen so much action, SMD disassembled the truck for optimizing vibrational behavior both from a mechanics point of down to the frame,” said John De La Hunt, Smith Power Products view, as far as loads, wear, durability, etc., and in terms of energy branch manager. “We helped them rebuild it with a new engine and efficiency with regards to damping, energy conversion efficiency.” components and the customer performed a zero-hour rebuild.” The SimulationX is used by development and design engineers as a truck’s original Series 60 engine performed admirably, so SMD system simulator and an integration platform. The idea behind the decided to stick with MTU. solution is to provide a homogeneous and open platform for mod- “The Series 60 engine was well-known for its longevity. It was eling and simulating mechatronic systems that can be easily inte- not at all uncommon for them to reach 20,000-25,000 hours before grated into existing development and design environments. requiring an overhaul,” said De La Hunt. From start to finish, the Engineers at Tenova TAKRAF, for example, use SimulationX to project was completed in about three weeks. Engine reliability, cost develop large gear units for bucket-wheel excavators with the goal of ownership and time between overhauls are important to an to optimize the drive system for high performance, Arloth explained. underground mining company’s bottom line. “Haul trucks must At their Leipzig site, TAKRAF created a simulation model for calcu- have the highest availability—its uptime has to be as close to lating dynamic behavior and for the virtual commissioning of a belt 100% as possible. When they need it, it’s got to perform,” said De conveyor. “Dynamics and efficiency of belt conveyors can thus be La Hunt. With MTU’s legendary engineering standards, the Series optimized accelerating the entire commissioning process,” Arloth 460 is perfectly suited to fit those qualifications. After all, when said. Romonta GmbH uses SimulationX to analyze the dynamic hauling gold and other precious metals, downtime can affect vibrational behavior of their bucket-wheel excavator and its cutting another valuable commodity—revenue. boom during operation. Working with SimulationX as a system sim- “While MTU’s reputation for dependability was a major factor, ulation tool makes analyses and evaluations, understanding, and engine and noise emissions were the two biggest reasons mastering the complexity of components and their interactions in we selected the Series 460,” said De La Hunt. “Newmont (the mine the entire system much easier. owner and operator) and SMD (underground mining contractor) strive to improve the air quality at their underground operations. Repowering Underground Mining Trucks And because SMD is a contractor for Newmont, they see a special For those who think their commute to work is rough, try getting need to provide the best technology for their customers.” behind the wheel of a haul truck at the Newmont Mining Leeville The Series 460 has established itself as the premier low-emis- project. The day starts at the mine entrance in Carlin, Nevada, sions engine in its power class. To comply with Tier 4i standards, the which averages only 9 in. of rain annually. From there, the truck addition of an SCR emissions system preserves the engine’s inher- makes its descent to work. It traverses miles through a steep, ent fuel efficiency and dependability, and requires no major winding tunnel until it reaches its destination—a mining face changes to engine design. “SCR provides an advantage for these 3,000 ft underground. engines,” said Dee Wise, MTU sales engineer. “It’s an automated Here, the truck gets a short break while it’s loaded with up to system that comes with the engine—so there’s nothing the owner/ 36 tons of ore. Then, it turns around and climbs back to the sur- operator has to do to maintain the system. It’s more efficient, and requires less engineering—all you need is diesel exhaust fluid.” Don Rathburn, maintenance superintendent at SMD, is pleased with the results. “The contribution toward our DPM (diesel particulate matter) program has been phenomenal,” he said. “The reduction in our particulate and NOx emissions has been significant— we’ve gone from the 400 parts per million range to nearly 120-130 parts per million.” Both Newmont and SMD are big believers in engines from MTU, with the vast majority of their fleets powered by MTU and MTU Detroit Diesel two-cycle engines through the years. With a Tier 4i Series 926 engine already in operation before the Series 460 was installed, SMD was first to Tier 4 in the marketplace. Rathburn said, “We’ve been moving toward repowering with the Series 460 and Series 926 on a variety of our older equipment. It’s brought a spark to that equipment and improved performance After 10 long years of constant work, a 1998 Atlas Copco mine haul truck significantly. It’s actually performing better than when it was is repowered with a Series 460 engine from MTU. Now with higher perfor- brand new. Since the initial haul truck, we’ve finished repowering mance and lower emissions, the truck is ready to serve Small Mine another haul truck and a loader, and we’re working on a second Development Co. for years to come. loader now.”

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“Underground mining operators are constantly searching for a LF 20. Each will be equipped with a multiple lance burner (MLB) solution to increasingly challenging emissions standards without and a start burner. Paul Wurth S.A. will be handle the compromising productivity or complicating operations,” says De La Dniprodzerzhynsk coal project and anticipates delivery of the VDMA Hunt. “SMD found the perfect solution in the Series 460. As we help Loesche mills for July 2014. them expand and repower the rest of their fleet, they’re going to continue to depend on MTU.” New Technology Monitors Slope Stability For many years, the Essen-based consulting and engineering com- Grinding Coal for Steel Mills pany DMT has contributed significantly to geodetic, geotechnical Two Loesche coal mills, type LM 26.3 D, are currently being built at and geophysical monitoring in hazardous environments through its Dniprodzerzhynsk Steel Works in the Ukraine. Paul Wurth S.A., a numerous geomonitoring projects. To process and analyze the Loesche client of many years, opted again to select the company’s extensive measurement data from various measuring instruments vertical mill technology. This time, it is being used for the injection and sensors, the company developed a hardware and software of coal dust into the blast furnace of the Dniprodzerzhynsk’s Steel solution that stores and analyses all gathered data in such a way Works in the Ukraine. that it's available for sharing: DMT Safeguard. There are already two coal mills in the Ukraine, provided by DMT Safeguard is a modular system for safe and reliable risk Loesche GmbH. Both are for the PCI Protects Jenakievo and assessment for engineering projects. The system can be applied to Zaporozh Steel Works. So far, Loesche has sold eight coal mills to assess slope stability in mining, measure noise and vibrations dur- clients in the Ukraine. ing tunneling operations, to secure “sensitive” buildings during the In Russia, three PCI projects are under way for Lipezk, Nizhny course of construction projects, or to monitor subsidence in former Tagil and Novokuznezk, totaling eight Loesche coal mills. All are mining districts. “Even in the early stages of development, we were currently in their construction phase. able to convince many important customers from the construction This means the existing PCI plants in Russia are 100% and mining industries of the benefits of this innovative solution,” equipped with Loesche mills—a total of 17 coal mills sold by said DMT project manager Karsten Zimmermann. Loesche for the use in steel plants. An integrated early warning reporting system enables fast, For the Dniprodzerzhynsk coal project, two Loesche mills are well-informed decisions, making it the ideal support tool for intended, grinding 70 metric tons per hour (mt/h) of brown coal to professional risk management. DMT Safeguard includes the fol- a fineness of 20% R DIN 0.09 mm. The mill motor for both vertical lowing functions: mills, type LM 26.3 D, will have a capacity of 780 kW. • Data collection (data port module): Integration of heterogeneous Loesche’s scope of supply for both coal mills LM 26.3 will also data from a variety of sources (geodesy, geophysics, geotechnical include two gearboxes and two hot gas generators (HGG), type engineering, hydrology, integration of image and video data); • Data management (core server module): Central database on high-performance servers for good data accessibility and security; • Data visualization (Web-view module): Online user portal for data presentation with interactive Web GIS maps; • Document management; and • Data analysis (evaluation and alarm module): Notification by SMS or email, as well as on-site signals. “The data from the monitoring network is consistently merged, saved centrally and securely managed, while simultaneously dis- playing up-to-date results to numerous users via Web-view,” Zimmermann said. “The advantage is that this Internet-based monitoring solution is not manufacturer-specific and delivers the high standard of safety.” The system is designed as a software as a service (SaaS) solution, a new service from DMT, which will gradually be enhanced with additional project-specific functions.

The Loesche LM 26.3 D mill grinds coal to a very fine consistency. The DMT Safeguard system can assess slope stability in mining.

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Hydraulically Powered Transverse Cutterhead Rokla GmbH has recently started the exclusive production of the latest generation of Webster Hydraulic Cutting Units with high- VDMA quality components from Germany. British engineer Ian Webster is well-known in the industry for being one of the world’s most innovative designers of cutting technology. Teaming up, Rokla and Webster have launched an innovation campaign under the brand name Rockwheel. The novel, extremely powerful transverse cutting units are robust, reliable and versatile, and available in various sizes. Components for the cutting units are sourced entirely from German suppliers and assembled by skilled employees in Baden-Württemberg. “This guarantees that a Rockwheel cutting unit is a top-quality product,” said Robert Piasecki. Rokla was founded by Piasecki and Klaus Volkert. The company has its headquarters and manufacturing plant in Langenburg. The company produces a wide range of gearless cutting units as well as cutting units with gearboxes in the lower to high performance category. In the middle-sized and medium-performance class, the Rockwheel cutting has only three main components: the housing, motor and cutting heads (with picks). Webster deliberately dis- penses with gearboxes on these four models. It is Webster’s point of A strong team: (left to right) Ian Webster, design engineer of the innovative view that on these cutting units, with outputs ranging from 29 to Rockwheel cutting units, with the founders of the company Klaus Volkert 110 kW and used on 10- to 40-metric-ton (mt) excavators, the and Robert Piasecki. Rokla GmbH combines British innovation and decades gearboxes offer no advantage, but they cost money. of experience in cutting technology. “Our three-part Rockwheel cutting units provide the required maximum performance at all times but are significantly lighter in result, it is possible to achieve a powerful performance with weight than those of the direct competitors,” Piasecki said. As a Rockwheel cutting units—even with smaller excavators.

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Currently the largest Rockwheel cutting unit is being produced—a four-part unit, with gearbox. This powerhouse for excavators of 40 mt and greater has a power of 140 kW to 220 kW. VDMA All Rockwheel cutting units are equipped with high-torque hydraulic engines and are designed so that the picks, which are mounted on the drums at an optimal angle, can penetrate the material with maximum power. The cutting heads of the smoothly and quietly operating cutting units rotate at a speed that achieves outstanding excavation and ensures a clean profile. The design and power components of the low-vibration Rockwheel cutting units are perfectly adjusted, ensuring that the picks grip strongly and hardly never bounce.

Mobile Conveying Equipment Uzbekcoal has launched a comprehensive program to modernize and improve the output of Uzbekistan’s most important open-cast mine at Angren. According to the company, coal production, which FAM spreader ST12100.60, overburden 21,100 t/h. in 2010 amounted to 3.2 million metric tons per year (mt/y), should increase to 6.4 million mt/y by 2015. The Magdeburg-based FAM, a manufacturer of mining and conveying systems and equipment, is largely involved in this process by supplying mobile equipment for overburden and coal handling and conveying. The total weight of the FAM equipment to be delivered for this project amounts to approximately 5,000 mt. FAM will provide three units designed for conveying overburden with a throughput capacity of 4,000 mt/h each. Furthermore, each system consists of a crawler-mounted crusher and a mobile conveyor bridge. The relevant spreader with tripper car is designed for 12,100 mt/h and capable of managing the material from three faces. The entire system is completed by four 800-mt/h belt wag- ons with hopper and cable-reel cars for transporting the coal to the bench belt conveyor. The mobile crushing plants are designed for a throughput of 5,250 mt/h each. They consist of an undercarriage with two steer- able twin crawlers. The machine’s frame is supported on the under- Mobile FAM crusher FZWB 2025 HS, throughput 5,250 t/h. carriage in a statically determined manner. Furthermore, a feed hopper, an apron feeder, a heavy-duty double roller crusher and a The height-adjustable discharge belt conveyor of the mobile discharge belt conveyor complete the system. Shovel excavators crushing plants transfers the material onto the mobile conveyor feed the systems and ensure conversion of the discontinuous flow bridges. The latter are 90-m long and designed so that the mate- of materials into a continuous flow. rial can be transferred onto the bench belt conveyor in a large Moreover, they also crush the material to grain sizes facilitat- range of angles and from three different crusher working levels, ing conveying on belt conveyors. The crushers are designed for high which can be positioned between -15 m and +15 m relative to the compressive strengths (up to 200 MPa) and can process rock up to level of the bench belt conveyor. This way a total working range of 1.1 m in diameter. 45 m is available.

Crawler-mounted crushing and conveying plant in the Angren open-cast mine, Uzbekistan.

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The conveyor bridge, which can be hydraulically leveled, is supported at both ends on a twin crawler mounted undercarriage. At the discharge head of the conveyor bridge, the crawlers are arranged on both sides of the bench and the material conveyed is VDMA transferred to the bench conveyor between the crawlers. The electric power required for the conveyor bridge and the crusher is supplied via a cable drum, which is connected to this undercarriage. Neither a change of the working level nor turning around at the tail station of the bench belt conveyor require decoupling of the system, i.e., the mobile crushers and the pertinent 90-m conveyor bridge need not be separated electrically. The three bench belt conveyors transport the overburden to the spreader whose 60-m-long discharge boom allows dumping up to a height of 22 m.

Rolling Bearings for Heavy-duty Use An FAG split spherical roller bearing. Whether for disassembly, loading, or transport, for milling, grading, or refining, Schaeffler, a leader in rolling bearings, supplies the Through intensive research and development programs, INA right bearings to all the leading manufacturers and operators in and FAG rolling bearings ensure high functional reliability and per- mining and raw material processing. Thanks to its Global formance even for the most extreme demands. The company’s Technology Network (GTN), the company has very rapid turnaround ongoing exchange of experience with manufacturers and operators, times even when developing individual customer solutions outside universities, and research institutes for mining and raw material of its standard product line that are customized to the operators’ processing continues to make new, customer-specific develop- requirements and challenges. Along with optimum consulting and ments and product improvements possible. High capacity and reli- services, Schaeffler provides solutions for practically every appli- ability with low life-cycle costs for the customer are the objective. cation in the mining and raw material processing industries. For bucketwheel shafts, bearings need to absorb high impact Its components can be found on haul trucks, crushers, vibrat- loading as well as compensate for shaft deflections and alignment ing screens, tunnel boring machines, and bucketwheel excavators. errors. FAG spherical roller bearings have an angular adjustment In any of these cases, machine failure can quickly cost the opera- facility and a high load-carrying capacity. They, therefore, provide tor vast sums of money. the best possible characteristics for this application.

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bearing cages, in particular, are subjected to heavy loads due to radial acceleration. In unfavorable cases, axial acceleration may also be superimposed. The rotating imbalance generates a circum- VDMA ferential shaft deflection and additional sliding movements in the bearings. This increases friction and thus the operating temperature of the bearings. Nonetheless, it is critical to achieve an operating life that is as long as possible. FAG E1 spherical roller bearings in X-life quality are used for support here as well; the bore of the bearings is coated with Durotect CK to prevent fretting corro- sion. The displacement capacity between the bearing bore and the shaft, which is necessary because of thermal effects, is maintained over the course of a long operating life. Reconditioning rolling bearings and bearing units can save money. This service is one of Schaeffler’s core areas of expertise and is offered at several certified locations around the world, where rolling bearings with an outside diameter of up to 4,250 mm are reconditioned and modified. On request, this is even possible for larger bearings—the main bearings of tunnel boring machines, for example. Moreover, Schaeffler’s bearing reconditioning service is No bearing is taxed in as many ways as a bearing on a vibrating screen. independent of the manufacturer. The biggest advantage: The costs arising from reconditioning are considerably lower than those The gearboxes for the bucket wheel are mounted directly on the for a new bearing, while the delivery times are mostly short. bucket-wheel shaft. Using welded-on flanges, it is only possible to To explain the importance of its Global Technology Network, mount split bearings. FAG split cylindrical roller bearings simplify Schaeffler offered a recent case from a copper mining operation. A and accelerate bearing replacement, especially in areas that are complex conveyor system at the mine was responsible for trans- difficult to access. Many assembly and disassembly steps are porting crushed ore. The strip mining conveyor transported 150,000 eliminated, downtimes are thus reduced considerably resulting in mt/h of ore over a distance of 8 km. The mine was planning to correspondingly high cost savings. For one mining customer, increase the system’s throughput by 50%—without making any Schaeffler also developed a customer-specific solution by using an changes to overall structure, framework, foundation or footprint. FAG cylindrical roller bearing with a triple split inner ring. The key challenge here was finding a bearing that would fit in the Split bearings are also useful for conveyor systems. FAG spher- existing housings, withstand the new, extreme loads, and have an ical roller bearings, which withstand very high loads, are a good acceptable operating life, all at the same time. In addition, since choice for the pulleys. The use of split bearings for this application the existing system was already subject to frequent tensioning/ is also particularly interesting from an economic standpoint. The take-up pulley failures, improved bearings and housings had to be inner ring, outer ring, and the roller and cage assembly are divid- developed for those locations as well. ed into two halves and held together with screws. The number of After a thorough analysis, the Schaeffler Technology Center in work steps required for a bearing replacement is considerably Danbury, USA, calculated that upgrading the existing bearings to lower, resulting in shorter downtimes that greatly reduce costs. the new E1 X-life version was the best solution for what was For the non-driven pulleys, which in conveying systems some- required. The problem was that this version was not yet in produc- times have internal bearings, Schaeffler has developed special tion. It was discussed with the relevant production line in Germany cylindrical roller bearings. The bearings have a particularly long and the company arranged for the production launch to be moved operating life and have long relubrication intervals. The ball bear- up by more than a year to meet the mine’s needs. At the same time, ings Schaeffler offers for idlers in conveying systems are com- an expert from Schaeffler Canada solved the problem with the pletely maintenance-free. Moreover, bearings from Schaeffler are take-up pulleys. He developed a special housing for a larger shaft characterized by their long operating life and require no mainte- size and bearing without changing the critical dimensions. So no nance since they are lubricated for life. changes were needed to existing mounts. The main bearings of jaw crushers harbor further potential The new X-life bearings and the special housing allowed the savings. Here, FAG E1 spherical roller bearings in X-life quality are system to increase its capacity by 50% without any large invest- particularly suitable. These bearings were specially developed for ments for rebuilding the existing system being necessary. The prob- the most extreme loads and are employed everywhere that angular lems affecting the take-up pulleys, which led to frequent failures, adjustment is a must. They work reliably, even in the most were eliminated, and greater system availability was assured. demanding environmental conditions. X-life quality extends the Thanks to the local expertise in the Schaeffler Technology Center bearing’s nominal operating life, potentially increasing it by up to and networking with experts around the world, it was possible to 70% for the same load—or resulting in the same operating life for quickly find the optimum solution for the customer. a much greater load. At the same time, the lubricant is subjected to a lower level of stress due to the reduced friction and bearing Heavy-duty Transport Crawlers temperature. This results in high system efficiency and reduced Crawlers units are indispensable for the transport of large and operating costs for customers. Moreover, smaller designs are heavy subassemblies of any kind, but also of complete open-cast made possible by downsizing. mining equipment, head or tail stations of conveyor systems or Virtually no bearing in the industrial sector is taxed in as many semi-mobile crushing plants. Basically, transport crawlers can ways as a vibrating screen bearing, according to Schaeffler. The be used for all heavy transport tasks according to their specified

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VDMA

An RT 250 transport crawler lifts some heavy gear at the Vattenfall’s Welzow South mine in Germany.

payload. The Takraf series for transport crawlers starts at a payload of 250 metric tons (mt) and ends at 1,200 mt including a grad- ability of up to 20% (1:5). The main component of a transport crawler is the substructure with two travel gears, which are normally rigidly connected with each other in case of the smaller machine sizes. Hinged crawler girders are, however, used in the bigger machine sizes from 500 mt. The lifting platform including centric guide is arranged on top of the substructure. The platform supports itself via hydraulic cylinders on the substructure. Fixed to the substructure as well, the transport crawler can optionally be provided with an operator’s cabin. The transport crawler is operated from the operator’s cabin or by radio control. Opposite the operator’s cabin, the diesel engine coupled with the hydraulic drive components is installed as a central unit in the substructure. All Takraf transport crawlers are diesel hydraulically driven. To date, Tenova Takraf has developed, designed and built nine transport crawlers and supplied them to clients in Thailand, Chile, Saudi Arabia, Australia, Germany and China. Supplying four transport crawlers of the 1 x RT 420, 2 x RT 350 and 1 x RT 250 design sizes, the past four years were particularly successful for Takraf. All transport crawlers being supplied are built, assembled and put into operation in the Lauchhammer works. The 325-kW RT 420, which is currently operating in Australia, has a maximum payload of 500 mt. It measures 11.2-m long and 7.6-m wide. The unit has a minimum height of 2 m and a lifting height of 0.58 m. A 480-kW RT 350 currently operates in China. It has a 440-mt payload. The machine has a similar length and width, but the minimum height is 2.3 m and the lifting height is 0.7 m.

The transport can be operated from the cabin or by remote control.

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Energy Efficient Pumps Help RWE VDMA Save Energy

A German electricity provider (RWE) was looking to conserve ener- and the units found during the inspection, RWE owns more than gy. The pumps used for mine drainage in the large open-cast lig- 2,600 submersible pumps. Since 2010, modern, efficient sub- nite mines are gradually being replaced with more energy efficient mersible pumps with premium efficiency motors (PEM), developed models. New, highly efficient submersible motor pumps developed by Andritz Ritz, have been gradually replacing their predecessors. by Andritz Ritz allow significant annual energy savings. Focusing “This is helping us to save a considerable amount of energy each on innovations for the total system (pump, motor and the applica- year,” Teichmeier said. tion), these pumping experts use modern, high-performance simu- With its well-thought-out well information and optimization lation software to build components with optimal flow in mind, system, RWE oversees all of the wells involved lignite extraction which makes the pumps even more efficient. and ensures that energy efficiency is constantly being improved. As “There are no alternatives to mine dewatering and it can only operators of the drainage system, Teichmeier and Sven Karsubke be discontinued at the earliest when the reserves are fully mined look after the pumps in the well galleries. The energy costs for con- and reclaimed. This is why it makes more sense to think about tinuous operation make up most of the pumps’ life-cycle costs. measures that will improve the energy efficiency of the pumps,” As mining advances into new extraction areas, the energy-opti- said Hans-Joachim Teichmeier from RWE, describing the situation mized SU submersible pump series will be used to replace existing as it was three years ago. RWE Power AG operates around 1,600 pumps. “We’ve substantially developed this series in the last few wells in the open-cast mines in the Rhenish mining area, where years—taking into account the suggestion of our customers too,” lignite is mined as fuel for power generation. In each well, a pump said Ludger Gottkehaskamp, product developer for Andritz Ritz. works to keep the mine water-free up to 450 m and to keep the “We’ve increased the efficiency of both the motor and the groundwater level below the working level of the enormous bucket- pump,” said Georg Cichon, product developer, based at the compa- wheel excavators. This means the pumps move approximately ny’s manufacturing facilities in Schwabisch Gmuend. In addition, 600 million m3 of water a year. Together with replacement pumps, the pumps were designed for optimal drainage, depending on the local geology and water flow situation. Seeing the motor, pump and electrical connection as a unit offers the Andritz Ritz experts plenty of ways to increase the overall efficiency. Using a wide range of methods, the developers have succeed- ed in pursuing contradicting goals and improving all areas of the pump motor unit. A stage of a newly designed 12-in. SU12-340 pump produces more than double the delivery head at the same output, in relation to the previous model. In other words, this means that the pump needs only nine stages, instead of 18, to achieve the same delivery head. This lowers material costs and the purchase price. By making targeted adjustments to the design of the motor, the PEM generation motors are substantially more efficient. To achieve the same output of 330 m3 and delivery head of 380 m, the new pumps requires 79 kW less power, which over the course of a year adds up to 700,000 kWh. The overall efficiency of the unit within the range +/-30% around the optimal operating point is now 72.2% instead of 64.4%. Smaller pump diameters are used for the same output. The new generation SU pumps can hold their own with the larger pumps of the previous generation. An SU12-420 with a new design and PEM technology produces the same in terms of output and delivery head as a 14-in. pump from the previous generation, and uses 20 kW less power to do it. This is also a big advantage for well construction. It is assumed that the construction costs rise considerably with an extra inch of well diameter, users can quickly make significant savings by building a more streamlined well. This means that Andritz Ritz can boast an ROI of 2.6 years. “For 30 years of expected service, any bookkeeper should be con- vinced,” said Matthias Muller, managing director and COO for Andritz Ritz. “This success is down to rigorous development work, as well as Andritz Ritz recently received a major order from China for the delivery of much more powerful software we can now rely on,” Gottkehaskamp three Heavy Duty Mining (HDM) submersible pumps. said. The developers have provided a computational fluid dynam-

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VDMA

Adritz Ritz uses a unique design that generates no axial thrust, yet delivers A cut-away view shows how the Feluwa hose-diaphragm pumps work. high head.

ics (CFD) program with 3-D simulation to optimize the flow inside developed comprehensive know-how and expertise in this field and the pump, for example, he added. Up to 250,000 points within a gathered valuable practical experience. flow channel can be taken into account when calculating the opti- Long distance hydro transportation of aggressive and/or abra- mum shape. sive slurries is a challenging task even for positive displacement “In the past, we could provide a calculation on just 90 points pumps. Feluwa’s multisafe double hose-diaphragm pumps use two per flow line and up to nine flow lines per blade,” said Cichon. hose-diaphragms, which are arranged one inside the other. They The further development of the submersible motors concerns ensure linear flow and are sealed redundantly between the wet and above all the organization and manufacturing of the sheet drive end. The dual separation guarantees high operating safety, metals. Sheet metals with optimized conducting functions are durability and efficiency. now used for this. The company recently announced a Quintuplex crank drive, Considering the motor and pump components separately allows which increases the pump technology by fivefold, setting a new the efficiency of both to be consistently improved. A further fine- standard in the industry. These huge pumps are primarily used in tuning process lets the developers at Andritz Ritz also ensure that the mining sector for high-pressure pipeline transport of slurry. The the overall efficiency is increased as much as possible. The best first three of these five-headed, double hose-diaphragm pumps example of this is the reduction of the number of the pump’s stages are headed to the El Boleo project in Mexico where they will handle and consequently a significant increase in the power density. It’s good to see this ongoing development at RWE, because it means that the workers in the open-cast mine are not likely to get wet feet until 2045 at the earliest. In what they describe as the largest single order in its history, Andritz Ritz also recently received a major order from China for the delivery of three Heavy Duty Mining (HDM) submersible pumps. The two larger submersibles required 4 MW, while the smaller unit will be powered by 3.2 MW. The pumps were manufactured at the company’s headquarters in Schwabisch Gmuend. “We had a very tight delivery time,” said Mueller. “There were just 12 months between the construction and the first test runs on the in-house test bed.” The pumps, each consisting of three individual components, are 22-m long or rather high and weigh more than 32 tons when mounted. The huge dimensions and high engine power made special measures necessary, such as the use of mobile cranes and careful coordination with the municipal utility, as far as the power for the test runs. In the Chinese mines, the pumps are installed at a depth of 900 m, and are capable of pumping 1,000 m3/h to a height of 1,000 m. The units are part of the mine’s safety program to prevent the mine from flooding.

El Boleo Deploys Three Gigantic Piston-diaphragm Pumps Feluwa Pumpen GmbH specializes in piston-diaphragm pumps for The Quintuplex design can convey any kind of pumpable slurries with a difficult slurry applications. Over the years, the company has capacity up to 1,000 m3/h and pressure up to 50 bar.

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750 m3/h of copper slurry at an operating pressure of 45 bar. Basically the Quintuplex design can convey any kind of pumpable slurries with a capacity up to 1,000 m3/h and pressures up to VDMA 50 bar, according to Feluwa. The required control and drive technology was also provided by Feluwa. Three 1.3-megawatt, medium-voltage motors and a control and diagnostics software, especially designed for these pumps, guarantee a smooth and well-controlled pump operation. With a weight of 150 tons each, these pumps are controlled by the mine’s process control system. A touch panel displays all operating data and it is transferred in real time to the mine’s control center and, if requested, to the Feluwa service engineers in Germany. An innovative diagnostics system detects the smallest leaks in the check valves even if the loss of output is still less than 1.5%. These and other important operating conditions are continuously transferred to and evaluated by the pump’s diagnostics system. This allows for reliable maintenance planning. By using modern sensor technology, maintenance downtime is reduced and energy efficiency is increased. Another advantage of the Quintuplex design over the existing Triplex and Duplex diaphragm piston pumps is the significantly lower residual pulsation. Even Abel’s HMQ-1000 pumps fly ash (66% concentration) at a rate of 115 m3/hr without pulsation dampeners, residual pulsation is reduced to and 25 bar to a discharge point 7-km from the plant. 5.1% peak-to-peak (vs. 23% of single-acting three cylinder pumps and 32.5% of single-acting four cylinder pumps), which Diaphragm Pump Pushes Fly Ash Slurry could be lowered if two or more pumps are coupled by an elec- Long Distances tronically controlled phase shift. The new five-headed multisafe With environmental protection as a priority, one of India’s leading pumps, according to Feluwa, are convincing even by comparison integrated steel producers needed to develop a system to dispose to centrifugal pumps. Normally the higher original costs are amor- of the ash produced at its 358-megawatt coal-fired power plant. tized within a few years due to the considerably higher efficiency Indian coals are notoriously low grade and this case was no excep- (normally 25% to 30%) and the significantly lower wear. tion. The coal burned at this plant was ranked as F, which is among

The flowsheet depicts the process of pumping fly ash using Abel’s HMQ-1000 diaphragm pump.

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the poorest grades with an average of 60% ash. The existing ash impoundment near the plant could no longer be used, making the task more difficult. Downtime in an ash disposal section of a power plant trans- VDMA lates directly to loss of revenue. The power plant would have to be de-rated to reduce the amount of fly ash produced, which was not an option. The proposed plan involved pumping high-concentrate fly ash slurry around the perimeter of the existing evaporation pond to another area and allowing the slurry to decant to form a solid outer barrier, increasing the overall capacity impoundment. This meant the fly ash slurry (approximately 65% solids content) would have to be pumped through a 7-km pipeline. Duchting’s MHK 250 has improved operating conditions at the Sobieski coal Fly ash is abrasive and it has cementitious properties. If the fly mine in Poland. ash slurry sits for too long, it would set up inside the pipeline. The challenge was to find a reliable pumping system that could not only and a high and constant efficiency is achieved over the lifetime of handle the flow and high pressure requirement, but also endure the pumps. The pumps run smoothly and the lower noise level leads high abrasion while limiting costly downtime and maintenance. to an increase of comfort and an improvement of working condi- Abel, in association with the ash handling system supplier, tions. The use of modern electric motors reduces the heat genera- Macawber Beekay, proposed a solution wherein the ash generated tion, which also improves working conditions in the pump station. would be mixed with water in a 65:35 ratio. Abel’s HMQ-1000 pumps An advanced monitoring system provides constant data on the would push this slurry to the new ash dyke. The HMQs are a piston- working condition of the pumps. The flow rate, pressure, bearing diaphragm pump, designed with a hydraulic section that separates temperatures, conditions of the slider and the power consumption the slurry from the drive piston and isolates wear to inexpensive elas- can be monitored remotely. Access to this information allows the tomer components, i.e., diaphragms, check cone valves and seats. mine to plan maintenance. The smaller physical size of the pumps Four of these pumps are now running at a high-concentrate improves access and safety when servicing the pumps. slurry disposal (HCSD) system since January 2010. Each of these Due to the positive experience with Düchting’s MHK 250-650x5, has an independent 7- to 8-km discharge pipeline to the ash pond. a complete modernization of all pump units in the main drainage Records from these plants show that the Abel pumps are operating is planned within the next few years, which will increase the ease at nearly 66% concentration. With these concentrations, the of use, improve the working conditions and safety. achieved flow rate is 115 m3/hr and pressures reached are about 25 bar. Even under these strenuous conditions, Abel said the HMQ pumps have constantly performed at their peak and the power plant has never had to derate its capacity.

Polish Coal Mine Refurbishes Main Dewatering Station The Sobieski coal mine in southern Poland is one of the wettest mines in Europe. The mine routinely pumps more than 60 m3/min of water to the surface. This requires powerful pumps and a reliable dewatering plan. Since its founding, and especially after production grew, the mine, similar to most mines, has become more environmentally aware. Investments to increase the efficiency of coal production are accompanied with matching funds for environmental considerations. One recent initiative involved modernizing the pumping station for the main drainage. An existing pump was replaced in the main drainage pumping station at a depth of approximately 500 m. After carrying out an economic analysis, which pursued a goal to reduce energy consumption, the mine decided to install modern pumping systems. After extensive search through a tender procedure, the mine found and selected Düchting Pumpen to modernize the pump station. The company could offer a pump capacity of 8.6 m3/min with a high efficiency, replacing the existng 10-stage pumps with five- stage pumps. The current analysis of the actual total costs of water management of the mine with the Düchting pumps (MHK 250-650x5) confirmed the expected environmental and economic effects. The mine saved 10% on energy costs compared to the previous system. Through the use of high-quality stainless steel components for the moving parts of the pump, the life span of the pump is increased

2014 • VDMA MINING SUPPLEMENT VDMA 51 VDMA_pg52-53_VDMA_pg52-53 1/16/14 9:52 AM Page 52

Safety: De-dusting Technology VDMA for Underground Mining

The underground mining industry is always striving for improved pensating the families that also become victims of the disease. After safety, looking for more solutions in the field of environmental health a plant is installed, miners no longer need to wear dust masks, which and safety (EH&S). Modern de-dusting plants offer an opportunity to improves workplace ergonomics. improve the atmosphere underground, which also has a positive By incorporating de-dusting plants into a ventilation strategy, effect on efficiency and cost reduction. coal mines can prevent the worst case scenario: a coal dust explosion. Since 1999, Compact Filter Technic GmbH (CFT) has been devel- CFT has mining experience and understands the field of tunneling, oping and constructing de-dusting plants for mining and tunneling and it can help miners apply innovative technologies to develop cus- applications. CFT is well-established with its brand as the “clean air tom solutions. company,” and it offers both dry and wet de-dusting plants. In addition to de-dusting, CFT also develops complete air tech- For coal mining applications, CFT plants can help combat coal nology packages with its clients. The company should be included in workers pneumoconiosis or “black lung.” Despite the industry’s best the early stages of ventilation, cooling and heating equipment selec- efforts to eradicate this industrial disease, it still persists worldwide. In tion as well as mine gas extraction systems. addition to its negative health effects, it also has severe consequences for mining companies and nations that rely on coal mining extensively. Reliable Gas Detection Technology The legacy costs associated with black lung are well-documented in Protection against explosive and toxic gases is an absolute necessity Germany and it’s believed that the disease has increased coal produc- for safe operations in the mining industry. Naturally occurring gases tion costs directly by 10% since it became accepted in 1953. remain a principal airborne hazard and continue to place miners at With the precise application of de-dusting plants, CFT says it can risk of poisoning through toxic gas exposure, suffocation and fire or achieve a dust separation rate up to 99.997% in underground work- explosion caused by combustible gases. Miners demand reliable gas ing places. The machines are especially useful in capturing the micro detection technology. Reliable sensor technology and gas detectors dust particles (less than 5 microns), which causes the most problems can certainly protect miners and mine rescue teams against invisible among miners. gas hazards, but only through regular maintenance, calibration and Furthermore, CFT de-dusting technologies are playing an impor- function testing can this reliability be maintained. tant role in avoiding potential explosive atmospheres in underground With its new automatic calibration and bump test station X-dock, coal where coal dust and methane form a deadly combination. In the Dräger optimizes the entire process chain surrounding its gas mea- last 20 to 30 years, these types of mine disasters and casualties, as suring technology, including calibration, documentation and analysis. well as production losses, were prevented successfully in Germany. This integrated approach saves both time and resources while This is partly a result of clean air technologies. increasing transparency and safety at the same time. CFT’s plants provide clean air for the work environment while General national industry guidelines require that each gas detec- helping the mine comply with dust regulations. Production downtime tor be tested with test gas prior to each use, and this process must be due to high dust generation is also reduced. documented. The standards EN 45544-4 and EN 60079-29-2, as well CFT de-dusting technology has had a significant impact as far as as U.S. Mine Safety and Health Administration (MSHA) guidelines also reducing the case of “black lung.” Not only does it improve the quali- require a daily bump test. ty of life for miners, but it also reduces the costs associated with com- These requirements cause particular challenges: Test gas must be ordered and replaced in time. The documentation must be complete and easy to access at the same time. A test should not take too much valuable work time. Which device needs servicing? Which person is currently using this device? Are the daily bump tests being performed? Many questions surround a complex task. If companies have to face these challenges anyway, why not use the gas detectors as a source of analysis for their operations? The devices record the average concentrations and alarms that have occurred, and sometimes can even identify who used which device at which time and where or when it was tested. This data provides useful information to safety engineers. The Dräger X-dock system has quick functional testing and its comprehensive documentation solves everyday concerns. Data is stored locally on the device, at a central database and, upon request, also on paper. As a modular system, it can check up to 10 gas detectors simultaneously with test gas in just about 10 seconds; and all this at a minimal test gas consumption: While the flow in most bump test stations is about 500 milliliters per minute and the duration is about 20 seconds, the X-dock value for this is 300 milliliters per minute at A CFT de-dusting plant can effectively clear the air underground. half the test period (average values). And simple operation allows for

VDMA 52 VDMA MINING SUPPLEMENT • 2014 VDMA_pg52-53_VDMA_pg52-53 1/16/14 9:52 AM Page 53

mining industry into the Kailuan Coal Group in the form of education- al and further training measures. The PPP project will run from 2013 until 2015 and includes safe operating procedures in the fields of roadheading, logistics and coal winning, ventilation, fire protection, VDMA hazardous substances, explosion protection, and mine rescue. RAG Mining Solutions (Beijing) Ltd., which was involved in the design and preparation of the project from the very beginning, will actively support the project as the local point of contact, service Dräger’s X-dock system can check 10 methanometers in 10 seconds. provider and clearing house. This also includes continuing talks between the two companies about the collaboration in other product an even faster process: Insert the unit, close the cover and the test fields, such as consulting services for mine development, ventilation begins. Flexible software automatically controls the test. All results, and climate technology, as well as automation. including the testing of alarm elements and the reading of exposure During the contract signing ceremony, which was chaired by reports, can be retrieved through an intuitive touch screen just like Zhang Zhiyou, chief human resources officer for the Kailuan Coal using a smartphone. Group, Zhiyou and Dieter Mantwill, general manager and head of the Networking the individual X-dock stations through a central health, safety and environment (HSE) division at RAG Mining database, allows full use of all features: The database not only stores Solutions, emphasized the special significance of the project, which the results of each individual bump test, but also various information will sustainably improve occupational safety in Chinese mining as collected by the unit during the last deployment. These include the part of this two-year program. “For us, it’s not about preaching and average concentration and duration of use, as well as the number of wagging fingers. Instead, we want to implement the project as part- alarms and their duration. ners,” Mantwill said after signing the contracts. With the use of a suitable evaluation software, such as the X-dock Dr. Jürgen Steiger, director of GIZ China, expressed the joy of his Manager, reports and graphs can be drawn from the database—one- organization about entering into another partnership with RAG, which time, periodically or only upon the occurrence of a pre-defined event. will completely conform to the objectives of the GIZ as well as those The Dräger X-dock has become an integral part of mining proof the Federal Ministry for Economic Cooperation and Development cesses. The close cooperation between the miners and Dräger has (BMZ). “The safety of miners is a subject that is now enjoying top pri- helped to provide this solution resulting in more safety, less downtime ority in China as well, and that we are pleased to support with this and great usability. proportional funding—we will use it as a flagship project for upcoming tasks,” said Steiger. Applying German Standards to The high significance that the subject of occupational safety and Occupational Safety health protection has within the Kailuan Coal Group can be seen by RAG Mining Solutions GmbH brings German mining know-how to the the fact that the mining company was accepted as a member into the international market and provides a wide range of consulting and engi- Association of International Social Security (ISSA) by Secretary- neering services, as well as organizing training programs. Their motto General of ISSA Mining Helmut Ehnes, who traveled especially for this is: “We know how… because we have done it ourselves.” The company reason to Tangshan. has been very active in China, trying to help underground coal mining RAG Mining Solutions GmbH brings German mining know-how to operations improve their safety and operating performance. the international market and provides a wide range of consulting and During July 2013, a contract was signed in Tangshan, China, engineering services, as well as organizing training programs, in between RAG Mining Solutions GmbH, Kailuan Coal Group Ltd. and areas like technical planning, logistics, mine support and develop- the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) ment work, building material technology, ventilation and climate con- GmbH concerning a Public Private Partnership (PPP) project. trol, methane emission/drainage, coal winning, automation, testing The objective of this project is to implement the knowledge about or HSE. RAG Mining Solutions can provide integrated solutions for occupational safety and health protection acquired by the German coal optimizing the processes involved in underground coal winning.

Dr. Jurgen̈ Steiger (GIZ), Wenjie Chang (Kailuan Coal Group) and Dieter Mantwill (RAG Mining Solutions) during the signing of the contract (front row, from left).

2014 • VDMA MINING SUPPLEMENT VDMA 53 VDMA_pg54-64 Matrix-BG_VDMA_pg54-64 Matrix-BG 1/14/14 2:44 PM Page 54

GERMAN VENDOR MATRIX

VDMA Software

•••• Consulting/Engineering

• • •• •• • • •• •• • Services

• • •••• • ••• • Mine Safety Mine

••• • • • Accessories, wear parts wear Accessories,

•• •• • ••• •• • Compressors

••• Pneumatic & hydraulic tools hydraulic & Pneumatic

•• • Communication, navigation Communication,

••• Power supply Power

•• • • • • Control equipment Control •••••••

Driving aggregates Driving •• • •

Stockpile equipment Stockpile ••

Feeding & withdrawal equipment withdrawal & Feeding •• •

Continuous conveyor & components & conveyor Continuous ••••••••

Coke oven plant equipment plant oven Coke •

Dewatering plant Dewatering ••

Dedusting, water treatment water Dedusting, •• Briquetting & granulation equipment granulation & Briquetting

Dewatering, proportioning, mixing eq. mixing proportioning, Dewatering, •••••

Sorting equipment Sorting ••••

Sizing equipment Sizing •••• ••

Crushers & mills & Crushers •••••• Preparation plants Preparation

••• Trackless underground vehicles underground Trackless

•• • • Winches & hoists & Winches

•• Shaft winding equipment winding Shaft

•• Conveying & haulage underground haulage & Conveying

••••••••• Blasting equipment Blasting

•••• Dewatering (underground & open pit) open & (underground Dewatering

in open pits (truck/shovel) pits open in •• •• •• Special equipment for open pits open for equipment Special

•••••• • Extraction

•• •• Extraction in open pits (continuous) pits open in Extraction

•••• Stowing

•• Ventilation & air-conditioning & Ventilation •• •••

Extraction (vein, room & pillar) & room (vein, Extraction •• •

Extraction (longwall) Extraction •• •••

Roof support/Shaft & roadways & support/Shaft Roof •••••

Roadway driving/Heading Roadway •••• • ••

Deep well drilling equipment drilling well Deep ••• • •

Shaft sinking Shaft •• • ABB ABEL AEM ALIMAK HEK Andritz Ritz Apollo Atlas Copco MCT AUMUND AViTEQ BARTEC BAT Bauer Maschinen Systems Mining Becker Bell Equipment BEUMER BHS-Sonthofen Bochumer Eisenhütte BRÄUTIGAM Caterpillar Global Mining CFT CIV PRÄZISIONSTECHNIK Cyrus DAT Deilmann-Haniel Mining Systems DEUTZ DMT Döpke Dräger Safety DÜCHTING Durum

VDMA 54 VDMA MINING SUPPLEMENT • 2014 VDMA_pg54-64 Matrix-BG_VDMA_pg54-64 Matrix-BG 1/14/14 2:44 PM Page 55

GERMAN VENDOR MATRIX

VDMA Software

• Consulting/Engineering

••• ••• • Services

•• Mine Safety Mine

••• • • • Accessories, wear parts wear Accessories,

•• •• ••• • •• • Compressors

• Pneumatic & hydraulic tools hydraulic & Pneumatic Communication, navigation Communication,

• • Power supply Power

•• Control equipment Control ••• ••

Driving aggregates Driving ••••• •

Stockpile equipment Stockpile •• •

Feeding & withdrawal equipment withdrawal & Feeding ••• • •

Continuous conveyor & components & conveyor Continuous •• • ••••

Coke oven plant equipment plant oven Coke • •

Dewatering plant Dewatering ••• •

Dedusting, water treatment water Dedusting, ••

Briquetting & granulation equipment granulation & Briquetting •

Dewatering, proportioning, mixing eq. mixing proportioning, Dewatering, •• • • •

Sorting equipment Sorting ••

Sizing equipment Sizing ••• •

Crushers & mills & Crushers •• ••• Preparation plants Preparation

•• • • Trackless underground vehicles underground Trackless

•• • Winches & hoists & Winches

•• • • Shaft winding equipment winding Shaft

•• ••• Conveying & haulage underground haulage & Conveying

•• • ••• •••• Blasting equipment Blasting

• Dewatering (underground & open pit) open & (underground Dewatering

in open pits (truck/shovel) pits open in ••• Special equipment for open pits open for equipment Special

••• •• • • • • Extraction

•• • Extraction in open pits (continuous) pits open in Extraction

•• • Stowing

• Ventilation & air-conditioning & Ventilation •

Extraction (vein, room & pillar) & room (vein, Extraction •• •

Extraction (longwall) Extraction •• • • • •

Roof support/Shaft & roadways & support/Shaft Roof ••• ••

Roadway driving/Heading Roadway •••• •••

Deep well drilling equipment drilling well Deep •• • • •

Shaft sinking Shaft ••• EEP Eickhoff Eirich EnviroChemie FAM FELUWA Pumpen FLSmidth Wadgassen FLSmidth Wiesbaden GEA Westfalia Separator GMH Gruppe Getriebebau Nord GHH GKN Stromag GOTHE GreCon GTA Habermann Hammelmann Hauhinco NIAGARAHAVER HAWE Hydraulik Hazemag & EPR H+E Logistik HADEF HEINRICH DE FRIES hema Herrenknecht Hese Hilti Howden HYDAC

2014 • VDMA MINING SUPPLEMENT VDMA 55 VDMA_pg54-64 Matrix-BG_VDMA_pg54-64 Matrix-BG 1/14/14 2:44 PM Page 56

GERMAN VENDOR MATRIX

VDMA Software

••• Consulting/Engineering

•• • •• • • • • • • Services

•• • •• Mine Safety Mine

••• Accessories, wear parts wear Accessories,

•••• • ••••• •• Compressors

•• Pneumatic & hydraulic tools hydraulic & Pneumatic

• • Communication, navigation Communication,

• Power supply Power

••• Control equipment Control ••••••

Driving aggregates Driving •••••

Stockpile equipment Stockpile ••

Feeding & withdrawal equipment withdrawal & Feeding •• •

Continuous conveyor & components & conveyor Continuous •• • • • •

Coke oven plant equipment plant oven Coke •

Dewatering plant Dewatering ••••

Dedusting, water treatment water Dedusting, •• • • •

Briquetting & granulation equipment granulation & Briquetting •• •

Dewatering, proportioning, mixing eq. mixing proportioning, Dewatering, •• • • • • •

Sorting equipment Sorting •• •• •

Sizing equipment Sizing •• • • •

Crushers & mills & Crushers •• • • • Preparation plants Preparation

•• • • Trackless underground vehicles underground Trackless

•• • • Winches & hoists & Winches

•• • • Shaft winding equipment winding Shaft

• Conveying & haulage underground haulage & Conveying

••••• Blasting equipment Blasting

•• • Dewatering (underground & open pit) open & (underground Dewatering

in open pits (truck/shovel) pits open in •• ••••• Special equipment for open pits open for equipment Special

•• • Extraction

••• • Extraction in open pits (continuous) pits open in Extraction

•• • • Stowing

••• Ventilation & air-conditioning & Ventilation •

Extraction (vein, room & pillar) & room (vein, Extraction •• •

Extraction (longwall) Extraction ••• • •• •

Roof support/Shaft & roadways & support/Shaft Roof •• • • •

Roadway driving/Heading Roadway •• • ••

Deep well drilling equipment drilling well Deep •• •

Shaft sinking Shaft •• • • IAG MAGNUM ITI JÖST KAMAT Kennametal Kleemann Komatsu KÖPPERN Krummenauer KSB Liebherr Loesche Lurgi Air Liquide Global E&C Solutions MAHLE marco MATO MBE Coal & Minerals MTU J.D. Neuhaus Nilos oddesse Outotec Paus PFISTER WAAGEN PFREUNDT PLARAD PRAKLA Preinfalk Pumpentechnik Erkrath Putzmeister

VDMA 56 VDMA MINING SUPPLEMENT • 2014 VDMA_pg54-64 Matrix-BG_VDMA_pg54-64 Matrix-BG 1/14/14 2:44 PM Page 57

GERMAN VENDOR MATRIX

VDMA Software

•• Consulting/Engineering

••••••••••• Services

••••••••••• Mine Safety Mine

••• Accessories, wear parts wear Accessories,

• • •• • ••• • ••••• Compressors Pneumatic & hydraulic tools hydraulic & Pneumatic

•• Communication, navigation Communication,

•• Power supply Power

•• Control equipment Control •••••

Driving aggregates Driving •••••••

Stockpile equipment Stockpile •• • • •

Feeding & withdrawal equipment withdrawal & Feeding ••••

Continuous conveyor & components & conveyor Continuous •• • • ••• ••

Coke oven plant equipment plant oven Coke •

Dewatering plant Dewatering •

Dedusting, water treatment water Dedusting, •• Briquetting & granulation equipment granulation & Briquetting

Dewatering, proportioning, mixing eq. mixing proportioning, Dewatering, ••

Sorting equipment Sorting ••

Sizing equipment Sizing ••

Crushers & mills & Crushers •• • • • • • Preparation plants Preparation

•• • Trackless underground vehicles underground Trackless

• Winches & hoists & Winches

•• Shaft winding equipment winding Shaft

•• Conveying & haulage underground haulage & Conveying

•• • •• • Blasting equipment Blasting

• Dewatering (underground & open pit) open & (underground Dewatering

in open pits (truck/shovel) pits open in ••• Special equipment for open pits open for equipment Special

•• • • • •• •• Extraction

•• • Extraction in open pits (continuous) pits open in Extraction

•• •• • • • Stowing

• Ventilation & air-conditioning & Ventilation ••

Extraction (vein, room & pillar) & room (vein, Extraction ••

Extraction (longwall) Extraction •••

Roof support/Shaft & roadways & support/Shaft Roof •

Roadway driving/Heading Roadway •••

Deep well drilling equipment drilling well Deep •• •

Shaft sinking Shaft •• Rensmann RWE Power SAMSON Sandvik Central Europe Sandvik Crushing Tech. SCHADE Schaeffler Technologies Schalker Eisenhütte Schopf Schulte Strathaus SIEMAG Tecberg Siemens STEINERT TAKRAF THIELE Thomas Magnete ThyssenKrupp Resource, Essen ThyssenKrupp Resource, Enningerloh ThyssenKrupp Resource, St. Ingbert TLT-Turbo TML Technik URACA Vattenfall Europe Mining Völkmann Voith Turbo WELLER WILO SE Wirtgen

2014 • VDMA MINING SUPPLEMENT VDMA 57 VDMA_pg54-64 Matrix-BG_VDMA_pg54-64 Matrix-BG 1/14/14 2:44 PM Page 58

VDMA Becker Mining Systems AG ABB Automation GmbH Barbarastr. 3 Geschäftsbereich Open Pit Mining Atlas Copco MCT GmbH 66299 Friedrichsthal Gaglower Str. 17 - 18 Langemarckstr. 35 Web: www.becker-mining.com 03048 Cottbus 45141 Essen Web: www.abb.com/mining Web: www.atlascopco.de

Bell Equipment (Deutschland) GmbH ABEL GmbH & Co KG Willy-Brandt-Straße 4-6 Abel-Twiete 1 AUMUND-Fördererbau GmbH 36304 Alsfeld 21514 Büchen Saalhoffer Str. 17 Web: www.bellequipment.de Web: www.abel.de 47495 Rheinberg Web: www.aumund.com

BEUMER Maschinenfabrik AEM -Anhaltische Elektromotorenwerk GmbH & Co KG Dessau GmbH AViTEQ Vibrationstechnik GmbH Oelder Str. 40 Daheimstr. 18 Im Gotthelf 16 59269 Beckum 06842 Dessau-Rosslau 65795 Hattersheim Web: www.beumer.com Web: www.aemdessau.de Web: www.aviteq.de

Alimak Hek GmbH BARTEC Sicherheits- und Frauenbrunner Str. 25 Schaltanlagen GmbH BHS-Sonthofen GmbH 75031 Eppingen Holzener Str. 35 - 37 An der Eisenschmelze 47 Web: www.alimakhek.de 58708 Menden 87527 Sonthofen Web: www.bartec-mining.com Web: www.bhs-sonthofen.de

ANDRITZ Ritz GmbH Güglingstr. 50 73529 Schwäbisch Gmünd BOCHUMER EISENHÜTTE Web: www.andritz.com BAT Bohr- und Anlagentechnik GmbH HEINTZMANN GMBH & Co KG Borntalstr. 11 Klosterstr. 46 36460 Merkers 44787 Bochum Web: www.bat-maschinenbau.de Web: www.be-heico.de Apollo Maschinenbau GmbH Grünauer Fenn 44 14712 Rathenow Web: www.apollo-maschinenbau.de

Bauer Maschinen GmbH BAUER-Str. 1 BRÄUTIGAM Gear & Mining Tech Arthur Habermann GmbH & Co KG 86529 Schrobenhausen GmbH & Co KG Goethestr. 12 Web: www.bauer.de Am Schürmannshütt 8 - 18 58453 Witten 47441 Moers Web: www.habermann-gmbh.de Web: www.braeutigam-group.com

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CATERPILLAR Global Mining Deilmann-Haniel Mining Systems VDMA Europe GmbH GmbH Industriestr. 1 Haustenbecke 1 EEP Elektro-Elektronik Pranjic 44534 Lünen 44319 Dortmund Am Luftschacht 21 Web: www.mining.cat.com Web: www.dhms.com 45886 Gelsenkirchen Web: www.eep.de

CATERPILLAR Global Mining HMS GmbH Karl-Funke-Str. 36 Eickhoff Bergbautechnik GmbH 44149 Dortmund Hunscheidtstr. 176 Web: www.mining.cat.com DEUTZ AG 44789 Bochum Ottostr. 1 Web: www.eickhoff-international.com 51149 Köln Web: www.deutz.com

CFT GmbH Compact Filter Technic El.-Ap. GOTHE & Co GmbH Beisenstr. 39 - 41 DMT GmbH & Co KG Kruppstr. 196 45964 Gladbeck Am Technologiepark 1 45472 Mülheim Web: www.cft-gmbh.de 45307 Essen Web: www.gothe.de Web: www.dmt.de CIV Präzisionstechnik GmbH

EnviroChemie GmbH In den Leppsteinswiesen 9 Tuchmacherweg 11 Dräger Safety AG & Co KGaA 64380 Rossdorf 39288 Burg Revalstr. 1 Web: www.envirochemie.com Web: www.civ-burg.de 23560 Lübeck Web: www.draeger.com

F. E. Schulte StrathausGmbH & Co KG Cyrus GmbH Schwingtechnik Fördertechnik - Dichtungssysteme Am Stadion 40 DÜCHTING PUMPEN Runtestr. 42 45659 Recklinghausen Maschinenfabrik GmbH & Co KG 59457 Werl Web: www.cyrus-germany.com Wilhelm-Düchting-Str. 22 Web: www.schulte-strathaus.de 58453 Witten Web: www.duechting.com

DAT Bergbautechnik GmbH FAM Förderanlagen Magdeburg Am Schornacker 61 DURUM Verschleißschutz GmbH und Baumaschinen GmbH 46485 Wesel Carl-Friedrich-Benz-Str. 7 Sudenburger Wuhne 47 Web: www.dat-bergbau.de 47877 Willich 39112 Magdeburg Web: www.durmat.com Web: www.fam.de

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VDMA HADEF HEINRICH DE FRIES GmbH GHH Fahrzeuge GmbH Hebezeugfabrik Emscherstr. 53 Gauss Str. 20 FELUWA Pumpen GmbH 45891 Gelsenkirchen 40235 Düsseldorf Beulertweg 10 Web: www.ghh-fahrzeuge.de Web: www.hadef.de 54570 Mülenbach Web: www.feluwa.com

GKN Stromag AG Hammelmann Hansastr. 120 Maschinenfabrik GmbH 59425 Unna Zum Sundern 13 - 21 FLSmidth Wadgassen GmbH Web: www.stromag.com 59302 Oelde Karl-Koch-Str. 1 Web: www.hammelmann.com 66787 Wadgassen Web: www.flsmidth.com

GMH Gruppe Neue Hüttenstraße 1 Hauhinco Maschinenfabrik 49124 Georgsmarienhütte GmbH & Co KG FLSmidth Wiesbaden GmbH Web: www.gmh-gruppe.de Beisenbruchstr. 10 Am Klingenweg 4a 45549 Sprockhövel 65396 Walluf Web: www.hauhinco.com Web: www.flsmidth.com

GreCon Greten GmbH & Co KG Hannoversche Straße 58 31061 Alfeld Web: www.grecon.com HAVER NIAGARA GmbH Fritz Rensmann GmbH & Co Robert-Bosch-Str. 6 Maschinenfabrik 48153 Münster Bünnerhelfstr. 33 Web: www.haverniagara.com 44379 Dortmund Web: www.rensmann.com GTA Maschinensysteme GmbH Loikumer Rott 23 46499 Hamminkeln Web: www.gta.eu HAWE Hydraulik SE GEA Westfalia Separator Group Streitfeldstr. 25 Werner-Habig-Str. 1 81673 München 59302 Oelde Web: www.hawe.de Web: www.westfalia-separator.com

H + E Logistik GmbH Josef-Baumann-Str. 18 44805 Bochum Web: www.helogistik.de HAZEMAG Mining Getriebebau Nord GmbH & Co KG Brokweg 75 Getriebebau-Nord-Str. 1 48249 Dülmen 22941 Bargteheide Web: www.mining.hazemag.de Web: www.nord.com

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Kennametal AMSG GmbH VDMA HYDAC INTERNATIONAL GmbH Max-Planck-Str. 13 Industriestraße 61381 Friedrichsdorf 66280 Sulzbach/Saar hema electronic GmbH Web: www.kennametal.com Web: www.hydac.com Röntgenstraße 31 73431 Aalen Web: www.hema.de

Kleemann GmbH Manfred-Wörner-Straße 160 IAG MAGNUM GmbH 73037 Göppingen Bessemerstr. 1 Web: www.kleemann.info 49084 Osnabrück Hermann Paus Maschinenfabrik GmbH Web: www.iag-magnum.de Siemensstr. 1 - 9 48488 Emsbüren Web: www.paus.de Komatsu Mining Germany GmbH Buscherhofstr. 10 40599 Düsseldorf ITI GmbH Web: www.komatsu-mining.de Schweriner Str. 1 01067 Dresden Web: www.itisim.com Herrenknecht AG Krummenauer GmbH & Co KG Schlehenweg 2 Wellesweilerstr. 95 77963 Schwanau 66538 Neunkirchen Web: www.herrenknecht.de Web: www.krummenauer.de J. D. NEUHAUS GmbH & Co KG Windenstr. 2 - 4 58455 Witten Web: www.jdngroup.com HESE Maschinenfabrik GmbH Magdeburger Str. 16a KSB Aktiengesellschaft 45881 Gelsenkirchen Pumpen & Anwendungen Web: www.hese.de Feststofftransport JÖST GmbH + Co KG Johann-Klein-Str. 9 Gewerbestr. 28 - 32 67227 Frankenthal 48249 Dülmen Web: www.ksb.com Web: www.joest.com Hilti Deutschland AG Hiltistr. 2 86916 Kaufering Liebherr-Mining Equipment SAS Web: www.hilti.com 49 rue Frédéric Hartmann 68025 Colmar, France KAMAT PUMPEN GmbH & Co KG Web: www.liebherr.com Salinger Feld 10 58454 Witten Web: www.kamat.de Howden Ventilatoren GmbH Stubentalstr. 44 89518 Heidenheim Web: www.howden.com

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VDMA Maschinenfabrik KÖPPERN oddesse Pumpen- und GmbH & Co KG Motorenfabrik GmbH LOESCHE GmbH Königsteiner Str. 2 Am Pappelwald 12 Hansaallee 243 45529 Hattingen 39387 Oschersleben 40549 Düsseldorf Web: www.koeppern.com Web: www.oddesse.de Web: www.loesche.com

Outotec (Filters) GmbH Maschinenfabrik Völkmann GmbH Eschweilerstr. 101 - 109 LURGI GmbH Rohdesdiek 32-42 52477 Alsdorf AIR LIQUIDE GLOBAL E&C SOLUTIONS 44357 Dortmund Web: www.outotec.com Lurgiallee 5 Web: Dortmund 60439 Frankfurt Web: www.engineering- solutions.airliquide.com

PFISTER WAAGEN BILANCIAI GMBH MATO GmbH & Co KG Linker Kreuthweg 9 Benzstr. 16 - 24 86444 Affing-Mühlhausen MAHLE Industriefiltration GmbH 63165 Mühlheim Web: www.pfisterwaagen.de Schleifbachweg 45 Web: www.mato.de 74613 Öhringen Web: www.mahle-industry.com PFREUNDT GmbH Robert-Bosch-Str. 5 46354 Südlohn Web: www.pfreundt.de MBE Coal & Minerals Technology GmbH marco Systemanalyse und Gottfried-Hagen-Str. 20 Entwicklung GmbH 51105 Köln PLARAD Maschinenfabrik Wagner Hans-Böckler-Str. 2 Web: www.mbe-cmt.com GmbH & Co KG 85221 Dachau Birrenbachshöhe Web: www.marco.de 53804 Much Web: www.plarad.com

MTU Friedrichshafen GmbH Maschinenfabrik Gustav Eirich Maybachplatz 1 PRAKLA Bohrtechnik GmbH GmbH & Co KG 88045 Friedrichshafen Moorbeerenweg 3 Walldürner Str. 50 Web: www.mtu-online.com 31228 Peine 74736 Hardheim Web: www.prakla.de Web: www.eirich.com

Pumpentechnik Erkrath GmbH + Co KG Maschinenfabrik Heinrich Döpke Nilos GmbH & Co KG Max-Planck-Str. 28 GmbH Reisholzstr. 15 40699 Erkrath Stellmacherstr. 10 40721 Hilden Web: www.pumpentechnik-erkrath.de 26506 Norden Web: www.nilos.com Web: www.doepke-gmbh.de

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VDMA Putzmeister Solid Pumps GmbH Max-Eyth.Str. 10 TAKRAF GmbH 72631 Aichtal Schaeffler Technologies AG & Co KG Torgauer Str. 336 Web: www.pmsolid.com Georg-Schäfer-Straße 30 04347 Leipzig 97421 Schweinfurt Web: www.takraf.com Web: www.schaeffler.de/ rohstoffgewinnung_verarbeitung

RWE Power International RE GmbH Stüttgenweg 2 50935 Köln Schalker Eisenhütte Maschinenfabrik THIELE GmbH & Co KG Web: www.rwepi.com or GmbH Werkstr. 3 www.rwe-mec.com Hunscheidtstr. 176 58640 Iserlohn 44789 Bochum Web: www.thiele.de Web: www.schalke.eu

Schopf Maschinenbau GmbH Thomas Magnete GmbH SAMSON AG Parkstr. 19 - 21 San Fernando 35 MESS- UND REGELTECHNIK 73760 Ostfildern 57562 Herdorf Weismüllerstr. 3 Web: www.schopf-mining.com Web: www.thomas.magnete.com 60314 Frankfurt www.samson.de

SIEMAG TECBERG GmbH ThyssenKrupp Resource Technologies Sandvik Mining & Construction Kalteiche-Ring 28-32 GmbH Central Europe GmbH 35708 Haiger Materials Handling Hafenstr. 280 Web: www.siemag-tecberg.com Ernst-Heckel-Str. 1 45356 Essen 66386 St Ingbert-Rohrbach Web: www.sandvik.com Web: www.thyssenkrupp-resource- technologies.com Siemens AG Schuhstr. 60 91052 Erlangen Sandvik Mining & Construction Web: www.siemens.com/mining Crushing Technology GmbH Kölner Str. 94 ThyssenKrupp Resource Technologies 51702 Bergneustadt GmbH Web: www.sandvik.com Mineral Processing Schleebergstr. 12 STEINERT Elektromagnetbau GmbH 59320 Ennigerloh Widdersdorfer Str. 329 - 331 Web: www.thyssenkrupp-resource- 50933 Köln technologies.com SCHADE Lagertechnik GmbH Web: www.steinert.de Dorstener Str. 360 44653 Herne Web: www.schade-lagertechnik.de

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VDMA URACA GmbH & Co KG Sirchinger Str. 15 WILO SE ThyssenKrupp Resource Technologies 72574 Bad Urach Nortkirchenstr. 100 GmbH Web: www.uraca.de 44263 Dortmund Mining Web: www.wib.com ThyssenKrupp Allee 1 45143 Essen Web: www.thyssenkrupp-resource- technologies.com Vattenfall Europe Mining AG Mining Consulting Wirtgen GmbH Vom-Stein-Str. 39 Reinhard-Wirtgen-Str. 2 03050 Cottbus 53578 Windhagen Web: www.vattenfall.de Web: www.wirtgen.de

TLT-Turbo GmbH Gleiwitzstr. 7 Voith Turbo GmbH & Co KG 66482 Zweibrücken Voith-Str. 1 Web: www.tlt-turbo.com 74564 Crailsheim WOLFGANG PREINFALK GMBH Web: www.voith.com Im Oberen Werk 4 66386 St. Ingbert Web: www.preinfalk.de

TML Technik GmbH WELLER Pumpen GmbH Daimlerstr. 14 - 16 Westicker Str. 44 - 46 40789 Monheim 59174 Kamen Web: www.tml-technik.com Web: www.weller-pumpen.de

ADVERTISING INDEX ABB ...... VDMA 41 Kamat Pumpen GmbH & Co KG ...... VDMA 13

Andritz Ritz GmbH ...... VDMA 51 Liebherr ...... VDMA 9

Bartec Sicherheits-Schaltanlagen GmbH...... VDMA 31 Loesche ...... VDMA 33

Betek ...... VDMA 29 marco...... VDMA 16

Beumer Group ...... VDMA 5 RWE Power Int’l ...... VDMA 11

Deilmann-Haniel Mining Systems GmbH ...... VDMA 23 Schopf Maschinenbau GmbH...... VDMA 21

Eickhoff ...... VDMA 15, 17 Siemag Tecberg ...... VDMA IFC

Erlau AG...... VDMA 36 Steinert ...... VDMA 35

Feluwa Pumpen GmbH...... VDMA 27 Tognum AG (MTU) ...... VDMA 39

Hauhinco Maschinenfabrik ...... VDMA 19 Voith ...... VDMA 43, 45

Hazemag ...... VDMA 37, IBC Wirtgen ...... VDMA 7

Hermann Paus Maschinenfabrik GmbH ...... VDMA 3 Wolfgang PrienFalk GmbH...... VDMA BC

ITI GmbH ...... VDMA 47

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