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Miners Supply the Natural Resources for a Growing Economy India and the USA continue to trade places as the No. 2 coal producer behind China. While China produced an incredible 3.5 billion tonnes of coal in 2017, the USA saw its total annual output grow to 715 million tonnes, an 8% recovery. At the same time, India’s production decreased to 639 million tonnes. How long the USA holds the No. 2 position will be largely decided by demand and continuing efforts of India to build output. In addition to coal, India is the fourth largest iron ore producer and is among the top 10 producers of various minerals such as chromite and zinc. Ironically, the country has been unable to satisfy demand with domestic Steve Fiscor/Editor-in-Chief resources. Three years ago India became a net importer of iron ore. India’s aluminum industry is in a similar position. Despite having some of the largest known bauxite reserves, India imports bauxite to produce aluminum. No doubt as its population steadily climbs toward 1.3 billion people and global demand for resources grows, India will need to find a way to better leverage its resources. It will need to invest in the equipment and technology to open new, more efficient mines, and to retool existing mines and the supporting infrastructure. Realizing its bad bargaining position as an import-dependent economy, India has even started to explore and develop projects in other countries. Obviously, mining and mineral processing is becoming a very serious business for India. Each year, Mining Media International produces several regional editions by repurposing technical information from Engineering & Mining Journal (E&MJ) and Coal Age, the two leading mining trade journals. E&MJ covers the metal mining and mineral processing business worldwide. It has about 20,000 readers who are mostly mine engineers, metallurgists and geologists. Coal Age covers the U.S. coal mining and processing sector, which only recently became the second largest coal producer behind China. It has more than 16,000 readers who are mostly mine engineers, mine managers and prep plant managers. For this 2018 edition of E&MJ/Coal Age India, several items were selected that previously appeared in E&MJ and Coal Age or were submitted specifically for it. This edition also includes a special section, the Best of Germany, which was produced in cooperation with the German Engineering Federation (VDMA). Many of the mines in Germany have closed, but the region still makes some of the best mining equipment, and it exports its expertise to mining regions around the world. In this special section, VDMA members talk about how they are improving safety and technology. It also includes a directory of those companies as a reference tool. The best way for India to quickly grow its resource production capacity is through the use of engineering and better equipment and technology. For more than a century now, these mining trade journals have offered mining and processing professionals ideas on how to accomplish these goals. Enjoy this edition of E&MJ/Coal Age India.

Sincerely,

Steve Fiscor Publisher & Editor, E&MJ and Coal Age [email protected]

Mining Media International Inc www.e-mj.com 11655 Central Parkway, Suite 306 www.coalage.com Jacksonville, Florida 32224 U.S.A. Phone: +1.904.721.2925 • Fax: +1.904.721.2930 2018 www.mining-media.com Editorial Publisher & Editor-In-Chief – Steve Fiscor, [email protected] Associate Editor – Jennifer Jensen, [email protected] Technical Writer – Jesse Morton, [email protected] Table of Contents Contributing Editor – Russ Carter, [email protected] Latin American Editor – Oscar Martinez, [email protected] India Mining Report ...... 2 Graphic Designer – Tad Seabrook, [email protected]

Sales Indian Coal Industry – An Overview ...... 6 Eastern U.S. & Canada – Victor Matteucci, [email protected] Western U.S., Canada & Australia – Frank Strazzulla, [email protected] Scandinavia, UK & European – Colm Barry, [email protected] Best of Germany 2018 ...... 9 Germany – Gerd Strasmann, [email protected] Production Manager – Dan Fitts, [email protected]

INDIA 2018 ( India Mining Report

An Overview of Mining in India One step forward, two steps back By Ajoy K Das

tion of private investment — domestic and foreign direct investment (FDI). It was reckoned private investments would plug the huge gap as exploration projects solely through government public expenditure had been sorely inadequate and a new policy would woo global resource majors to invest in such projects in the country. A reality check: The policy framework for years allowed 100% foreign direct investments in mining and mineral projects in the country barring atomic minerals. Optimism over a new policy attracting fresh foreign investments into exploration is tempered by recent data. In 2017-2018 FDI in the Indian mining industry fell to lowest level in recent years The Indian Government has set a ambitious goal of 300 million mt/y of iron ore. at a mere $36 million down from a peak of $659 million touched in 2014-2015. “Time is short. If you have to achieve Data on Index of Industrial Production The previous low of FDI in mining industry much, you’ve got to run,” said Peter Munk, (IIP) released by the government in October was in 2013-2014 when it hit a low of founder and former chairman, Barrick 2018, showed that industrial production $13 million. Gold. The Indian mining industry promised growth in August 2018 was at a three- As a share of total FDI inflow into the to achieve much. But it is definitely not month low at 4.3% with the mining sector country, the mining sector accounted for running and time is running out too. proving to be the primary drag, recording just 0.8% of the total FDI during 2017- Gaps between enunciation of lofty a negative growth of 0.4% in August com- 2018 against a share of 2.06% in 2014- potential and policy procrastinations, pared to 9.3% same month a year ago. 2015, and an indication of unattractive- delays and actual performance of the sec- The mining industry has the second highest ness of the domestic mining industry to tor, including investments on the ground weightage in IIP at 14.6%. overseas investors. have become glaring. Underlining ‘under exploration’ the The adage sometime attributed to Thomas The Exploration Logjam government policy think-tank reports that Edison, “Vision without implementation is The vision: the government outlining it, Indian exploration expenditure averaged just hallucination,” could well describe the stated its intention of publishing a new around $17/km2 against $5,850/km2 in Indian mining sector in recent times. national mineral policy which inter alia Australia and $5,310/km2 in Canada. A grandiosely titled report, “Unlocking laid down the road map of doubling min- In terms of global share of exploration potential of Indian Mineral Sector,” of the eral exploration every year with participa- expenditure, Canada was ranked in first in federal Ministry of Mines laid out a vision the pecking order with 14%, Australia at of adding investments of $250 billion and Indian Production and 13%, China 6% and Europe 5% and India lagging at 0.2%. 6%-7% of GDP with collateral benefit of Imports in Value creating 15 million additional direct and Information from the Indian Bureau of indirect employment by 2025. Value of Value of Mines (IBM), the government regula- The vision statement was in 2011. Year major minerals minerals tory body, of India’s entire Obvious produced imported Seven years down the line, the mining Geological Potential (OGP), area of industry has not exactly inched towards 2013-2014 499.06 3,364.51 570,000 km2, identified by state-run, such a goal. 2014-2015 444.05 3,364.51 Geological Survey of India (GSI), only In fact contribution of the Indian mining 10% has been explored and mining oper- 2015-2016 411.93 3,668.38 sector to Gross Domestic Product (GDP) has ational in 1.5% to 2% of this area. been on a downward trend from 3.2% in 2016-2017 474.31 3,458.11 Years of under-exploration was begin- 2012 to 2.2% in 2018, according to data 2017-2018 607.30 3,500.00 ning to tell on mineral industries with sourced from the government’s Ministry of • All ﬁgures in billion Rupees imports rising despite abundant mineral Statistics and Program Implementation. • Source; Ministry of Mines reserves. The compounded annual aver-

)INDIA 2018 India Mining Report

age growth rate (CAGR) of Indian mineral Policy Procrastination Iron Ore imports between FY 2012 and FY 2018 Being caught between the rock and hard The fourth largest producer of iron ore was 6.1% which in value terms increased place are inherent risks for Indian miners. in the world with 8% of world’s deposit from $15.81 billion in FY 2012 to $28.14 About 288 mineral operational blocks has turned from a net exporter of the billion in FY 2018. were slated to be up for auction in 2020 steel-making raw material to a net import- Simply put, trade date revealed that but neither the federal government nor er, indicating the impediments of increas- during 2016-2017, for every 1 ton of state governments, responsible for holding ing production from domestic mines. And domestic mineral production, downstream the auctions were geared up to tackle an this with the Indian government setting an mineral processing industry imported impending possibility wherein these mines ambitious target of domestic steel produc- about 10 tons of mineral resources. would be forced to shut operations unless tion of 300 million mt/y from 90 million the mining leases were allotted to new mt/y at present. Policy Quirks investors for continued production. Indian iron ore production during So why are private investors, domestic The legacy issue being that these 2017-2018 has been pegged at 210 mil- and foreign, keeping a distance from vast mines had been allocated under the lion mt, but the moot point was that growth unexplored mineral resources. Blame it on erstwhile dispensation of preferential allot- in domestic production has been ranging intended or unintended policy quirks. Ever ment. But jolted by Supreme Court verdict, between 2%-5% over the past five years. since, 2015 auction route was made man- a 2015 auction route was made manda- During April-August 2018, Indian iron datory for allocation of a mineral block tory for allocation of all mineral resource ore imports surged 190% to 6.34 million for development following Supreme Court blocks. So once the existing mining lease mt and forecast to cross the 12 million mt verdict, private investors found the playing of 288 assets lapsed in 2020, the gov- mark during full fiscal. In contrast iron ore field rather uneven. ernments would either have to complete exports from the country fell 40% during Non-exclusive reconnaissance per- auction and grant new mining leases to this period at 4 million mt. mits (NREPs) granted by the government successful bidders or close mines where “Imports would not have been a neces- for exploration projects found few tak- leases lapsed. sity had iron ore been available in the ers. Simply because a NREP holder was Alongside, the federal Ministry of domestic market, at competitive prices. expected to undertake exploration proj- Mines has directed all state governments That is why we are asking domestic mining ects, invest high risk capital but on success- to conduct fresh exploration of all existing companies to adjust the price of iron ore fully establishing a economically viable mining leasehold areas up to level of G2. in line with quality of ore. At the same mineral blocks, had to hand over the asset But the state government maintain that con- time, the problem is that even if iron ore back to the provincial government for sub- ducting such levels of exploration through is getting mined, there are transportation sequent auction. few government run exploration agencies issues and costs of sourcing from mines A NREP holder did not have any long within stipulated timelines was a challenge and comparative logistical costs of imports term interest in the project apart from and the country facing possible risks in are more competitive,” Seshagiri Rao, reimbursements on cost plus basis not no mineral production post-2020. joint managing director, of private steel stake in ultimate development of the asset The Federation of Indian Chamber producer, JSW Limited said. established by it. of Commerce & Industry (FICCI) in a However, the present Gordion’s Knot The government has now promised to paper titled: “Indian Mining, A Different of the Indian mining sector is how does ensure a level playing field by amending Perspective” suggested the following to the government, both state and federal, the legislative framework under which a increase the financial attractiveness of get iron ore mines in coastal state of Goa NREP holder would be granted the first the sector: back into operation. right-to-refusal at the auction of any miner- • Tax holidays for exploration and mineral Goa mines accounting for an estimated al block successfully explored by it. production in initial years of the project; 50 million mt of iron ore, albeit low grade • Enabling full transferability of mineral for export markets, have remained closed Taxes are Taxing concessions acquired at the auction to since March 2018. This after the Supreme The Indian mining industry is the highest another entity at a pre-determined fees Court ruled in February 2018, that renew- taxed in the world. According to the to ensure that no concession is disrupt- al of lease holds of some 88 mines in Goa Federation of Indian Mineral Industries ed in case of consolidation in the industry were done not through the now mandatory (FIMI) the representative body of miners, through mergers and acquisitions; auction route and directed closure of all the effective rate of tax in case of mines • A single rate of tax subsuming all taxes pay- these mines until the government cancelled allocated earlier through the preferential able at every stage of mining operations; the renewed mining leases of existing allotment dispensation stood at 64% while • Adoption of the Canadian TSX enabling holders and conducted auction to allot in case of mines allocated through auction venture capitalists and private com- mining leases afresh. the effect rate amounted to 60%. The panies to raise funds dedicated to min- The seemingly intractable imbroglio aggregate incidence of tax comprise mineral exploration; before the governments entailed either ers’ contributions to District Mineral Fund • Aligning the effective tax rate payable amend related legislations that will grant (DMF) and National Mineral Exploration by a mining company be benchmarked legality to the last non-auction lease renew- Trust (NMET) apart from indirect tax rates to the global average; and als of Goa mines but then at the very under Goods and Service Tax (GST) as • Replacing flat rate of 15% royalty on least dilute the provisions of the law that applicable, making total levy one of the iron ore with a graded rate depending entailed that all mineral resources should highest in the world. on ferrous content of the ore mined. be allocated through competitive bidding.

INDIA 2018 * India Mining Report

As things stood now, the government being bauxite reserves in Niyamgiri hills in a limbo. Reason? Roadblocks to open- promise of resolving legalities and get- in eastern Indian province of Odisha, ing up a new bauxite mine. ting Goa mines operational by December earmarked for Vedanta’s smelters in the For over decades, indigenous pop- 2018 is unlikely to be met. Meanwhile the region but caught in political crossfire ulation at the proposed bauxite mine mines face uncertain closure, including between pro-development and environ- located in Andhra Pradesh, backed by large mines of Vedanta, and impacting a mental activists with the Supreme Court various opposition political parties and net loss of an estimated 2% of the resource finally stepping in to ban mining in the even extreme-Left wing armed militants major’s consolidate annual revenues. region leaving Vedanta’s smelters in lurch have been opposing development of the Largest state-run iron ore producer, with no raw material. bauxite reserves. NMDC Limited has firmed up investments Vedanta’s 1 million mt/y bauxite refin- to the tune of $902 million over the next ery at Lanjigarh Odisha and adjunct Copper two years as part of its plans to increase aluminum smelter starved of raw material Close to 30% of India’s domestic demand production to 67 million mt/y against pres- since bauxite mining at Niyamgiri hills for refined copper was currently being ent production levels of 37 million mt/y. was banned might see light of day with met through imports, given the inherent But the country’s largest iron ore pro- the Odisha government moving rapid- limitations in developing greenfield copper ducer was unlikely to significantly increase ly to auction new bauxite mining lease deposits across the country. volumes of raw materials for merchant and offering long term bauxite linkages Indian imports of refined copper was sales to other steel producers considering based on competitive bidding for supplies 250,000 mt during 2017-2018, up from that a large part of its projected incre- from existing mines controlled by Odisha around 65,000 mt during 2010-2011 mental production would go in for cap- Mining Corporation, the mining arm of the with domestic demand for refined copper tive consumption for NMDC’s 3-million-mt local government. increasing at average 6%-7% per annum. Greenfield steel mill located in central Early this year the local government Indian refined copper production province of Chhattisgarh and scheduled to had announced that 10 bauxite mining during 2017-2018 was estimated at go into commercial production next fiscal. leases would be put up for auction but little 843,000 mt compared to 798,000 mt NMDC, one of the few Indian govern- has been heard since then. With bidding in the previous fiscal with consumption ment owned company to have successfully for these assets uncertain, Vedanta would during 2017-2018 pegged at around taken controlling stake in an overseas therefore in all likelihood have to depend 660,000 mt. company, is working to make its ASX listed on bidding for supply linkages with OMC Indian refined copper prices have Legacy Iron ore Limited, headquartered to ensure raw material security for its baux- surged between 9%-15% since May 2018 in Perth to spearhead its foray into base ite refinery. when Sterlite Industries copper smelter metals and gold and take up exploration Meanwhile even as it awaits for in southern state of Kerala was closed across Australia. domestic raw material resources, the Anil down after police opened fire and killing Legacy had made applications to gov- Agarwal controlled resource major has 13 people among a mass of protestors ernment of Western Australia seeking decided to ramp up capacity of it alumina against pollution created by the smelter three exploration tenements for tungsten to refinery to 6 million mt/y based on import- in the region. Sterlite which produced add to its existing exploration across 19 ed bauxite for which the company has 400,000 mt of refined copper based on other tenements Down Under. reportedly tied up with Emirates Global imported copper ore was subsidiary of Aluminum for global sourcing of the raw London headquartered Vedanta Resources Bauxite material. Post expansion, the Odisha alu- and having about 33% share of domestic Ironically, even with proven bauxite minum complex would required an estimat- copper market. reserves of 3.5 billion mt, ranked fifth ed 18 million ton of bauxite per annum. Hindustan Copper Ltd., sole integrated largest in the world, no mine has been Nalco, the state-run aluminum com- copper producer, with its own captive developed in the country over the last pany, has lined up a capital expenditure of mines, has firmed up a corpus of $764 several decades. And its long term impact $164 million to part fund its plans to add a million to expand its existing copper is coming home to roost with domestic 1 million mt/y fifth stream alumina refinery, mines aiming to increase production of bauxite production falling over the last two development of coal blocks for its captive copper ore to 20 million mt/y over the consecutive year. thermal power plant after having achieved next five years from current level of 12.4 During 2017-2018 bauxite produc- 100% capacity utilization of its existing million mt/y. tion was estimated at 20.63 million mt, alumina plant during the current year. The company reported that it has down 16% and the downtrend was clear- But close to exhausting its captive completed almost 50% of development ly gaining momentum since production bauxite operations at Panchpatmali hills, work at its Malanjkhad mines in central during 2016-2017 was 12% lower than Nalco has commenced work on opening state of Madhya Pradesh and expending previous fiscal. up a new bauxite deposit in proximity to to commence production next fiscal which Most of the bauxite reserves in the its existing mining operations. The new would give the company an incremental country were located in predominantly mining face would just about enable the 500,000 mt/y of copper ore. forested areas across eastern India with aluminum producer to maintain its require- HCL was also working on brownfield predominant population of indigenous ment of more than 6.8 million mt/y. expansion of is Ghatsila mines in eastern people leading to classic conflict between However, Nalco’s plans to construct India which the company in a statement development and protection of local cul- a new aluminum complex in neighboring reported held a potential of adding 1.5 ture and people. The biggest example state of Andhra Pradesh has been caught million mt/y of copper ore production.

+INDIA 2018

Indian Coal Industry – An Overview

India Plans to Open Many New Mines to Meet Domestic Demand The world’s third largest coal producer remains on track to meet future needs By Rajesh Nath and Ajmal Fawad

Future Projection of Production from Projects (millions of mt)

Projects 2014-2015 2015-2016 2016-2017 2017-2018 2018-2019 2019-2020 Existing + Completed 190.57 190.57 185.03 177.24 177.64 164.96 Ongoing 315.56 354.93 399.76 437.56 502.65 561.48 Future 000.07 002.55 012.81 045.89 093.40 181.66 Total 506.21 548.05 597.60 660.68 773.70 908.09 Rajesh Nath — Ajmal Fawad — Managing Director, Business Analyst, Production of Coal and its Share by Type of Mining VDMA India VDMA India Type of mining Open-cast Underground Total Production Indian coal production grew to 663 mil- 2015- Production 592.82 46.41 639.23 lion metric tons (mt) during FY2016-2017 2016 Share (%) 092.7% -7.26% 100% from 639 million mt achieved during the 2016- Production 618.44 44.35 662.79 previous year, a compound annual growth rate of 3.7%. Most (84%) of the coal pro- 2017 Share (%) 093.3% -6.69% 100% duction in the country comes from Coal Growth (%) 04.32% -4.44% 3.69% India Ltd (CIL). The company has eight subsidiaries: Bharat Coking Coal Ltd., Central coal production by FY2020. To meet this Pradesh and Government of India. The Coalfields Ltd., Eastern Coalfields Ltd., target the government has set a goal of 1 Singareni coal reserves stretch across Western Coalfields Ltd., South Eastern billion mt coal production for CIL by FY2020 350 km of the Pranahita, Godavari Coalfields Ltd., Northern Coalfields Ltd., and the company developed a roadmap in Valley of Andhra Pradesh with a proven Mahanadi Coalfields Ltd., and Central 2015 for meeting the challenge. The goals geological reserves aggregating to 9.7 Mine Planning & Design Institute Ltd. for coal production were 97% achieved by billion mt. SCCL is currently operating 17 To meet the coal demand and minimize CIL in 2015-2016 and 99% achieved by opencast and 30 underground mines in coal imports, the government has put coal Singareni Collieries Co. Ltd. (SCCL). Andhra Pradesh. production in the country on a fast track and SCCL is a coal-mining company jointly SCCL produced around 60 million mt has set a target of 1.5 billion mt of domestic owned by the Government of Andhra of coal in FY 2016. To achieve the target of 100 million mt by 2020, SCCL is planning to start 20 to 25 new mines in the near future. In FY2016-2017, India imported of 191 million mt compared to 203 million mt registered in 2015-2016. It is observed that the share of coking coal in the total quantity was 23%. With 48% share, Indonesia has remained the leading supplier followed by Australia (24%) and South Africa (18%). These three countries together accounted for 90% of the total import to India in 2016-2017. The demand for power, steel and con- crete in a developing country is closely related to its economic growth. Global as well as Indian steel and cement production The Indian Government has set a goal of 1 billion mt/y of coal by 2020 for Coal India are dependent on coal. That is why distribu- Ltd., its largest coal producer. tion of coal of adequate quantity and qual-

-INDIA 2018 Indian Coal Industry – An Overview

of a capacity of 94 million mt/y and six projects are expected to produce 13 Sectoral Off-take of Raw Coal (mt) are coking washeries of capacity of 18.6 million mt/y. Three washeries, each with Cos. Achieved (2016-2017) million mt/y. 1 million mt/y capacity are in operation Power Steel Cement Others Total CIL and Bharat Coking Coal Ltd have on build-own-operate basis--Ramagundam, agreed to set up 12 new coking coal wash- Mandamarri and Manuguru. Three more CIL 442 05 4 096 547 eries by 2019-2020. CIL is also working coal washeries with 10 million mt/y are in SCCL 052 00 3 004 059 on acquiring coking coal assets, increas- pipeline: JVR (4 million mt), RG-II (3 million Others 033 07 0 004 044 ing domestic production and minimizing mt/y) and Khairagura (3 million mt/y). Total 527 13 6 104 651 diversion of coking coal to thermal plants. Coking coal imports is expected to reduce Indian Coal Geology Off Take of Coal in 2016-2017 (mt) by 20%-25% due to these measures. and Reserves SCCL has a total of 26 projects, Coal is the most abundant fossil fuel Sectors 2016-2017 22 mining projects and four non-mining resource in the country. India, currently, Metallurgical Uses 013 projects. Out of these 22 projects, eight stands fifth in terms of total world coal Power (Utility) 471 projects are on schedule and 14 projects resources, whereas it is third from the point Power (Captive) 056 have been postponed. of view of identified reserves. The Adriyala Shaft Project has been The coal occurrences in India are main- Cement 006 approved by the Government of India. ly distributed along the river vallies i.e. Sponge Iron 006 With a capital outlay of EUR168.27 mil- Damodar Valley, Sone-Mahanadi Valley, Others 099 lion, it has a rated capacity 2.8 million Pench-Kanhan Valley, Wardha-Godavari Total 651 mt/y. Production from longwall technolo- Valley etc. There are 69 major coalfields gy in Adriyala Shaft Project commenced located in the peninsular India besides, ity to power sector followed by steel and during October 15, 2014. 17 located in the north-eastern region. cement manufacturing sector is considered Other new coal projects in India include: The bulk of the coal reserves are confined a priority for the Indian coal industry. • Shree Cement’s coal-based CPP project to the south-eastern quadrant of the coun- at Baloda Bazar, Raipur, Chhattisgarh; try in West Bengal, Jharkand, Orissa, The Coal Project Pipeline • Chettinad Cement’s expansion of its coal- Chattisgarh & Madhya Pradesh. CIL has 121 major ongoing coal projects based CPP unit in Sangem. K, Gulbarga; The coal reserves of India have been under implementation, which are expected • GPC’s Khadsaliya-I lignite mining unit estimated by the Geological Survey of India contribute an additional 561 million mt in at Khadsaliya, Lakhanka & Thalsar; at more than 315 billion mt–up to the depth FY 2020. Among the large projects are • Paras Power & Coal Beneficiation’s coal of 1,200 m, as of the beginning of 2017. the Kusmunda project (50 million mt) and washery in Bilaspur, Chhattisgarh; and Of the 308 billion mt of coal reserves, Gevra expansion project (70 million mt). • MNH Shakti’s coal mining project in prime coking coal is 5.3 billion mt, medi- Further 129 new projects, with a target- Sambalpur, Orissa. um and semi-soft coking coals are 27.5 ed capacity of 494 million mt have been SCCL is planning to open 10 new proj- billion mt and 1.70 billion mt and non-cok- identified, of which project reports for ects in the beginning of next financial year, ing coals reserves would amount to 280.6 101 projects have been formulated. Out including Bellampally OC -2, Kasipeta billion mt. Most of these resources occur of these 101 projects, 30 projects having -2, Shanthi Khani Continuous miner, in Gondwanas and the balance in the ultimate capacity of 330 million mt have Koyagudem OC-2 Pit-1, J.V.R.O.C.2, Tertiary formations. been approved. Out of the 30 approved Manuguru OCP, K.T.K. OC-2, P.V.K. Currently, lignite reserves in the country projects, 18 are expected to contribute Continuous miner and KKOC. These new have been estimated at around 44.7 bil- 117 million mt in FY 2017. South Eastern Coalfields Ltd., a sub- The Production of Coal Over the Years (millions of mt) sidiary of CIL, would be setting up country’s largest coal washery with a capacity Cos. 2013-2014 2014-2015 2015-2016 2016-2017 of 25 million mt/y in Korba district of ECL 36.05 40.00 40.21 40.52 Chhattisgarh. The project would be known BCCL 32.61 34.51 35.86 37.04 as Kusmunda coal washery. It would be an CCL 50.02 55.65 61.32 67.05 integral part of Kusmunda open-cast coal mine, one of the three mines operated by NCL 68.64 72.48 80.22 84.1 the SECL in Korba coalfields having an esti- WCL 39.73 41.15 44.82 45.63 mated reserve of more than 10 billion mt. SECL 124.26 128.28 137.93 145.33 CIL currently operates 15 washeries; three non-coking coal washeries with feed- MCL 110.44 121.38 137.90 139.21 stock capacity of 13.5 million mt/y and NEC 0.66 0.78 0.487 0.6 12 coking coal washeries with feedstock CIL-Total 462.41 494.23 538.75 559.46 capacity of 23.3 million mt/y. The com- SCCL 50.47 52.54 60.38 59.53 pany had planned to set up 15 new coal washeries in next three years. Of the 15 Others* 15.19 24.48 40.10 43.8 new coal washeries, nine are non-coking All India 565.76 609.18 639.23 662.79

INDIA 2018 . Indian Coal Industry – An Overview

lion mt, most of which, occur in Tamilnadu. Other states where lignite deposits have Coal Reserves in India as on January 4, 2017 (millions of mt) been located are Rajasthan, Gujarat, Type of Coal Proved Indicated Inferred Total Kerala, Jammu and Kashmir and Union Prime Coking 004,614.0 000,699.0 0 005,313.0 Territory of Pondicherry. Medium Coking 013,501.0 012,133.0 001,879.0 027,513.0 Coal Resources Semi Coking 000,519.0 000,995.0 000,193.0 001,708.0 India ranks second amongst the coal pro- Non Coking 124,423.0 125,485.0 030,706.0 280,615.0 ducing countries of the world in terms of Tertiary Coal 000,594.0 000,099.0 000,895.0 001,588.0 annual coal production. Of the 315 billion mt of Indian coal resources up to a depth Total 143,058.0 139,311.0 032,779.0 315,149.0 of 1,200 m, about 143 billion mt are con- Lignite 006,540.7 026,014.4 012,143.0 044,698.1 sidered proven. This constitutes about 9% of the world proved coal resources. (as much as 40 in number) pose great 1.0% in 2012. With current growth rate, When India gained its independence challenge to mining operations. Presence India will require 160 million mt of iron in 1947, the coal production was nearly of a large number of thick seams, though ore import (10% of global seaborne), 300 30 million mt/y and the coal mining oper- a blessing for open cast mining, is again million mt of thermal coal import (25% of ations were primarily private. By 1972, a major underground mining problem. global seaborne trade) and 70 million production increased to 72 million mt/y. Reserves in steeply inclined seams are, mt of met coal import (20% of global The entire Indian coal industry was nation- however, only marginal. seaborne) in 2025. This will create uncer- alized during FY1972-1973 and massive Geological inconsistencies like faults, tainty due to high dependence on imports, investments were made by the Government folds, washouts etc, common in most of with possible supply shortages depending of India to the basic infrastructure sector. the coalfields, tend to reduce the mining on global situation. Mining depths in Indian coalfields are potential of deposits. Intrusions such as Mining involves digging of soil and quite shallow, barring a few mines in dykes and sills often lead to operational going down to hundreds (sometimes thou- Jharia and Raniganj coalfields. Major problems and quality deterioration. sands) of feet deep below the ground share of coal resources lies at a depth Nearly all Indian Coal seams are level. The annual growth in the mining of less than 300 m. About 87% of coal prone to spontaneous heating. The incu- sector in India has been varying from resources lie within the depth range of bation period varies widely from two to 3% to 8%. Any effort to have abnormal/ 600 m. However, in most of the coalfields, 12 months. However, compared to gas unusual growth may bring environmental exploration work beyond 600 m depth emission in other parts of the world, the issues, besides causing safety hazards to has not been completed. It is expected that coal seams in India are less gassy. Indian men and material engaged in mines. the resource figures will improve consider- coals in general have a high ash content The purpose of this factual statement ably, with increased depth of exploration. when compared to the bituminous coals is to highlight that there is a limit to Deposit characteristics vary widely found in the U.S. and Australia. Despite expect growth in the mining sector. The from coalfield to coalfield. In some areas this, Indian coals in general have a low projections being worked to bring the like Jharia and Raniganj coalfields, high sulphur content and low chlorine content. country’s coal production level to 1,000 mt concentration of super imposed seams The exploration database, created so by 2018/2019 mean a required annual far, is adequate for preparation of a long- growth rate of 18% has to be achieved. Lot Import of Coal to India term perspective plan for mining of coal is to be done to achieve this very high rate. in 2016-2017 in the country. Coal deposits in India are Going by the country’s projection for the confined to eastern, southern and central growth rate of 8% in GDP, it would be a Type of Coal Quantity (mt) parts of the country, consisting of 27 good achievement if the coal sector grows Coking 041.6 major coalfields. The shares of overall coal annually by 12% in a consistent manner. Non-Coking 149.3 resources of the different Indian states are: This can be done by opening many large Chhattisgarh 18% coal projects and make them operational in Total 191.0 Jharkhand 26% a shortest possible time. The aim should be Madhya Pradesh 0 9% to make the country self sufficient in coal. Source Country-wise Import of Telangana 0 7% Opening the coal sector fully for commercial Coal to India During 2016-17 Odisha 25% mining, to private investors to compete with Country Quantity (mt) % Share West Bengal 10% CIL, is the key and answer for the country to Indonesia 091 048 The remaining balance of coal resourc- accomplish self sufficiency in coal. es is distributed over Arunachal Pradesh, The apex court’s decision should act as Australia 047 024 Assam, Meghalaya and Nagaland. an opportunity for the government to have South Africa 034 018 a full review of the coal sector policy and USA 005 003 Conclusion come up with appropriate coal reforms. India’s mining sector has grown at a Therefore, it is now the time to think, address Russia 004 002 slower rate compared to GDP, resulting in and find the right way forward to resolve Others 010 005 decrease in contribution of mining sector the challenges that have emerged from the Total 204 100 to India’s GDP from 1.3% in 2002 to just cancellation of allotment of coal blocks.

/INDIA 2018 Mining Equipment BEST OF GERMANY and Technology 2018

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

In cooperation with VDMA

Mining Foreword:

The latest fi gures show us that our industry has obviously come out of the downturn, with incoming orders boasting a two-digit growth rate. This will be the year of renewal, which leaves behind the problems of low demand and low prices. But the challenges are manifold: not only fragmented markets, but also the digitalization. The Europe 28-countries remain the largest region. This region is followed by the USA, China and Russia as the biggest single markets. The near-middle east is actually developing well while Africa — last year a booming region —and Latin America show weak tendencies. In this particular context — USA, China, Russia — there are concerns about the future of free trade because of tendencies to close the markets for different reasons. In principle, we believe in a free market on the basis of reciprocity and mutual interest. One should keep in mind that closing off national markets reduces the competitiveness because of the exclusion of the technical advancement. The driver for future technical advancement is digitalization. Ideas, such as Germany’s “Industrie 4.0,” are transforming the mining industry worldwide. German manufacturers are working on this area to offer more information, better decisions and higher effi ciency of operations. VDMA Mining supports manufacturers of mining equipment in “going digital.” VDMA provides a long list of documents, practical guides and links to facilitate the ongoing development of digital services. At present, they work on connectivity and standard interfaces as well as on IT-security or the ownership of data. VDMA Mining member companies want to give the best possible support to the global mining industry. We hope that you fi nd value in this publication, wherever you are in the world.

Glückauf!

Dr. Michael Schulte Strathaus President VDMA Mining

Table of Contents:

A Special Supplement to: Your Contacts in the Mining Equipment Association ...... 11 Engineering & Mining Journal (E&MJ) and Coal Age VDMA Mining Prepares for the Future ...... 12 Produced by: Mining Media International Inc. Looking to the Future Continuously ...... 14 11655 Central Parkway, Suite 306 Jacksonville, FL, 32224, USA Tel: +1-904-721-2925 Smart Underground Mining ...... 18 Fax: +1-904-721-2930 www.mining-media.com Technology Improves Open-pit Mining ...... 24 Copyright 2018 Mining Media Int’l, Inc.

Sponsor: Moving More Material More Effectively ...... 30 German Engineering Federation Verband Deutscher Maschinen und Intelligent Processing...... 32 Anlagenbau (VDMA) e.V. Lyoner Str. 18, D-60528 Frankfurt/Main Equipment and Technology...... 34 Tel: +49-6966-031262 Fax: +49-6966-032262 www.vdma.org Vendor Matrix and Buyers Guide ...... 36

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

Published by Mining Media International in cooperation with VDMA Mining EQUIPO | INGENIERÍA | TECNOLOGÍA

VDMA 10 VDMA MINING SUPPLEMENT • 2018 Your Contacts in the 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]

Christoph Danner Jörn Lehmann Manager Markets Manager Standardization Latin America Phone: + 49 69 6603-1134 Phone: + 49 69 6603-1254 Fax: + 49 69 6603-2134 Fax: + 49 69 6603-2254 Email: [email protected] Email: [email protected]

Alexandra Landgraf Yvonne Golle Assistance Assistance Phone: + 49 69 6603-1577 Phone: + 49 69 6603-1577 Fax: + 49 69 6603-2577 Fax: + 49 69 6603-2577 Email: [email protected] Email: [email protected]

Rajesh Nath Thomas Junqueira Chief Representative Ayres Ulbrich VDMA Representative Ofﬁ ce India Chief Representative Phone: + 91 33 40602364 VDMA Representative Ofﬁ ce Brazil Fax: +91 33 23 21 70 73 Phone: + 55 11 430580-42/-43 Email: [email protected] Fax: +55 11 3078 4335 Email: [email protected]

Sven Flasshoff Claudia Barkowsky Chief Representative Chief Representative VDMA Representative Offi ce Russia VDMA Representative Offi ce China - Beijing Phone: + 7 499 41803-71 Phone: +86 10 87 73 02 12-8 08 Fax: + 7 499 41803-72 Fax: +86 10 87 73 02 09 Email: sven.fl [email protected] Email: [email protected]

2018 • VDMA MINING SUPPLEMENT VDMA 11 VDMA Mining Prepares for the Future Smart mining concepts lead the way toward safer, more-efﬁcient operations

Markets improved appreciably for the mining sector throughout to work through the downturn without sacrificing engineering and 2017. Demand for metals and coal increased and prices began to design staff. Many of the VDMA Mining members used that down- stabilize. Miners who had taken austere measures began to invest time to develop or further improve Smart Mining techniques that in operations again. At first, many were skeptical, but now this up- will automate mining and mineral processing systems. Combining turn looks as though it may be sustainable for a few years at least, the power of the Internet of Things, or Industry 4.0 as the Germans maybe more. refer to it, with real-time data analysis, they have developed some As the recovery in mining markets begins in earnest, the min- great concepts for moving miners out of harm’s way and improving ing segment of the German Engineering Federation (VDMA Mining) efficiency. And now they are ready to roll these programs out. stands ready to help miners restore and optimize operations. This Speaking at the group’s annual meeting at the Zollverein coal collective group of more than 100 machinery manufacturers and mine in Essen, Germany, during November, Chairman of VDMA Min- engineering firms has a notable history of achievement and that ing Dr. Michael Schulte Strathaus said he believes that rising de- reputation continues today. mand for raw material as well as increasing metal prices will allow What separates these companies from their counterparts is the mining industry to begin investing again. Based on the figures German dedication to craftsmanship, their expertise and the fact for the first nine months of 2017, mining equipment manufacturers that many are privately held, which gave them the wherewithal were expecting to at least repeat their turnover of EUR 2.95 billion from 2016, Schulte Strathaus explained. After seeing revenues de- cline for four consecutive years, the VDMA Mining members are now expecting to break even in 2017 and a further improvement in 2018. Even though many of the mines in Germany have closed, VDMA Mining helps its members export their services to other mining dis- tricts around the world. Looking at projections, Schulte Strathaus said the group was expecting revenue from foreign markets to grow by 1% to EUR 2.84 billion, while revenue from the domestic market was expected to fall by 15% to EUR 110 million. The optimistic outlook is based on an increase of incoming orders from abroad. “In the first nine months alone, orders increased by 38% compared to the previous year,” Schulte Strathaus said. “With this sector, it is not unusual that a year or more passes between incoming orders and invoicing, which is why turnover is expected to grow in 2018 and 2019.” Schulte Strathaus also explained that the companies’ presence on virtually all world markets allows them to balance even significant fluctuations. At the moment, 96% of turnover comes from abroad and about 11,600 staff members are employed.

VDMA 12 VDMA MINING SUPPLEMENT • 2018 According to Schulte Strathaus, the decrease in domestic business to EUR 110 million is a byproduct of the general uncertainty in the German raw material sector, which includes the closing of the last two hard coal mines. Brown coal (lignite) mines are also facing an uncertain future. Policymakers are demanding a quick withdrawal from coal-based electricity and that places a burden on the power generation sector. “Germany energy policy is fragmented, unpredictable and, from an energy-economy perspective, not always comprehensible,” Schulte Strathaus said. “Although there is no ready substitute at hand, the energy supply safeguarded by brown coal is being undermined.” German experts have long warned about the incalculable risks for network stability and power supply, so the sector hopes to maintain its domestic turnover in 2018 and 2019. For the medium and long term, however, the overall downward trend for mining in Germany is expected to continue. European countries account for much of the VDMA Mining exports. In 2017, approximately 28% of exports went to European countries, which is 7% more than the year before. In particular, conveyor technology, safety systems and accessories were popular exports. Tunneling is also an important mining-related industry for Europe. Tunneling turnover is expected to remain the same or even grow in 2018. The mines throughout the Americas are investing in operations again. The U.S. alone accounted for about 15% of VDMA Mining exports in 2017. This represented an increase of 5% compared to the previous year. Mining technology carrying the “made in Germany” label remains popular in the Near East and the Far East as well. Both regions are now focusing on creating large high-performance mining installa- SOME THINK tions, while closing small, unsafe and inefficient mines. This higher level of mechanization requires new equipment and better technology. RAW MATERIAL Smart Mining When asked, most people would likely associate the digital revolu- TRANSPORT tion for industry with aerospace or manufacturing, not necessarily with underground mining. Surprisingly, this edition of Best of Ger- REQUIRES A man reveals that underground mining is one of the hot bed areas that could benefit most from it, and several groups are making that COMPLEX INFRA- a reality, especially when it comes to longwall mining. Many surface and underground mining systems already had some level of autonomy. The next stage under development involves STRUCTURE. communication and cross-linking of machines and systems with each other throughout the entire operation. Mining in a connect- WE THINK ed environment means using new technologies for connecting and communicating with sensors, machines, systems and people. DIFFERENT. Autonomy and digitalization may be the two terms that are used to describe the future of mining. Digitalization tools can be integrated into all aspects of mining, from exploration to engineering Mined raw materials travel along extensive transport routes. and design simulation to advanced process controls. The mining Overland and pipe conveyors are an energy e cient, reliable industry will see a paradigm shift as strategic and real-time plan- and environmentally friendly way of transporting the ning and scheduling are aligned, while remote mining operations commodities over long distances to the plant or storage are controlled by decision-support systems based on key perfor- area. We customise the curved belt conveyors to overcome mance indicators. any challenging topographical circumstances. This minimises Use of these techniques means that operators can step away the transfer points and the number of systems and reduces from active control tasks in a hazardous environment and concen- investment, operational and maintenance costs. trate on monitoring and control functions from the safety and com- For more information visit www.beumergroup.com fort of a control room. All of this should lower the mine’s cost per ton and give the mining company the flexibility to respond to changes in geology as well as demand. The proud members of VDMA are ready to assist mine operators as they develop and install these “smart” mining systems.

2018 • VDMA MINING SUPPLEMENT VDMA 13 Looking to the Future Continuously From fostering fairness to exporting German craftsmanship, VDMA Mining and its members celebrate 125 years of achievement

Last year, the German Engineering Federation (or VDMA) celebrat- Königstein im Taunus. In the 1950s, it established its own published its 125-year anniversary. An association steeped in mechanical ing house and a program to represent the engineering industry at engineering expertise, its members are credited with many major trade fairs and exhibitions. achievements, and that also holds true for the mining industry. To- By 1960, the value of German machinery exports had in- day, the organization has more than 3,200 members and its mining creased almost tenfold compared with 1950, and the industry segment, VDMA Mining, has more than 100 members. employed more than 1 million people. The VDMA moved its head- The VDMA was founded in 1892 and has remained one of the quarters to Frankfurt, where it is still located today. For the first most important voices for the mechanical engineering discipline. time since the end of World War II (1967), German engineering Spanning two world wars, several economic rallies and downturns, companies were making more money from international sales the association has consistently represented the mechanical and than they did domestically. plant engineering sector in Germany and Europe and protested In the 1970s, in a hearing before U.S. Congress, the VDMA the issues affecting it. It successfully accompanies its members formulated arguments against the 10% duty levied on imports. in global markets. Its technical expertise, industry knowledge, and The protests were successful. By the end of the decade, the asso- straightforward positioning make it a recognized and valued point ciation was advocating for the use of modern technology in me- of contact for companies as well as the general public, science, chanical engineering. administration and policymakers. The VDMA opened its first international office in Tokyo in 1984, Over the years, the VDMA has looked continuously toward the which would be followed by offices in Brazil, Russia, India and Chi- future, while representing the common economic, technological and na. In 1986, the VDMA created a foundation for an annual prize rec- scientific interests of this diverse industry. ognizing special achievements in the field of mechanical engineering. After the fall of the Berlin Wall, there was a sense of optimism Promoting German Engineering among companies in East and West Germany as well as a lot of new The VDMA was formed by an association of 29 machinery factories. interest in the VDMA. At the time, German companies were sending engineers abroad By the mid-1990s, the networking of documents via the internet to learn about international markets. Originally headquartered in was a major step toward the digitalization of production processes Düsseldorf, the association began to campaign against low-import in mechanical engineering. Cross-disciplinary forums were set up to duties for foreign machinery in 1901. It then criticized the Central explore matters such as the automation of factories. The globaliza- Association of German Industrialists for not representing interests tion of Germany’s mechanical engineering sector continued. and decided to act independently in matters of trade policy. A boom in China in 2004 ushered in several years of strong By 1907, the German engineering sector was exporting 19% of growth for the engineering sector. Demand from the BRIC countries its production and within a year, German machinery exports overtook was responsible for a sharp increase in the volume of business. U.S. machinery exports for the first time. Then the global financial crisis and the ensuing recession threat- After World War II, the VDMA was reformed as a powerful fed- end the very existence of the engineering industry. Order books went eration of trade associations in the House of the German States in from being completely full to practically empty. Always looking toward the future, the VDMA began to build again. It pressed for the introduction of Industry 4.0 technologies. By 2012, engineering revenues were twice as high as in 2002, with the export rate climbing from 45% to 64%. Despite enduring five successful years without little growth, the German engineering industry employs 1 million people and generates revenue of approximately €220 billion. Through this snapshot of the VDMA’s history, it’s easy to see that some of the VDMA Mining’s members have also had a history of achievement that runs parallel to that of the VDMA.

Engineering Expertise Based in Bochum since it was founded in 1864, Eickhoff is one of the few companies that existed when the VDMA was originally formed. The Bochum-based equipment manufacturer has successfully placed its longwall shearer loaders and continuous miners in some of the most arduous conditions. While experience and service are a big part of the company’s success, they also have their own VDMA Mining promotes its members’ services worldwide. foundry where they have developed special alloys and they have

VDMA 14 VDMA MINING SUPPLEMENT • 2018 wall business in the USA. Today, they have mining and industrial partners around the world. The Hauhinco production facilities in Sprockhövel look much different today than they did 110 years ago. At peak times, 300 employees were building Pickaxes and rock drills to support not only the local miners extracting coal in the Ruhr Valley, but also to mines in neighboring countries. Today, the company’s engineers and factory workers have the same level of commitment to quality manufacturing, but they have more sophisticated tools and they supply equipment and solutions worldwide. The German coal mines may be closing, Hoffmann explained, but the suppliers in Germany are still developing leading mining The Eickhoff shearer loader remains a vital, progressive aspect of longwall mining. technology. Following the mining industry’s needs, Hauhinco has evolved from a component supplier to an engineering company over maintained their commitment to the mining business, retaining the last 110 years. specialists at a time when others were downsizing. Eickhoff manufactures machinery and gearing technology de- Of Cranes and Mining Equipment signed to withstand extreme conditions. Those offerings range from Hans Liebherr founded his company in 1949, Hans Liebherr equipment used in deep underground mines to wind turbines 100 Maschinenfabrik (engineering works), in Kirchdorf, Germany, to meters above the Earth’s surface. supply tower cranes to ports. By the end of the 1950s, Liebherr had From the beginning, the engineers at Eickhoff were pioneers introduced companies in Ireland, South Africa and Austria to expand in the ﬁeld of mechanical engineering. The foundry established by the organization beyond its own borders. The company began explor- Carl Eickhoff in 1864 has become a high-tech company, located in ing production sites for crawler excavators and eventually settled the heart of the Ruhr Valley and at two additional production sites on Colmar, France. This central location in Europe was ideal for main Germany. chine transportation. Eickhoff has adapted with time. Many in the mining industry After the cornerstone was laid in July 1961, the Colmar site recognize Eickhoff’s line of equipment, which is used for cutting soft developed rapidly. As the industries for excavators expanded, rock such as coal and potash. The company’s wealth of experience the design and technology of the machines were enhanced, and has been very helpful in other markets, too. Long ago, it recognized the French factory became a prominent manufacturer of techno- developments, which not only included the growing need for energy logically advanced crawler excavators. This progressive spe- and raw materials, but also the trend toward urbanization and the cialization lead to new business areas, one of which was min- demand for renewable energy. ing-class excavators. Eickhoff Bergbautechnik GmbH produces shearer loaders and In 1970, Liebherr took root on the North American continent. continuous miners for underground mining, Schalker Eisenhütte Service as well as the proximity to local customers were import- Maschinenfabrik GmbH manufactures locomotives for ore and coal ant to Hans Liebherr, and subsequently, Liebherr-America Inc. was mining, and meanwhile also state-of-the-art hybrid locomotives for founded in Newport News, Virginia. The company supplied the Amer- urban underground service and maintenance applications. Eick- ican market with hydraulic excavators, crawlers and wheel loaders hoff Antriebstechnik GmbH has entered an important market with and also represents the company’s other interests. During this pe- the manufacture of gearboxes for wind turbines. Eickhoff Gießerei GmbH and Eickhoff Maschinenfabrik GmbH develop new materials and processes for all areas of the company, such as improving standards for metallurgy.

Hydraulic Power When it comes to experience, Hauhinco has been serving the underground coal mining sector for 110 years. The company was founded in 1908 in Sprockhövel, Germany, as Hausherr, Hinselmann & Co. During those times, it made the pneumatically powered Pickaxe, a major mechanical improvement for coal miners, and Hauhinco supplied more than 400,000 of them. Hauhinco continued to expand its mining portfolio, adding rock drills, conveyor belts, chutes and other products. In 1964, it began building high-pressure pumps for longwall mining operations around the world. By the late 1980s, most of the company’s business was focused on water hydraulics for mining and other industrial applications and they were developing entire system solutions. Beyond the high-pressure plunger pumps and valves, they were looking at the hydraulic network and where they could make improvements. Hauhinco has evolved with mining markets. In 1981, they es- Liebherr supplies some of the largest mining equipment in the world from a tablished a subsidiary close to Pittsburgh to service a growing long- network the company began to build nearly 70 years ago.

2018 • VDMA MINING SUPPLEMENT VDMA 15 riod, new companies were founded in Guaratinguetá, Brazil, and Burlington, Ontario, Canada. In Europe, the company responded to rising demand by introducing new production sites in Austria and Switzerland. During the 1990s, excavator manufacturers began to pair up with haul truck makers. Liebherr Mining Equipment acquired Wise- da, a haul truck maker in Kansas, in 1995. The company renamed its electric drive KL-2450 haul truck as the Liebherr T 262 haul truck. Eventually, haul truck production moved to Newport News, where it’s headquartered today. The market for Liebherr hydraulic excavators continued to grow. In 2011, Liebherr Mining Equipment established a new production and development center for mining excavators at the Colmar location. The new facility specialized in the development and production of large hydraulic excavators for surface mining, as well as the associated service. The Liebherr mining excavators have some of the highest digging forces in their class. To harness those digging forces, the machine must have the most robust and fatigue resistant design. In Cat Global Mining Europe’s factory was established on the banks of the Lippe addition to high levels of productivity, these diggers can be found in River in Lünen in 1826. some of the most remote, extreme conditions, such as high-altitude arctic or arid, high-temperature desert settings. (LHDs and trucks). The aim is to apply technologies that will achieve For nearly 70 years, the Liebherr Group has grown steadily. high-performance, safe and continuous hard-rock mining. Long-term investments, organic growth and strategic enhance- Over the years, the Lünen facility has accomplished many ments to equipment production have proven to be significant fac- achievements. They are credited with inventing plowing technology tors for success. Today, Liebherr embraces future challenges, yet for longwall mining in the early 1940s. They produce the world’s remains faithful to its trusted principles as a family-run business. first AFC for longwall mines in Poland and Germany. In 1971, the world’s first lemniscate shield was introduced here. In the 1990s, Power Transmission the company introduced controlled soft-start systems for longwall Voith traces its roots back to 1867, where it was founded in Heiden- mining, another technology breakthrough. Today as longwall oper- heim, Germany. The company began supplying heavy equipment to ators focus their attention on automation, the Cat Global Mining the paper industry. In 1870, it began producing water turbines and Europe is providing the equipment and tools to make those systems has been involved in many major hydroelectric projects ever since. work as well. Gearbox construction began in 1929, based on the hydrodynamic power transmission, which was invented by Hermann Föttinger. From Hardware to Data Voith then developed its first fluid couplings. A fluid coupling factory For more than 50 years, Becker Mining Systems AG has been a was established in Crailsheim, Germany, in 1956, and it is still the preferred infrastructure supplier for mine operators from around headquarters for fluid couplings today. Last year, Voith founded a the world. The company was founded by Walter Becker in 1964 digital solutions group to accelerate the digital revolution. in southwest Germany to repair and service hydraulic machinery for the surrounding coal mines. He soon recognized the poten- Longwall Longevity tial for properly engineered equipment. The immediate success The foundation was laid for today’s Cat-owned facility back in 1826 of high-quality Becker products made an expansion of the young on the banks of the Lippe River in Lünen, Germany. Originally, the company into other German areas and France possible. With the plant started as iron works, and it quickly moved on to a foundry foreseeable conclusion of the German underground mining mar- and machine works before finally becoming a specialized mining ket, however, Franz Becker began to develop export markets for the equipment manufacturer in the early 1900s when mechanized min- family business in 1983. With a mixture of new subsidiaries and ing was become increasing popular in the area. acquisitions, the Becker Mining Systems Group is now represented Today, the Lünen plant is a world-class manufacturing facility in every major mining region around the world and provides on- specializing in underground mining equipment for a global market. site sales and services. It exports equipment to all major mining markets for both hard and The company’s product range has evolved and today it pro- soft rock operations. vides solutions in the five areas of energy distribution, automation, Formally known as Caterpillar Global Mining Europe GmbH, the communication, infrastructure and haulage/transportation. Becker 120,000-m2 Lünen facility employs 1,000 people, who build long- Mining Systems’ 1,500 employees have a common goal of constant- wall mining equipment for miners around the world. The product ly improving products and adopting the leadership in innovation. line includes hydraulic roof supports (shields), shearer loaders, Becker’s electrical products were always considered to be at the plow systems, armored face conveyors (AFCs) and the associated technological forefront of their fields. drive system technology. With the Internet of Things moving more and more into focus More recently, the group has been developing new products of industrial products and the characterization of the German term for underground hard rock mining. The company believes this Industrie 4.0 and the related term in mining, Mining 4.0, the Becker continuous rock-cutting and haulage equipment will complement Mining Systems Group leads the market once again with connect- the company’s existing portfolio of hard rock underground vehicles ed products for underground production. The company’s integrated

VDMA 16 VDMA MINING SUPPLEMENT • 2018 mine wide software solution MineView is available to the markets passed, yet they gave profound impetus to a new era in safe min- and will be updated with further features. When complete, it will be ing technology. able to process any incoming data from a mine operation and to dis- At the start of the 20th century, Dräger’s founder, Johann play the information in a comprehensible program surface. Existing Heinrich Dräger, was motivated to develop an oxygen-compatible installations will be authorized online updates. pressure reducer. He knew that “carbon dioxide causes death, and oxygen causes life.” Along with his son, Bernhard Dräger, the Excavating Evolution company was the first to envision using this technology in un- Within Komatsu Ltd., Komatsu Germany GmbH’s mining division derground operations. Their vision and innovation gave birth to is responsible for the development, production and marketing of the first closed-circuit oxygen rebreather. At that time, this was super large excavators from its factory in Düsseldorf, Germany. breakthrough technology. The company traces its history to the early 20th century. In 1907, In 1906, tragedy hit the French town of Courrières, when more Carlshütte AG built the first electrical driven rope shovels for an than 1,000 miners lost their lives as a result of a fire-damp ex- open-pit mine in Lizenz controlled by DEMAG (Deutsche Maschinen- plosion. In the memoires of Elfriede Dräger, Bernhard’s wife, she bau AG). In 1925, Carlshütte AG was taken over by DEMAG, which recollected, “There he [Bernhard] saw our equipment being used by relocated the company to Duisburg. The plant in Düsseldorf where the Pompiers [firefighters]. Never was the fellowship between people production continues today was built in 1939. Over the years, that arises from rescue work demonstrated to me so clearly as it was DEMAG has continually set new milestones in the global mining during those days in Courrières.” branch. In 1949, the rope shovel BL 335 was the biggest rope This heroism and fellowship under dire circumstances took shovel in the world, and during the 1954 industrial fair in Han- a life of its own. At the 1911, the National Mining Contest in nover, DEMAG sensationally introduced the world’s first fully hy- Pennsylvania, most rescue miners wore Dräger rebreathers — draulic diesel driven excavator. Moreover, in 1972, DEMAG devel- to support, protect and rescue miners underground. They called oped the first hydraulic excavator with a total machine weight of themselves “Drägermen,” heroes to underground miners. It is in- more than 100 tons. teresting to note that even Superman needed Drägerman’s help in In 1978, DEMAG was integrated into the Mannesmann trust a 1938 comic. After five generations, this name runs deep into the and was renamed Mannesmann Baumaschinen GmbH. With the heart of the Dräger family. introduction and inauguration of the world’s biggest hydraulic ex- For more than 110 years, Dräger has been a permanent and cavator, weighing more than 500 tons, it continued to maintain trustworthy partner in the mining industry. Dräger mine rescue a pioneering role in the global mining market. In 1999, Komatsu equipment, such as the BG 174 Model introduced in 1966, became acquired Mannesmann Baumaschinen GmbH and renamed the an industrial standard used by miners worldwide. The company’s company Komatsu Mining Germany GmbH. The mining-class ex- commitment to innovative technologies in mining is largely due cavators were paired with Komatsu’s existing line of haul trucks. to its close collaboration with its customers — the miners them- More recently, Komatsu Düsseldorf and Komatsu Hanomag in Han- selves. This spirit of working together has resulted in safe and nover merged to form Komatsu Germany GmbH with the mining practical solutions for mine rescue teams around the world facing and construction divisions. today’s challenges. At the 110,000-m2 production plant, located to the south of Düsseldorf, Komatsu Germany’s mining division produces Pump Engineering five different types of mining-class excavators with machinery In 1947, Wilhelm Abel founded a mining engineering company in weights of 250 metric tons up to 760 metric tons. Depending Düsseldorf, specializing in the manufacturing of pumps for the coal on each model, the size of the bucket varies from 16 m 3 to 42 m3 mining industry. Today, ABEL GmbH, a subsidiary of Hillenbrand Inc., on the PC 8000. is headquartered in Büchen, Germany, and it designs and manufactures a wide range of pump products including membrane, solids Mine Rescue handling, high-pressure and marine pumps. ABEL pumps are still For centuries, the only protection miners had against carbon di- used in mining, as well as wastewater management, the energy in- oxide was a cloth mask soaked in vinegar. Those days have long dustry and other sectors. ABEL GmbH is considered a specialist for abrasive media and they sell their pumps worldwide. “It is, for me, a particularly exciting task to make, over the next years, a successful made in Germa- ny company become more successful in the emerging economies worldwide,” said Jaak Palisaar, managing director, ABEL GmbH. When it comes to transferring difficult copper excavation material in Chile or highly concentrated fly ash in India, the HMQ series represents the ideal pump for the reliable transfer of large volumes of abrasive and aggressive slurries under high pressure. The ABEL staff worked very hard to make the success story of this HMQ pump hit a new milestone. In fact, just in time for the company’s 70th anniversary, the 100th pump of this product series was shipped to India. These few examples demonstrate the wealth of expertise that can be found within VDMA Mining. For more than 125 years, the group has been exporting and promoting German engineering and For more than 100 years, the Draegermen has rescued miners. craftsmanship.

2018 • VDMA MINING SUPPLEMENT VDMA 17 Smart Underground Mining Traditional equipment suppliers gravitate toward system engineers

When one thinks of Industry 4.0 applications, underground mining “The shearer communicates continuously with the roof supports and would not be the first image that comes to mind. The harsh environ- the conveyor. Information such as conveyor loading status, shearer ment and extreme conditions run juxtaposed to modern factories, position, active identification of hazards, and other operating and but it is one of the areas that could benefit quite a bit from its process data can be exchanged and relayed to the operator station use. Most mines are looking toward process automation to withdraw and to the surface control room in real time.” Modern shearers also miners from the active face area and improve operations. For these have additional sensors designed to improve the precision of the autonomous systems to achieve their potential, massive amounts coal-cutting operation and determine the geological boundaries, of data need to be transmitted, interpreted and acted upon in real such as the coal-rock interface. time. And, a few mines are already taking advantage of this concept As the shearer passes by, the roof supports (or shields) are au- using German equipment and technology. tomatically reset and the armored face conveyor (AFC) is advanced. German manufacturers are also using the principles of Industry “If the system observes any irregularities, such as a shield set too 4.0 and continuous improvement programs to build the best equip- low, the system assesses the situation and appropriate measures ment. Consider a deep mine that must hoist ore 2 kilometers to are taken,” Mavroudis said. “Video systems allow miners to monitor the surface or support tons of rock safely, the equipment and the the conditions on the face and this requires powerful and reliable supporting infrastructure must be built to withstand the massive communication systems. The technology used in the mining industry forces it will encounter. Despite their size, the tolerances for these today meets all established industrial standards. It is designed for rather large pieces of the kit are extremely tight. redundancy, can be power-cable connected or may even be based on The digital transformation will play a vital role in underground DSL, fiber-optic cable or WLAN.” mining operations. Smart underground mining systems will har- In July 2015, the Siberian coal operator (SUEK) commissioned ness new technologies for connecting miners with machines and a new longwall face with a seam thickness of 1.7 m. This face was machines with other machines in mining systems. These systems then used as a test bed for newly developed remote-control and au- will allow miners to operate the machines in safe, less dusty envi- tomation elements that for the first time took the industry close to ronment. In addition to improving safety, mining companies will see the vision of the “manless coal face,” Mavroudis explained. “The greater production and lower costs per ton of rock moved. overall planning and practical implementation work needed to deliver this project was carried out jointly by German companies, in- The Manless Face cluding Eickhoff as the shearer manufacturer.” This face and other The vision of unmanned longwall faces, where miners monitor oper- SUEK faces have set world production records. ations from a control room in a safe location, is now an attainable Video cameras mounted on the shields and the shearer creat- goal. In addition to removing miners out of aqharm’s way, it also ed a longwall-face monitoring system and allowed the operator to represents a cost-efficient method for increasing production and follow the trajectory of the cutting machine, Mavroudis explained. improving operational flexibility. “Rapid data links were used so that all the data needed for the con- Dr. Fiona Mavroudis with Eickhoff Bergbautechnik GmbH, Bo- trol of the shearer and face installation can be exchanged between chum, Germany, views the longwall shearer loader as the key in- the face components and the gate-end stations,” Mavroudis said. telligent, collaborative element. “Nowadays, shearers are equipped “The entire coal-cutting process can be observed and controlled with numerous sensors that redundantly perform different tasks from the remote-control panel in the headgate.” and should pursue different operating principles,” Mavroudis said. The system uses additional interfaces to ensure data are relayed to the surface control room for display purposes. Miners obtain information on the face equipment and coal-cutting operation that is accurate to the second. “The introduction of this system has led to a new stage of technology in longwall mining,” Mavroudis said. “These features were also systematically introduced with the development of the new Eickhoff SL300L thin-seam shearer and the technology was subsequently improved and refined during initial operational trials.” More recently, a coal operator in Australia implemented the next stage in the evolution of longwall mining: the overall communication and cross-linking of sensors, machines and systems. Process data are exchanged and sent to the surface. Sensors for relative and absolute position and navigation provide a detailed description of the face profile. “Working in conjunction with highly complex control algorithms, the coal-cutting process can be controlled to millimeter accuracy,” Mavroudis said. Collaborative sensor systems operating beyond the boundaries of the machine provide environment perception and detection, and The shearer is the central element on the longwall face. support the autonomous regime as it copes with dynamic geological

VDMA 18 VDMA MINING SUPPLEMENT • 2018 conditions, Mavroudis explained. “Despite the dynamic and extreme For full autonomous mining, the system will have to control the mining conditions found underground, these optimized systems are longwall face between the gate entries as far as asynchronous cuts adapting independently to their operating environment, and per- (the shearer grades the floor correctly), and identify the coal-rock forming their own regulation and control functions.” interface and marker bands. The systems would have to know its Another optional system developed by Eickhoff allows miners to boundaries and how steer the longwall. “We not only want it to plan observe all of this in real time with the Eickhoff Face camera system cuts, but we also want it to control the face mechanically and pro- (EiFaceControl). The system’s data exchange and analysis enables vir- tect the equipment from damage,” Becker said. tual longwall visualization, which gives the operator the ability to focus “We have to look at the entire longwall system as a numeric ma- on monitoring and control functions from a secure room on the surface. chine,” Becker said. “We need to know exactly where our extraction At the same time, they can access historical data within seconds. “All tools are located in relationship to the face. That data can be gained of this enlarges the sphere of knowledge in the control room, which in by sensors placed on the shearer that communicate with sensors on turn allows the cutting sequences to be planned, implemented, and the roof supports.” Ideally, the system would consider the angle to executed in a proactive and more precise manner,” Mavroudis said. the conveyor for the advancing system while protecting the lemnis- The nerve center for the control process is the state-based Eicon- cate and preventing the shearer from cutting into the canopy or the trolSB automatic system. This is effectively the core element of the flippers on the shields. shearer loader, as it separates the cutting process, methodically into Marco is designing an inertial navigation system, which would be different and independent steps. The preconfigured process can be attached to the shearer. It would use RFID to talk to the PM32 on the altered and extended by the user at any time so that it can be adapted shields. The data from the sensor could be downloaded either through to meet external requirements. The machine reacts independently and the trailing cable or wirelessly. The PM32 controls the hydraulics on in a manner that is tailored to the changing conditions. The remote each shield and the data could be retrieved. Cameras with ethernet operator can correct parameters and alter the process accordingly. connection could also be used to support decision-making. “The shearer follows a defined profile, cut by cut, until it receives a “To make the system work autonomously, the shearer needs to correction,” Mavroudis said. “The shearer is operated completely un- be integrated into the process,” Becker said. “Cut planning and manned with a 99% use of ranging arm and haulage automation.” feedback from the shearer makes it possible for the system to find Initial results show a more even mining operation and better a relative position to avoid collisions. Currently, the Eickhoff system longwall conditions for the manless face in Australia. These new de- would be the best option for data exchange. Once we can exchange velopments in longwall mining will transfer people from monotonous, and see the operating data, we can use the sensors and the cut physically demanding and hazardous workplaces to other fields of profiles to transfer and get the feedback accordingly.” activity. A main challenge is preparing and integrating the people He emphasized the use of cameras. “That is what customers are into the new processes. In most cases, it’s the longwall operators demanding,” Becker said. “We have been looking at ways to improve and that are asking for and advancing this technology. But an important incorporate more video into longwalls. Our first step was the so-called hot prerequisite for the success of such advanced automation projects is spot strategy, where the operator doesn’t need to click through dozens of based upon the transformation in how the mines change their culture camera screens to see what is happening where. Rather, we control the around managing a longwall. Mine operators and industry suppliers process in such a way that the screens will be shown that are relevant to will have to undergo a fundamental change in vision and in strategic the process at that point in time. The other screens are hidden.” focus if the substantial changes needed are to be achieved. Manual cutting processes often lead to mistakes and they need to be optimized. Especially unexperienced shearer operators only react Machine Communications is Key to to the current situation, which can cause oscillations. This effect is Autonomous Longwall Mining exacerbated by information loss due to shift exchange. Correcting this Longwall controls have developed progressively with continuous requires time and at least three to five shearer cuts. Becker proposes improvements in safety and reliability, increasing performance at intelligent cut planning as a solution with the marco’s Horizon Control the same time, explained Mark Becker, mining engineer with marco system. “There is always resistance to change, but it’s more important systems. “The industry is currently converting from electrohydraulic that the operator understands what’s happening within our system,” controls that automatically move banks of roof supports to a digital Becker said. “We want to offer the operator the opportunity to visualize process that will automate mining,” Becker said. “The next step will the cut sequence, the seam height, the seam thickness, the deviation, be the intelligent use of data to optimize the entire process.” the general inclination and most importantly, the goal,” Becker said. Drawing the bow to the principles of Industry 4.0, Becker add- So how does intelligent cut planning work? The system gathers ed: “At Marco, we apply the principles, which Industry 4.0 is mainly all the data and calculates the horizon. Using the data on the shield based on, in the following way: using a solid backbone, we meet the technological requirements of cross-linking, which allows us to consolidate all data in our control and visualisation system, called integrated face control (IFC). IFC enables a wide area of technical assistance and peripheral decisions, such as direct horizon input and intelligent cut planning.” He outlined some milestones for the longwall industry to consider. Based on fully automated shield control, the milestones for autonomous mining, would be face basis and position capture in 3-D, direct horizon input and shearer integration. “Many longwalls have already achieved fully automated shield controls,” Becker said. “Then next step is to control the system in 3-D by controlling the horizon by direct Manual operation versus planned automation for an optimized consideration cut inputting and planning the cuts intelligently.” of geological and operational issues.

2018 • VDMA MINING SUPPLEMENT VDMA 19 height from the PM32 and the position of the AFC, it calculates the will also be the first Koepe necessary cut sequence and transfers it to the shearer control sys- system used at a hoisting tem. The graphic visualization of the face is not only shown in the height of 2-km.” control room on the surface and the headgate computer, but also on Both systems were every PM shield control unit. Becker pointed out that, due to cus- designed, engineered and tomer requirements, no connection to the surface is required, as the manufactured by SIEMAG entire process is done on the underground IFC-computer. TECBERG. Both will be In the future, corrections will be made automatically based on the equipped with SB1 decel- roof and the boundary layer. “In Russia, we have a face that is perform- eration-controlled brakes ing a boundary analysis with the sensors on the shields, so we can rec- and the company’s own ognize any boundary violations,” Becker said. “That data is fed into the types of slide bearings IFC, where adjustments are calculated and transferred to the shearer.” and brake elements. Looking toward the future, Becker discussed an inertial navigation The four-rope Koepe system. “Independent of the longwall manufacturer, we want to be able hoist of Ø 6.5m will be to exchange cut data with the shearer,” Becker said. “We have an in- used for service. In ad- ertial sensor attached to the frame of the shearer. It is connected to a dition to the hoist, the PM32 and just like every PM shield, it has an RFID antenna. To determine system will have two sets machine geometry, we will place additional inclination sensors on the of Ø 6.5-m deflection ranging arms. With our cameras in every fifth or 10th shield, the system sheaves, a large cage will identify the marker band and make a cut correction automatically.” and counterweight with For an autonomous longwall to plan cuts intelligently, the in- rope attachments, head tegration of the shearer is essential. The industry already has the and tail ropes, supplied prerequisites. With further developments, such as the inertial navi- together with a four-point The Blair hoist uses load compensating sheaves to avoid long-term damage. gation system, autonomous longwall mining will soon be within the lifting system to install industry’s grasp. the heavy-load components. It has a 20-ton payload and maximum operating load of 360 tons (T1 + T2). Engineering Russia’s Deepest The double-drum Blair production hoist of Ø 5.75 m has two Shaft-hoisting System ropes per drum, rope-load compensating sheaves, the related steel Norilsk Nickel plans to pursue ore at deeper levels, and the company work with guiding beams and two 30-ton skips. SIEMAG TECBERG de- recently approached SIEMAG TECBERG to provide what is believed to signed a complete loading system at the shaft bottom as well as the be Russia’s deepest shaft-hoisting system. Over the years, the com- discharge system on the surface, supplied together with the required pany has provided hoisting equipment for many Norilsk Nickel instal- belt conveyors. SIEMAG TECBERG also designed the head-rope attach- lations, but this one, the SKS1 project, is different. In addition to being ments and selected head ropes for carrying the skips and payload. more than 2-km deep, SIEMAG TECBERG will be supplying a complete “We are now in the supply phase,” Krenzer said. “This hoisting shaft-hoisting system with a defined yearly ore output for the Siberian shaft is currently scheduled to go into operation during the fourth nickel miners, rather than simply supplying individual components. quarter of 2019.” They are also providing rope-handling equipment, The SKS1 project will add around 500 m depth to other exist- such as a 200-ton, four-rope clamping and lifting device (2,000- ing hoisting installations in Russia. It will use two types of hoist- kN), a 1,800-kN friction winch with a component weight greater ing arrangements, a Koepe system for service applications and a than 150 tons, along with rope reelers, messenger winches, related double-drum Blair system for the production. “For this project, we horizontal and vertical deflection sheaves, and special tools. are supplying a complete system with the best hoisting technology, In addition to its hoisting system construction experience, designed based on long years of experience,” said Michael Krenzer, SIEMAG TECBERG is also familiar with the local Russian machine senior project manager, hoisting technology, SIEMAG TECBERG. “This building guidelines. “An important part of the equipment supply was to be certified to fulfill the local requirements for explosion protection to work underground,” Krenzer said. The double-drum Blair production hoist is powered by an 8.6-megwatt motor. The weight of the drum shaft alone is 90 tons. The 30-ton skips will travel at 14 m/s to hoist approximately 1.5 million tons of ore per year to the surface, based on 12 operating hours per day and 330 days per year. “The double-drum Blair hoist uses rope-load compensating sheave technology, and this is only the second time we have supplied this complex technology,” Krenzer said. “The hoist has two ropes attached to each drum. For different reasons (e.g., rope elongation), the rope load varies. Basically, each sheave is supported by a hydraulic cylinder that is hydraulically connected with the cylinder of the corresponding second sheave, which enables load compensation for each other. The use of this system avoids long-term damage of The double-drum Blair production hoist of Ø 5.75 m has two ropes per drum, the hoisting ropes. If for whatever reason a rope coiling failure oc- rope-load compensating sheaves, the related steel work with guiding beams curs, for example, this system would detect it immediately and the and two 30-ton skips. hoist can be brought to a safe stop.”

VDMA 20 VDMA MINING SUPPLEMENT • 2018 What sets SIEMAG TECBERG apart for others is its detailed engi- When asked how often pumps are rejected once they reach the neering and design work, and its ability to fabricate large systems. test bench, Hoffmann said, “Rejected? Never. The quality is moni- Over the last 10 years, the engineering team has used modern fi- tored throughout the entire production process. If there is problem, nite element analysis systems to improve existing designs and to it is rejected earlier in the chain. Once it reaches this test bench, it’s produce new drum technologies. The company has its own types of an ISO-certified product.” specially designed slide bearings, types of brake elements and ap- “Ruhrkohle AG has Hauhinco pumps that have run for more than proved electrohydraulic braking systems with deceleration controls. 30 years without a problem,” Hoffmann said. “We come from the “We are only one of a very few companies in the world with the abil- underground mining sector and deliver products to the industrial ity to deliver such types of large hoisting sytsmems,” Krenzer said. sector, while most of our competitors come from the industrial sector “And, the 90-ton main shaft for the Norilsk Nickel double-drum Blair and now also supply to underground mines.” hoist is the largest hoist shaft we have ever supplied.” Hauhinco offers seven models for the mining business that From a mining engineering perspective, Norilsk Nickels’s SKS1 range from the EHP-3K 75 to the EHP-5K 400, which would be five project will be a major shaft-hoisting achievement. Designing a plungers, 400 kilowatts, 725 m3/min and 500 bar pressure. “The Koepe system that will hoist 2 km in a single lift is a feat unto itself. EHP-5K 400 is currently our largest pump and it is becoming very In addition to the 90-ton main shaft, SIEMAG TECBERG will also popular with the longwall mines,” Durst said. “We have installed ship about 3,000 tons of equipment to the mine site and they will them in Russia, China and the USA.” charter a vessel to transport the two shaft-hoisting kits with service The pressure requirements in underground longwall mining auxiliaries form Germany to Russia. have changed. “The new Russian longwalls need the power,” Hoff- “This is a very big, exciting project for us with a lot of firsts,” mann said. “Some Russian longwalls have as many as four or five Krenzer said. “For many years, Norilsk Nickel has relied on our equip- 5K 400s for a single face.” ment, but now they have asked us to supply complete service and The company is modifying existing pumps and also developing production hoisting systems with a defined yearly output.” entirely new plunger pumps and systems. “We have also improved Throughout its history, which began in a blacksmith shop in the condition monitoring system,” Hoffmann said. “Normally, we 1871, SIEMAG TECBERG has always focused on quality craftsman- measure temperature, pressure and energy consumption. Now we ship and has never shied away from major projects. Today that tra- can also measure vibration, which allows users to see problems de- dition continues as the company broadens its scope from a compo- veloping.” Hauhinco has supplied more than 1,000 systems world- nent supplier to a systems provider. wide and it keeps $6 million in parts for pumps and valves in stock. They have air freight area ready to ship pumps, valves and spare Water-based Hydraulic Solutions parts anywhere at moment’s notice. The Hauhinco name is synonymous with water-hydraulic systems Six years ago, Hauhinco started to develop water treatment for longwall mining, and they have evolved with mining markets. In systems for underground mining. With this system, the company 1981, they established a subsidiary close to Pittsburgh to service reacted to the concerns of mines and OEMs on the possible effects a growing longwall business in the USA. Today, they have mining bad water quality can have on the entire longwall equipment. “We and industrial partners around the world. “Wherever there is a are working with water as a hydraulic medium and it’s important to longwall market, you will find Hauhinco,” said Holger Hoffmann, have a clean medium,” Durst said. “Longwalls are a high capital general manager. “We are the leading supplier for high-pressure expense and coal companies want to make sure that they operate for water hydraulic applications and we are developing new solutions a long time. Water is the blood of the system and it must be clean.” here in Germany.” A hydrocyclone filters solids from the water before it enters a The Hauhinco production facilities in Sprockhövel look much three-step filtration process with a fineness-of-filtration of 100 different today than they did 110 years ago. At peak times, 300 microns (µm), 50 µm and 25 µm, and an automatic backwash. A employees were building Pickaxes and rock drills to support not 50-µm bag filter clarifies the returning water-HFA-emulsion from only the local miners extracting coal in the Ruhr Valley, but also to the longwall face. The water treatment system filters the impurities. mines in neighboring countries. Today, the company’s engineers and Hauhinco asks the mine for a water quality analysis and they cus- factory workers have the same level of commitment to quality man- tom design a treatment system to filter the water. “Miners are much ufacturing, but they have more sophisticated tools and they supply more in tune with water quality,” Hoffmann said. “Customers on the equipment and solutions worldwide. “We have made a significant industrial side often take water quality for granted.” The standard investment in our manufacturing and testing machinery during the system converts 2,000 liters per hour (l/h) of water with a conduc- last three years,” said Christopher Durst, strategic marketing man- tivity of 1,990 micro-Siemens (µS) to 1,000 l/h of clean water with ager, Hauhinco. “Tolerances today are tight and to meet production standards, we need to use the most modern equipment.” Training, quality control, and research and development are three areas where the company is committed to excellence, Hoffmann explained. Hauhinco not only has an apprentice program to train its own employees, but they also have a training center for their customers. They have a shield sitting on the factory floor next to a classroom where instructors can teach both theory and offer hands-on training. Hauhinco is certified according to DIN EN ISO 9001-2015. “Each system is tested and receives a certificate before it leaves this factory,” Hoffmann said. “We want to make sure everything works as Hauhinco’s water treatment system produces 1,000 l/h clean and salt-free planned. The last thing we want is for a mine in Australia to take a water. The conductivity of the water is approximately 20 µS after the treatment pump or a valve underground only to find it does not work.” process and nearly salt-free.

2018 • VDMA MINING SUPPLEMENT VDMA 21 19.5 µS. The system can be adapted to water characteristics and Recent production results recorded during automation implemen- the required volumes of water. tation on a high-production Australian longwall illustrate the positive The main 6,000-l tank holds 5,000 l of water-HFA-emulsion and roll that automation can play. In brief, weekly production grew from 1,000 l of HFA concentrate. An automatic emulsion-mixing system 61,592 metric tons (mt) to 118,094 mt as automation grew from 0% enriches the water with concentrate. Analog measurement devices to 98%. Production grew more than 90% as the use of automation in the HFA and concentrate compartment show the filling level. A increased, as indicated by shearer ranging arm override commands. transmitted light refractometer with a biprism monitors the emul- Cat said it has found similar results at two other Australian longwall sion. “All of our pumps and components are running with HFA [97% mines owned and operated by different mining companies. water and 3% emulsion] or clear water,” Hoffmann said. “Clear wa- In the first case, the average time taken per shearer pass ter is of course used for dust suppression.” dropped from 56 minutes to 44 minutes as automation was imple- The high-pressure station is also equipped with two hydraulic mented. The reduced travel time increased the average number of accumulators that reduce pressure spikes and shocks. Two auto- passes per week from 68 to 91. matic high pressure double back-flush filters clean the mixture In addition to increases in productivity, automation increased again before it leaves the high-pressure station for the roof sup- equipment availability and reduced in-panel parts usage, specifi- ports in the longwall. cally replacement of conveyor flights, shear pins and conveyor con- Mines in different parts of the world use different pump station nectors, also known as dog bones. Over three panels, longwall sys- designs. Hauhinco for example supplies high-pressure pump sta- tem availability increased from 91% to 96.5%. The data collected, tions and water spray stations mounted on crawler tracks through- however, does not distinguish between mechanical availability and out mines in Australia. Onboard the crawler track mounted pump mine attributable delays, such as repair time and parts availability. station is a dual-shaft motor system with pumps on either end of The use of variable frequency drive (VFD) technology in longwall the motor. A variety of pumps with different flow and pressure ap- applications is a recent trend that has already made a positive im- plications can be suited to this system. pact on many installations. Using VFD technology and an innovative This system was developed to ensure all equipment is located low-speed, high-torque motor, Caterpillar is working to step up long- in the one high-pressure area and therefore simplify transport lo- wall face conveyor performance even more. The permanent magnet gistics when only moving one piece of equipment in the mine. On synchronous motor (PMSM) combined with the VFD promises multiple the run, maintenance with minimal downtime can also be achieved benefits, such as higher productivity and reduced total cost of owner- with this design. “With the dual-shaft arrangement, one pump can ship through low maintenance and high mechanical availability. be quickly disengaged without any hot works or additional labor re- The drive system also features an extensive automation pack- quired to achieve this, then the other pump application can still age, programmable for the application. It can be adapted to special be left in operation. General maintenance can be carried out or the applications or geological situations (roof falls, geological faults, pump can planned to be removed if required, therefore continuing etc.). Because the torque motor delivers max torque at any speed, operation reducing downtime and production. the automation system can adjust speed to optimize production, This design is very compact and mobile, but the mine also must reduce electricity consumption, and minimize wear on components have a minimum 2.2-m seam height to accommodate the dual shaft such as sprockets and flight bars. design on crawler tracks. The automation system is combined with enhanced condition The dual shaft application can be incorporated into a monorail monitoring to make sure that the machinery is protected and can mounted station or a transportable base sled design. However, gen- run at maximum output. All of the necessary data is linked to a erally we can accommodate all types of configurations. database to support predictive and condition-based maintenance. The High Torque Drive system is built around the low-speed mo- Improving Longwall Productivity and Safety tor, which delivers the same high torque at all speeds. The convert- While the use of automation grows, Caterpillar Global Mining Europe er-controlled torque motor operates at speeds between 0 and 300 GmbH, continues to develop new longwall system components that rpm versus 1,500 rpm for induction motors. Lower speed reduces lend themselves to automation, such as its High Torque Drive system. inertia acting on the output shaft by a factor of eight and enables The armoured face conveyor (AFC) drive system improves longwall the system to react quickly, which translates to little or no damage to performance by replacing traditional components with more efficient the gearbox and conveyor chain in the event of a conveyor blockage. ones. Such evolving and new technologies, according to Cat, promise In addition to soft start and stop, the High Torque Drive delivers to drive longwall production higher and cost per ton lower while reduc- very fast acceleration. The variable conveyor chain speed can be ing exposure of miners to health and safety hazards. efficiently adapted to the production conditions — resulting in less wear on the conveyor. The system also is about 5% more efficient than conventional drives. The improved system efficiency means lower energy consumption and reduced cooling requirements. The new drive system consists of two main components — a variable frequency converter and the motor-gearbox combination. As compared to previous systems, a medium-voltage converter-controlled torque motor replaces the AC induction motor. The control principle of the drive is direct torque control — the most advanced AC-drive control technology available. High torque even at low speeds enables using only one gear stage, which results in smaller dimensions while retaining the same torque capabilities as systems In addition to soft starts and stops, Cat’s High Torque Drive system reduces that are as much as 20% larger. The low speed of the motor also AFC wear. reduces wear and extends service intervals.

VDMA 22 VDMA MINING SUPPLEMENT • 2018 Experience the Progress.

Liebherr’s Innovative Mining Solutions

Integrated smart technologies lower the total cost per tonne Intelligent design to increase uptime and reliability Highest productivity and efficiency through intelligent energy management Ergonomic design for safe and user-friendly operation and maintenance Customer-focused support throughout the entire equipment lifecycle Liebherr’s continuous focus to reduce environmental footprint across all machines

Liebherr-Mining Equipment SAS 49 rue Frédéric Hartmann - CS 50038 68025 Colmar Cedex Phone: +33 369 49 20 00 E-mail : [email protected] www.facebook.com/LiebherrMining www.liebherr.com Technology Improves Open-pit Mining Using new intelligent tools, miners pursue automation with haulage and maintenance as well as selective mining

Most open-pit mines face similar, significant challenges, such as program is well under way and Liebherr plans to begin field trials at extreme operating conditions and decreasing ore grades. In addi- a customer site in 2019. tion to the expected wear and tear on equipment, they must also “We will offer three options to support various customer approach- move more rock to produce the same amount of metal or coal, which es to autonomy,” said Bryant Ward, executive vice president of engi- increases the mine’s operating costs. Today, many open-pit miners neering and development, Liebherr Mining Equipment. “Some custom- are looking toward automation and machine-to-machine communi- ers would like a single supplier to do everything in a turnkey approach. cations to improve safety and streamline loading processes. Others want multiple supply options and are prepared for a larger When it’s time to service these large mining machines, it’s im- integration effort. In this way, Liebherr will deliver the most flexible and portant to have the proper components for replacement, all of the cost-effective way to achieve an autonomous haulage solution.” additional parts, and the right tools to get the job done as safely Liebherr intends to provide an open architecture allowing and quickly as possible. Mines for the most part have developed mining companies flexibility with respect to the level of OEM content rather impressive maintenance programs, many of which have al- and integration from Liebherr to compliment their existing invest- ready made the digital transformation away from the paper trail ments in fleet management and telemetry. This approach will allow of work orders. Now some are looking to further develop apps for mining companies to use Liebherr equipment along with other equip- personal devices that will take this initiative one step further. ment and choose the most suitable suppliers for third-party solutions, Most importantly, however, is the cost per ton. Large equipment Ward explained. For example, Liebherr’s new autonomous ready-haul represents economies of scale. While automation and reduced down- trucks will be compatible with the Mobius, autonomous command and time related to maintenance are extremely important to keep this control platform provided by Autonomous Solutions Inc. (ASI). equipment loading and hauling, adopting the best extraction method is Liebherr has addressed the mining industry’s need for interop- equally important. Allowing waste rock to enter the processing stream, erability and openness. Its decision to work with ASI means that the also known as dilution, can also increase the cost per ton. Being able to company’s autonomous equipment can be controlled under an OEM mine selectively is as important today as it was 100 years ago. agnostic command system, providing a high degree of flexibility for mining companies that will likely be looking to integrate other au- Smart Haulage and Loading Solutions tonomous vehicles throughout a mine site. Liebherr Mining Equipment certainly understands Smart Mining Liebherr manufactures large equipment for open-pit mines, in- principles. In November, the company unveiled a new autonomous cluding haul trucks designed to handle payloads as great as 363 met- haulage solution at a trade show in Cologne, Germany. Testing an ric tons (mt) as well as mining-class excavators. Liebherr has recently initial prototype since 2016, its autonomous haulage development placed several of its largest truck at mines in Latin America. A new

All three pieces of Liebherr mining equipment work together to move more rock.

VDMA 24 VDMA MINING SUPPLEMENT • 2018 A copper mine in Panama recently purchased several Liebherr T 284 haul trucks. copper mine in Panama purchased three. The company also placed its The Liebherr group has relied on its extensive market knowledge first T 284 in Canada as well. In additional to a full line of trucks and and experience of the mining industry to manufacture V-type en- excavators, Liebherr also makes and supplies ancillary equipment gines tailored for these kind of applications. The engines have been that supports the mining business, such as dozers and diesel engines. engineered to face the most challenging mining environments, such At a field demonstration at the Erzberg iron ore mine in Leo- as dust, heat, humidity, vibrations and extreme cold conditions. All ben, Austria, during October, Liebherr showcased its T 236 mining Liebherr diesel engines are also based on solid and secure designs truck. This 100-metric-ton (mt) haul truck, which is powered by a with constant quality assurance and process monitoring to ensure diesel-electric drive system, is the first in this class to incorporate the highest quality standards, parts reliability, and on-site safety. an oil-immersed braking system with four-fcorner retarding capa- With productivity and efficiency as key factors for excavators, bilities, providing reliable braking technology. Liebherr engines can reach outstanding performances and deliver The T 236 takes advantage of Liebherr’s electric-drive sys- required horsepower at the most demanding moments. This results tem innovations with the introduction of the vertically integrated Li- in a reduction of everyday costs per ton while optimizing the fuel tronic Plus Generation 2 AC-drive system. Referring to it as the next consumption of the machines. The Liebherr engines also benefit from evolution in electric-drive system design, Liebherr said the drive sys- best-in-class cylinder power densities, increasing cycle times for the tem introduces advanced, active front-end technology. Making efficient excavators, and delivering greater productivity outcomes. Further- use of electrical energy during retarding events, the drive system con- more, the engines comply with the most stringent emissions regula- trols engine speed with almost no fuel consumption. A variable-speed tions thanks to innovative exhaust gas aftertreatment solutions. hydraulic system reduces parasitic losses to provide maximum power, Liebherr offers dedicated parts supply and technical service while lowering fuel consumption when power is not required. support to its customers in order to reduce operating costs and With its high take-off torque and continuous power to ground maximize machines uptimes. Liebherr diesel engines are designed capability, Liebherr said the T 236 is less sensitive to grade and for quick and easy servicing, extending maintenance intervals. Lieb- payload variations. herr is finally combining its in-house engines with Liebherr mining Liebherr also rolled out a new crawler tractor at the Erzberg excavators to achieve on-site availability and low total cost of own- mine. The 50-mt PR 766 crawler tractor was designed for power, ership, the company said. low emissions, efficiency, driver comfort and durability. The dozer features a hydrostatic drive, ECO function, a 310-kW engine, and an A Paradigm Shift for Maintenance ergonomic cab. Seeing the promise that digitalization holds, RWE Technology A LiDAT fleet management system, which comes standard, International GmbH continuously improved its maintenance pro- provides comprehensive machine data via state-of-the-art com- gram by eliminating paper and developing an app. Soon it plans munication technology, Liebherr reported. This improves efficiency to add component tracking with real-time updates similar to the by enabling optimized operational planning and reliable remote service consumers receive today from DHL or Amazon. monitoring. Data is updated several times a day and can be called RWE generates power for Germany burning brown coal that is up at any time using a web browser. An automatic alarm can be mined from large open-pit operations that use a combination of 20 set for important information, for example, if the machine leaves a bucketwheel excavators (BWEs) and 19 spreaders and more than predefined zone or if a critical operating situation arises. 250 km of conveyors. The massive mining equipment and coal Liebherr’s components division designs and manufactures min- transportation network require regular maintenance. ing engines from 565 kW up to 2,013 kW for the Liebherr hydraulic About eight years ago, RWE began to look at a holistic approach excavators. The R 9100 B and R 9150 B are using the D9512, a V12 to maintenance that has now evolved into mobile solutions with engine assembled in Bulle, Switzerland, and the R 9400 is currently apps. In 2010, the company introduced a maintenance management testing the brand new D9812 from Colmar, France. system based on key performance indicators (KPIs). A year later, they

2018 • VDMA MINING SUPPLEMENT VDMA 25 were defining various mobile requirements, especially for mainte- RWE is now developing a Material Ready App for logistics, nance management. In 2015, RWE rolled out the Asset Care app, which will digitally track the material management process. “We and today they are refining it by incorporating IT/SAP technology do not want to reduce jobs, we want to empower the worker to be that will optimize purchasing, storage and delivery of spare parts. more productive,” Eberlein said. Looking toward the future, Eber- Recalling the paperwork and the issues with logistics and down- lein envisions an integrated system, consisting of maintenance and time, Mark Eberlein, technical support, RWE Power’s Maintenance materials that knows what the company has in stock and what it and Engineering Center, described the company approach to digita- needs to transport to the site. Similar to Amazon, when ordering a lization. “We couldn’t fit all of our equipment with sensors overnight component, it would suggest other parts that are usually ordered to because it would simply cost too much money,” Eberlein said. “So, complete a certain job. It would track materials on lorries and, like we approached the equipment through the people and then back to DHL, give the users updates as far as arrival time. the system. They were taking photos of the parts and sending it to other people using private email or WhatsApp, which is a great use Integrating Surface Miner Technology of technology, but all of the information is lost.” The company began The New Acland coal mine in Queensland, Australia, recently incor- to develop an app for the maintenance technicians that does the porated a Wirtgen 4200 Surface Miner (SM) into an existing mining same thing and keeps the information inside the company. fleet. While it was a major departure for a group that ordinarily re- The RWE system offers tailored solutions according to needs and sists change, the mine realized many benefits as far as health and priorities of the equipment and maintenance. It has reduced main- safety, environmental performance, productivity, particle size distri- tenance periods through real-time capture of systems data. It has bution, loss and dilution, and unit costs were realized. Working with reduced equipment downtime through predictive equipment data one of the leading German schools for mining engineering, RWTH and maintenance. It has a high level of KPI transparency as far as Aachen University, and Wirtgen GmbH in Germany, New Acland im- costs, performance and safety on an equipment level. “It’s also easy plemented a new mining method. to use and intuitive with a simplified user interface,” Eberlein said. Located 35 km northwest of Toowoomba, the New Acland mine, “Technicians always have precisely the right tool for the job at hand. which is part of the New Hope Group, has been operating since 2002 Maintenance and repair information is monitored continuously and and today produces about 5 million metric tons per year (mt/y) of backed up.” The system connects the KPIs to Big Data systems and it thermal coal. will eventually offer real-time updates as well as tracking systems. Because of its close proximity to adjacent neighbors, the mine To make a system like this work, upper management and the operates within strict environmental limitations. Noise and dust employees must both understand the value proposition. Over time, emissions are especially relevant and lower environmental impacts barriers were identified and managed. “People want access to data are desired. The coal is washed on site and then railed to the Port of and information, but they won’t use the system if it doesn’t function Brisbane for export. properly,” Eberlein said. The geologic formation consists of multiple coal seams ranging Today, RWE’s Asset Care App (www.rweti.com) connects its peo- in thickness from 0.3 m up to 3 m, interrupted by partings of the ple with the company’s system, and the company’s efforts in this same thickness. In total, the number of different bands exceeds 40, area were recognized with an innovation award from Handelsblatt resulting in high importance of selective mining practices. Consid- IT for digital products, projects and business models. ering these geological conditions, the Wirtgen 4200 SM offered a Jointly developed by RWE and Apple IBM, the Asset Care App potential solution to reduce the amount of operating equipment and is used by maintenance engineers, technicians and craftsmen. deliver greater control and accuracy to the mining process. It has been deployed to RWE field forces using iPads to improve The 4200 SM began mining at New Acland in June 2014 and maintenance efficiency. When the app is launched, the user sees has been selectively mining coal and partings. Operator training their personal tasks and settings. An intuitive function, Around Me, commenced in overburden. The decision to test the surface miner shows them jobs that need to take place near their location. “They was based on multiple expectations such as increased production can review maintenance plans,” Eberlein said. “All backup docu- rates, reduced mining costs, better coal recovery delivered through mentation is available online, even some of the old paper records. less loss and dilution, improved Run-of-Mine (ROM) coal quality, They can also find short instructions for maintenance tasks and simplification of the mining process, and reduced environmental view work order details.” The app uses photos and has red-lining emissions. To validate those expectations, a structured trial was capabilities as well as speech recognition. conducted from June to September 2014, evaluating machine performance against defined key performance indicators (KPI). With about 500 machines sold worldwide, Wirtgen GmbH, located in Windhagen, Germany, is the market and technology leader for surface miners. The direct-loading Surface Miner cuts, crushes and loads the material in one step and thereby replaces multiple conventional mining steps. Depending on job requirements, the Surface Miner can also side-cast the cut material or even cut-to-ground. The cut-to- ground option requires a different machine setup, i.e., different drum housing, no conveyor system. With the Surface Miner models 2200 SM/2200 SM 3.8, 2500 SM and 4200 SM, Wirtgen provides three performance classes, which can be configurated exactly to project needs. The strongest Wirtgen miner is powered by a 1,623-hp power plant and it weighs about 200 mt. The cutting drum, located in the RWE’s Material Ready App will eventually track the material management center of the machine between front and rear tracks, is equipped process digitally. with cutting tools, i.e., picks that grind the material. Cutting tool

VDMA 26 VDMA MINING SUPPLEMENT • 2018 New Acland participated in a four-month trial that compared the use of a Wirtgen Surface Miner against its traditional mining techniques and realized several benefits with the new system. holders are mounted onto the drum in a job-specific layout. Number The conventional mining system consisted of dozers and a of picks, pick spacing, and pick design are a few of the parameters wheel loader for loading rock and coal into the 130-mt to 190-mt that are designed to the conditions on the mine site and desired haul trucks. This dozer-assisted, truck-and-shovel operation has project deliveries, e.g., particle size distribution or cutting rates. been well developed over the years at New Acland. The dozer oper- In the development of the cutting drum for the New Acland proj- ators have extensive experience and achieve good loss and dilution ect, the engineers had to design the Surface Miner to cut both coal figures. New Acland, however, wanted to improve recovery and fur- and rock partings. On the direct-loading machine, the tool holders thered reduce coal loss and dilution. are mounted in a helix layout to pull the material toward the mid- A change in the mining process can be risky and uncertain so New dle of the drum. The cutting depth can be adjusted to follow the Acland opted for a four-month trial. For the successful implementation coal-rock interface, down to 830 mm. A scraper is located behind of new technology, it is important to take a whole-of-process view, which the cutting drum and from there the material is transported onto a requires cooperation between the divisions. KPIs of the Surface Miner primary conveyor, which transfers the material onto the discharge trial were not only limited to productivity and mechanical availability, conveyor that slews 180° with an adjustable height. It can load haul but also addressed impacts across the whole process chain. An example truck easily and efficiently while minimizing dust emissions. is the particle size distribution (PSD), particularly fines generation.

A WIRTGEN GROUP COMPANY

Surface Miner = Mining made easy. www.wirtgen.com/mining

4200 SM: WIRTGEN Surface Miners cut, crush and load material in a single operation. WIRTGEN is the only manufacturer to cover a performance spectrum of up to 3,000 tons per hour with direct loading by conveyor belt. This high output is based on high- performance cutting technology and a wealth of experience acquired in three decades of application technology. Take advantage of innovative solutions from the technology leader. www.wirtgen.com 2018 • VDMA MINING SUPPLEMENT VDMA 27 WIRTGEN GmbH · Reinhard-Wirtgen-Str. 2 . D-53578 Windhagen . T: +49 26 45 / 131 0 During the commissioning of the surface miner, New Acland and as “fine coal generation less than 2 mm not to exceed limitation of Wirtgen jointly conducted an extensive comparison of the gradation dozer/loader system.” of the specified coal. To this end, Wirtgen supplied a tracked MS Operators with no previous experience were trained to operate 19 triple-deck screening plant from Kleemann to analyze the grain the 4200 SM. A ramp up was applied to some KPIs to account for sizes of the 5-mm to 150-mm fractions and a laboratory screening that training. During a period of four months, performance of both plant to analyze the grain sizes of the fractions between 0.5 mm and mining systems was measured and compared against each other. 5 mm. A total of 100 individual 30-ton samples were analyzed. The The assessment revealed that about 70% less machines would samples for the conventional mining equipment and the 4200 SM be required for the Surface Mining system compared to the conven- were taken from identical mining fields, which were divided into two tional ripping, stacking and loading system. The 4200 SM has less for this purpose. impact on the environment, less equipment resulted in less emis- The Wirtgen Surface Miner was tailored to mine-site specifica- sion of noise, vibration and dust. The fuel usage per volume mined tions and arrived at the mine site in May 2014 and was commis- material was around 65% lower with than the traditional method. sioned within two weeks of arrival. The implementation of the new The operators experienced a number of ergonomic benefits as well. mining system required some adjustments to the traditional block mining system. Optimized Methods for Moving Ore The Surface Miner cuts lanes alongside each other. At the end After successfully installing two gearless conveyor projects in Peru of each cutting lane, it cuts its own ramp and turns around 180° (Antapaccay and Las Bambas), Siemens completed the world’s big- to start the next lane. The cutting lane length is a major parameter gest installation of a direct conveyor drive system. In this modern- influencing productivity. With increasing cutting lane lengths, the ization project, the belt conveyor replaced the railway system that fraction of operating time spent turning around decreases while was previously used to transport ore from the mine to the processing actual cutting time increases. To enable an efficient surface mining plant. The conveyor consisted of three individual sections equipped operation, it is recommended to operate the 4200 SM in blocks of with a total of five integrated drive systems. For the largest of the more than 300 m. New Acland’s conventional mining method oper- belt sections, Siemens supplied two gearless drive systems with an ated in 150-m x 150-m blocks. So multiple traditional mining blocks output of 6,000 kilowatts each. were added together to create a mining area of up to 600 m, allow- Siemens is also supplying a new conveyor system with gearless ing the Surface Miner to operate efficiently. and conventional drives to thyssenkrupp Industrial Solutions for the An in-depth trial program, designed around the KPIs, formed an Oyo Tolgoi underground copper mine in Mongolia. The new system essential part of the implementation process. They were categorized expands the existing open-pit mine and is expected to bring 95,000 as performance; health, safety and environment (HSE); financial metric tons per day (mt/d) of copper ore to the surface. The conveyor and downstream impact. Most of the KPIs refer to the continuous system has to overcome differences in elevation of almost 1,400 m. mining system employed. The KPI for fines generation was defined Production is expected to commence in 2020.

Building on technological advances, such as gearless drives and other high-angle conveying methods, Siemens believes untapped potential still exists for conveyor systems.

VDMA 28 VDMA MINING SUPPLEMENT • 2018 Despite these advances, there is still more potential to be produced data is then integrated with data from other sources, such as tapped with conveyors. ContiTech, thyssenkrupp and Siemens field service reports. Through advanced analytics, experts can predict have founded a research and development consortium to devel- impending failures and take action in time. An added advantage is that op and market the Chevron-MegaPipe conveyor. The new conveyor they can also uncover opportunities for performance improvements, as design is set to help reduce conventional heavy-duty truck traffic well as energy and cost savings. For remote-asset health management and the resulting high operating costs in open-pit mines. High- services, Siemens can go online from a competence center and provide strength, ribbed steel cable Chevron-MegaPipes with a nominal instruction to help mine personnel fix a problem. strength of up to 9,500 N/mm and an outer diameter of up to 900 A further tool for smooth operation is uniform IT structures. mm facilitate cost-effective conveyance of ore and overburden Vale, one of the world’s biggest mining companies, is implementing with lump sizes up to 350 mm over mine slopes with angles of a single manufacturing execution system to replace 17 production inclination of 30° to approximately 45°. The solution has already management systems used at its operations in Brazil. Siemens was proven its feasibility in a 350 m deep open-pit mine with a mass selected to develop and commission a manufacturing execution sys- flow of 5,000 mt per hour (mt/h). tem (MES), which goes under the name Vale Production Manage- On the island state of Papua New Guinea, Ok Tedi Mining Ltd. ment-Mining (GPV-M). It guarantees comprehensive transparency (OTML) runs a copper and gold mine. Like many mines in Papua New along the entire value chain and at all facilities, from the mines to Guinea, the drive train infrastructure on the grinding mills there is the railway and port facilities. Nowadays, GPV-M is one of the foun- in excess of 30 years old, and OTML was aware of the potential prob- dations of Vale’s digital strategy, which aims to establish a platform lems with the aging equipment. The company’s people also knew that will allow Vale to reach new heights of productivity through the that, to ensure long-term profitability, a move to industry standard combination of new technologies and processes. Results are already variable-speed control of the SAG mills was required. apparent. To date, more than 20 million mt of iron ore have already Siemens was selected to equip the two SAG mills at Ok Tedi with been shipped using the newly commissioned GPV-M. Plus, the IT new drive train infrastructure. The project will commence in 2018. costs for MES technologies will be reduced up to $19 million by 2020. Also part of the delivery scope: a cloud-based condition-monitoring Digitalization also makes autonomous operation of stock- system combined with remote access as well as contracts for main- yard machines — such as stackers and reclaimers — possible. tenance and analytics. Advanced material handling systems like these are paramount in Another area of bulk material handling gaining attention is pre- helping mines reduce operational costs with the added benefit of ventive maintenance. Here the goal is to minimize unexpected shut- increased safety. Digitalization of stockyards allows mining compa- downs caused by system failures. A continuous recording system — or nies to track quantities and quality. It provides real-time material data logging system — is connected to all components of the convey- inventory. Storage levels can be simulated and products with pre- ing system, including mechanical and electrical parts. The mass of cise qualities can be blended.

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2018 • VDMA MINING SUPPLEMENT VDMA 29 Moving More Material, More Effectively The use of intelligent, variable-speed systems help miners reduce transportation costs Once those primary earthmovers extract coal and ore from the face, The company recently introduced the TurboBelt 500 TPXL fluid it must be moved to its final destination, which could be a miner- coupling, which combines the fill-controlled advantages of hydro- al processing plant, a power plant or another transloading facility. dynamic drives with intelligent control technology. With cascading For years, the solution to moving more materials was simply larger speeds and torque control software, it offers smooth conveyor oper- systems with longer and wider conveyors and more horsepower. The ations for conveyors operating under any conditions. This controlla- problem, however, is that if the system is fully loaded and pushed bility extends the belt life and eliminates downtime. to the limit, it could take the entire operation down when it fails. For steep inclines or long overland conveyors, the company also By monitoring and actively managing the material handling offers a TT linear booster drive, which increases the drive power and system, mines can not only avoid mishaps, such as broken belts reduces tension forces within the conveyor significantly. By lowering and drive slippage, but reduce the tension and horsepower the sys- conveyor system’s effective tension, engineers can reduce the cost tem demands. This in turn would allow engineers to specify low- of the belting and structure by as much as 20%, according to Voith. er-rated belting and hardware, reducing overall capital costs as Voith’s latest offering, the TurboBelt DriveControl system, could well as energy consumption. serve as the core for the operational data for modern conveyor networks. It controls the conveyor behavior and features several capa- Intelligent Drive Solutions bilities, such as self-diagnostics, condition monitoring as well as Voith traces its roots back to 1867, where it was founded in Heiden- active-load balancing. heim, Germany. The company began supplying heavy equipment to “Everything comes together with the control system collecting the paper industry. In 1870, it began producing water turbines and data from the conveyors and the drive components,” said Maike has been involved in many major hydroelectric projects ever since. Bechtel, business developer for drive technologies, Voith. “Miners Gearbox construction began in 1929, based on the hydrodynamic not only want to know how the couplings are running, but also power transmission, which was invented by Hermann Föttinger. how the belt is driven as far as operational data, load conditions Voith then developed its first fluid couplings. A fluid coupling facto- and run times. For this, we have developed a controller with a ry was established in Crailsheim, Germany, in 1956, and is still the simplified interface.” headquarters for fluid couplings today. Last year, Voith founded a Voith has found new ways of combining its products with a digital solutions group to accelerate the digital revolution. logical control system, explained Helmut Fleuchaus, business de- For mining applications, Voith provides intelligent-drive com- velopment manager, Voith. “The control system monitors the torque ponents, which can operate in innovative, automated networks. during startup and operations,” Fleuchaus said. “The difference is The company’s fluid coupling systems are well-known and extreme- that we have combined everything into one main unit.” ly robust, this ensures safe and reliable operation even in harsh Modern high-capacity conveyor systems can be large and com- environments. plex with multiple drives using multiples motors. “Beyond load-bal-

Voith’s latest offering, the TurboBelt DriveControl system (above), could serve as the core for the operational data for modern conveyor networks.

VDMA 30 VDMA MINING SUPPLEMENT • 2018 ancing, the system understands a conveyor’s starting behavior,” solution for the medium-power range (1.3 MW per motor) to make Fleuchaus said. “The system knows why the conveyor was shut down this technology economically feasible for a broader range of conveyor and the operating conditions when it was shut down. Startup would systems, including on mobile equipment. A core element is a perma- be influenced by the load and, if it’s a multimotor arrangement, the nent magnet motor specifically designed for mining applications. motors and drives might require a staggered start and the control Working with local mine operator LEAG, ABB is now implement- system would decide which motor would start first.” ing a pilot project of this solution that is showing very encouraging The TurboBelt 500 TPXL, which has been developed especially for results in operation. The new gearless solution was installed on a new belt conveyors, is a smarter solution and has a smaller footprint high-capacity (15,000 mt/h) discharge conveyor of a bucket-chain for the same level of power transmission. It operates at a higher excavator in parallel with the existing geared drive. The operational efficiency and has a simple method for controlling the fluid inside the data demonstrate the advantages of the gearless solution with less coupling. “By changing the fluid level of the fill control coupling, we components like: alter the starting behavior of the coupling,” Fleuchaus said. “If you • Higher reliability (50% lower failure rate) and less maintenance; have an emergency stop with a belt that is potentially 10% to 15% • Higher efficiency with lower energy consumption (according ISO overloaded, you have to ensure safe restarts.” 50001) and lower noise emission; and As far as logic, two lines run between TurboBelt DriveControl to • Extended lifecycle (expected motor lifetime of 25 years is 10 years the main PLC. In the past, an open source architecture was designed longer than with a traditional gearbox). by PLC manufacturers, that may not have understood the principles The new solution can be applied for both greenfield and brown- of fluid couplings. “The function of the coupling and its behavior is field systems, and significantly decreases the cost threshold for a topic of its own,” Fleuchaus explained. “So we created our own gearless conveyor technology. controller based on the features necessary to start and operate the After the successful implementation of the stockyard manage- system for reliable operation,” Fleuchaus said. “With PID control- ment system (SYMS) at Vale’s iron ore distribution hub in Malaysia, lers and sensors, we can focus on the coupling’s behavior as far as ABB has extended the functional scope for the material tracking torque and speed. We can calculate the power absorbed from the and quality management in integrated lignite mine and power motor based on coupling slip. plant systems. These systems in Europe are often characterized “We focus on the driven side of the conveyor and analyze the by the combination of different mines feeding a nearby thermal torque transmitted to the belt at what speed,” Fleuchaus said. “We power generation plant without additional coal processing. The know exactly when the system was stopped and the last level of quality of the mined lignite is highly variable in terms of calorific motor power consumption. Now, we can perform an optimized restart value, ash, sulfur content, and influenced by non-ideal coal seam because our controller has saved the last value, which forms the courses. To secure an efficient combustion process, it is neces- basis of the restart conditions. It knows the difference between an sary to homogenize the coal feed by selective mining and blending emergency or overloaded shutdown and it automatically selects the processes on stockyards. proper restart scenario.” ABB is now executing an online coal quality management system project that tracks the quantity and quality of the excavated Providing the Power coal directly on the conveyor lines by the use of belt scales and on- ABB, as well as the VDMA, has a long history in the mining industry. line analyzers. The system compares the parameter from the pro- Located in a traditional German mining area, with the Center of Excel- duction planning system, which is based on the geological model lence in Cottbus, ABB has decades of expertise in electrification and of the coal deposit with the real measured values. It then creates automation for open-pit mining and bulk material handling applica- a feedback loop to the production system. The new parameters for tions along the entire mining chain from pit to port. The many years of the excavating and blending process, which are calculated online, experience was always coupled with innovative solutions that incorpo- are transmitted directly back to the mine’s control system and the rated the newest technology trends, such as digital mining solutions stockyard. So the system then enables continuous quality control of based on ABB Ability, its open industrial internet technology platform. the coal feed with an optimal mix of blending directly on the convey- ABB also has long-term successful partnerships with worldwide or lines, or if necessary, by the use of stockyard blending in parallel. leading mining equipment suppliers, such as Komatsu for electric rope shovels and TAKRAF Tenova for high-power gearless conveyor drives. ABB Germany has engineered a product platform for low-voltage AC Drives for extreme mining conditions and has made more than 100 deliveries during the past 12 years. The product life cycle of this successful AC Drive system will now go into classic phase to ensure the availability of spare parts from ABB Drives Service for another 12 years. Reliability and performance convinced Komatsu to deploy the next generation of ABB low-voltage drives, which provide more power in the same footprint. A FEM structure analysis of the cabinet system and IGBT live time analysis will ensure the proven quality level for high capacity shovels. Together with TAKRAF Tenova, ABB is partnering in the development of gearless conveyor solutions. A recent example is the execution of the world largest conveyor system at the Chuquica- matacopper mine in Chile, which will connect the newly developed underground operation directly with the concentrator. While recent projects were mainly driven by gearbox limitations for high-power drives (3.7 MW per motor), ABB recently developed a ABB has a new gearless solution for medium-powered conveyor drives.

2018 • VDMA MINING SUPPLEMENT VDMA 31 Intelligent Processing The proliferation of technology leads to automated processes and new grinding techniques

The control room at the mill or a processing plant has always Efficient Tailings Treatment been a technology center for most mines, especially when it A South American gold mine was looking for a single filter press ca- comes to instrumentation and control. More recently, the use of pable of covering the plant’s entire demand for tailings treatment. distributed controls gave way to programmable logic controllers The goal was to fulfill every environmental regulation as effectively (PLCs), which allowed a higher degree of automation. Now sen- and economically as possible. The mining company selected an AN- sors embedded throughout the plant are giving engineers the DRITZ overhead filter press A4 F 2500 in combination with Metris ability to recognize trends in data and make decisions based on addIQ automation. different criteria. The plant produces around 1,500 metric tons per day (mt/d) Despite their high levels of sophistication, plants and mills of tailings containing cyanide, at an ambient temperature of ap- still rely heavily on gravity-based systems where the ore is convert- proximately 1°C-15°C. The solids in the pulp average 51%, but ed to slurry and separated by size. This process requires two import- the solids content needs to reach more than 80% for the cake to ant inputs: water and energy. Both can be expensive commodi- be stored safely. Every day the plant initiates 36 filter press cycles ties in remote parts of the world. Any process improvements that lasting around 30 minutes each at feed pressure of 6 bar and max- reduce water and power consumption would be welcomed by imum pressure of 15 bar. mining companies. To ensure that production forecasts could be met reliably and Tailings treatment is another challenge for the mining sector. better cake moisture achieved, ANDRITZ sold an extraordinarily large In addition to the water needed to transport tailings, there are con- overhead filter press that features 2,500-mm x 2,500-mm plates to- cerns related to environmental risk and storage space constraints. gether with a Metris addIQ package for fully automated operations. Safe tailings disposal has become a major consideration for the Safe tailings disposal has become an intrinsic cost factor in mining industry. the mining industry, and the filter press is one way of reducing oper- The ANDRITZ GROUP, headquartered in Austria, has the broad- ating expenses when producing dry stacked tailings. Not only does est portfolio of separation technologies and it also specializes in it have the longest lifespan, it is suitable for very rough climate high-capacity technologies for tailings, including the world’s larg- conditions, offering excellent durability and reliability. In combina- est decanters and filter presses. The technology has now become tion with the addIQ automation system, it also requires extremely even smarter with the Metris addIQ automation solution for fully low maintenance. automatic operations. The fast filter cake discharge system has yielded some of Metris addIQ combines all of ANDRITZ’s extensive experience in the highest tailings throughputs, and operators can also adjust operation, troubleshooting and startup into one tailored automation the speed for different applications and cake properties. Clogged solution. Its nucleus is a modular, PLC-based control system that filter cloths can be a major source of downtime in less advanced allows operators to maximize machine performance regardless of systems, and that’s why the heavy-duty press features a filter cloth whether they are using ANDRITZ filter presses or other makes. washing device. The use of the Metris addIQ system has resulted in measurable improvements in throughput, safety, reliability and costs. The hydraulic closing pressure control, for example, enhances operating safety because the pressure is maintained at a safe, constant level. Metris addIQ automatically measures and controls the hydraulic and feed pressure. For faster filter cake discharge, the speed of the plate shifter can be adjusted. The drip plates are moved by means of hydraulic cylinders, also controlled by Metris addIQ. This ensures that the drip trays are in the open position for cake discharge and in the closed position during filtration. A key benefit here is that the filtrate is kept sepa- rate from any containers or the conveyor system. The next step toward achieving a fully autonomous filter press for 24/7 operations without operator supervision is an optical monitoring system for filter cake discharge. The filter cloth washing device enhances operating convenience because filter cloths are subsequently cleaned after the fully automatic filter cake discharge. The filter press feed is continuously controlled by pressure-feeding and load cells to obtain the optimum filling level, while the best possible dewatering is achieved by means of an optimized mem- This ANDRITZ large overhead filter press with 2,500- x 2,500-mm plates integrates brane squeezing system. In the final process steps, fully automatic a Metris addIQ package for fully automated operations. conveying systems ensure efficient filter cake discharge and the

VDMA 32 VDMA MINING SUPPLEMENT • 2018 sequences for filter cake washing are preconfigured for optimum the logbook functionality and automatic email notifier for the most washing results. critical process alarms. Metris Internet of Things (IoT) products focus on smart sensors, Big Data analytics and augmented reality. These technologies are Dry Ore Grinding applied and adapted individually to meet the requirements of each Santral Mining has decided to use a Loesche dry vertical roller mill to individual customer — exploiting the capabilities of systems al- grind gold ore in Turkey. The project is attracting a lot of attention world- ready installed and measurably enhancing plant performance. wide because the gold content of the raw ore is relatively low, and there- In combination with additional upgrade packages, the Me- fore, the profitability of the finish grinding and subsequent flotation is of tris addIQ control system maximizes performance regardless of particular importance. In grinding and flotation tests, it was proven that whether it is applied to ANDRITZ filter presses or other makes. The Loesche grinding technology not only works in a more energy-efficient packages available for filter presses include addIQ Dynamic, addIQ and wear-resistant way than the conventional wet ball milling, but it also Prime and addIQ Flex. makes a significantly higher yield of the dryly ground product possible. All four addIQ packages can be equipped with addIQ Footprint, The energy demand for vertical roller mills depends on the pressure a long-term data trending tool whose features include a dashboard, and, in particular, the speed when grinding hard rock. Loesche is also trends, a logbook, updates and reports, mobile access, and QR Iden- developing vertical roller mills with drive-power capabilities of up to 18 tification. What’s more, with addIQ Connectivity, one can monitor the MW for use in mining applications. Wet grinding systems (SAG and ball health status of their machine 24/7 from anywhere in the world. mills) have drive systems with power capabilities of up to 25 MW. The These add-ons allow users to store trend data for 24 months Loesche mill requires substantially less power for comparable grinding and present the most important KPIs for process values on the capacities of up to 2,000 mt/h. The cost benefits of using large grinding dashboard, all with a certified data connection and backup in plants with vertical roller mills will encourage the more widespread use of the data cloud. Operators can also generate and email automatic this technology, which is a relatively new concept for the mining industry. reports with process values and corresponding trend curves. The The largest Loesche mills to date have drive-power capabilities mobile app provides direct access to live data and machine-relat- up to 10 MW. The mills have redundant systems to avoid machine ed documentation, while peace of mind is guaranteed thanks to failures and to be able to ensure high levels of availability.

Loesche vertical roller mills operate dry and require substantially less power than SAG Mills for comparable grinding capacities of up to 2,000 mt/h.

2018 • VDMA MINING SUPPLEMENT VDMA 33 High-pressure Pumps for Large Volume Flows

of the pump. As a result, wear is significantly reduced since the pump, the pipes and the valves are subjected to far less load. The first 530-kW quintuplex pump was quickly followed by an 800-kW model. The two versions are already produced in the series, and the operators benefit from significant cost savings in terms of energy consumption and maintenance and service bills: Three 800- kW pumps — one each as a master, slave and standby unit, which is the common constellation — are able to generate even very large volume flows at pressures up to 3,500 bar at highly economical rates. In 2017, KAMAT added a quintuplex pump with a rating of 1,200 kW to the portfolio.

Transporting and Charging Explosives With the increasing number of panel-caving operations, where ore is mined by conventional drill-and-blast operations, transporting explosives to the loading locations and scheduling blasts are two very important underground mining issues. Many mines rely on a mixture Economies of scale: KAMAT has developed the first quintuplex (five-cylinder) pumps with a rating of 530 or 800 kW on the basis of the thoroughly redesigned of ammonium nitrate and fuel oil (ANFO). Production drill holes can triplex pumps. be as long as 25 m with a diameter up to 3 inches, which means the typical round requires approximately 3,000 kg of ANFO. By lim- The (water-based) hydraulic systems in various high-pressure iting the hole-charging time and reducing the transportation costs, plunger pump applications, especially longwall roof supports, are mines could achieve a higher level of productivity at a lower cost. getting larger and larger. As a result, longwall operators are using Paus has developed an ANFO-charging concept that combines multiple, large triplex pumps given that the volume flow of these the transportation and charging of ANFO in one machine to extend pumps is limited by design and the high pressures involved. And, charging capacity for one full pattern. The system is based on the the cylinder size is limited by cavitation, which implies that it makes Universa 50-2 with a Deutz TCD 2012 diesel engine, Posi Stop axles sense to produce triplex pumps with ratings of “only” about 400 kW. and a hydrodynamic drive line from Dana Spicer. The Universa 50 is KAMAT has now taken the next step and developed, on the ba- equipped with an ANFO storage platform with a maximum capacity of sis of the thoroughly redesigned triplex pumps, the first quintuplex up to 120 ANFO bags (22 kg each), a 500-l ANFO vessel, rotary vane (five-cylinder) pumps with a rating of 530 or 800 kW and the capabili- compressor and a telescopic platform in the rear part of the machine ty to reliably deliver distinctly larger volume flows than triplex pumps. to cover the full drilling pattern with a fixed-carrier positioning. The advantages for the longwall operator result from “econo- The carrier with boom/basket at the rear is also the ideal platform mies of scale.” A large pump is working far more cost-effectively for all kinds of emulsion units. An experienced driver can accomplish than two or three smaller ones, and clearly needs less space — an this changing procedure within a maximum of 5-10 minutes. important argument in most modernization projects. In addition, the Uni 50 can be equipped with a working platform, A lot of detailed design work was, however, required to transfer which permits working heights above 7 m to cover 40-m2 faces. All the basic concept of the triplex design to the quintuplex pump. The machines implement extended safety features. This concept enables crankshaft, for example, is supported by multiple bearings, and the the increase of charging time of every unit and the use of the 500-l crossheads are oil-spray lubricated rather than splash lubricated so vessel keeps the machine dimensions as compact as possible. that sufficient lubrication of the center crossheads is ensured as well. With its famous hydraulic quick changing system, the Uni 50 KAMAT, nevertheless, managed to keep spare parts stocking eco- can quickly switch cassettes to a scissor platform, cement mixer nomical through the use of many parts that are common to the triplex and sprayer, tire handler, diesel generator, loading platform, etc. pumps. The housing was developed and optimized by KA- MAT in close collaboration with the IFAS Institute at the Ruhr University Bochum who also simulated the thermal load of the pumps and carried out the respective optimizations. The quintuplex pumps furthermore offer the same advantages as the redesigned triplex pumps. They operate at extremely low-noise and low-vibration levels and are capable of working at full operating pressure over a speed range of 10% to 100% in conjunction with speed-controlled drives. Thus, they can ideally be adapted to the respective volume flow requirements. The flow rate is not controlled through unloading valves in on/off technique but through an electronically controlled speed regulation The Universa 50 from Paus can be equipped with a full ANFO charging platform.

VDMA 34 VDMA MINING SUPPLEMENT • 2018 Mine Duty Air Hoists or ancillary equipment eliminates the potential for ignition risk, while JD Neuhaus air hoists have been designed specifically for mining and increased spark-protection features ensure the highest ATEX ratings other underground applications including their M series air hoists. They for hazardous area operation. Hydraulically operated hoists can also be operate off a 4-bar pressure and can be supplied in lift capacities of 1, provided where a compressed air supply may not be readily available. 2, 3 and 6 metric tons (mt). Twin chain pulls are provided for alternate working and all hoists feature a top hook mounting to accommodate Communications for Mine Rescue Equipment oblique or horizontal pulling of loads. These products can be equipped Rescue operations have been and are still one of the most challenging with two optional control systems for single- or two-handed operation. jobs in the mining industry. During training, rescue teams of five to six The DS system, which is designed for the two-handed operation, members are confronted with demanding situations that push them has compressed air connected to the hand-control valve. A built-in to their limits, both physically and mentally. Some of the possible sce- pressure regulator prevents hoist overload in the event of inadmissi- narios they face include bad visibility, presence of toxic and/or explo- bly high air pressure. An oiler, situated directly at the hoist motor, is sive gases, fire and smoke, rock fall and injured miners. Exceptional operated from the controller housing to ensure the oil flow automat- training, which for many includes competitions at state and national ically ceases when the hoist stops. The operating air immediately levels, prepare them well — to quickly assess the risks and to know initiates the motor when the hand lever is activated. This lever is how to deal with them. spring-loaded and returns automatically to zero position when re- The need for a clear exchange of information is imperative in these leased. This forced release also serves as an emergency stop. critical circumstances, and verbal communication is usually the pre- The optional PS control is for single-handed use with emergency ferred option. A rescue team needs to be able to talk to the fresh air base, stop fitted as standard. It operates indirectly with a compressed air the surface, to miners and to each other. Today, traditional technology supply connected to the control valve of the motor. The control pistons such as mining telephones is still widely used. Mine rescue teams carry of the motor are actuated by the hand control push buttons, which au- their own cables for communication. They do this for good reason—it tomatically return to zero position. In the control valve of the motor, a works. Unfortunately, there are certain limitations that could result in pressure regulator protects the hoist from inadmissibly high pressure, miscommunication, misunderstanding and wrong decision making. while the integrated oiler provides the necessary lubrication. Modern communication technology has been available for years and The Profi TI series hoists are also suitable for underground work- is a common tool for everyone. This same technology is used in under- ing and operate off air pressures of 4 or 6 bar, with hydraulically op- ground mines for a completely different challenge, however. Here, the con- erated units also available. Lift capacities from 250 kg up to 100 mt ditions are extreme. The rescuers face harsh environmental conditions, are available with traverse trolleys for overhead monorail operation such as humidity, water ingress, danger of collapse, risk of explosion, fire also available for lift ratings up to 20-mt maximum capacity. as well as excessively handled equipment. Modern communication needs A Profi TI hoist with 37-mt lifting capacity was recently used for to support the task of a mines rescue team, not distract from it. the safe and successful handling of an assembled 1,000-m string The Dräger FPS-COM 5000 is a communication device that is de- of pipeline. This involved the connection of individual pipeline sec- signed to fill that gap. It attaches to the widely used Dräger FPS 7000 tions, each 8 m long, to create a completed string weighing 30 mt, RP full-face mask easily. In addition, it includes a voice amplifier that which had to be positioned within a shaft. is voice activated, so it is hands free, allowing for more mobility. Every These compact hoists offer excellent weight/load ratios, with the unit has an interface that connects to a radio with a cable or via Blue- Profi 37 TI having an all-up weight of 880 kg (with a standard 10-m tooth. Connections to the most frequently used radios underground chain length) while providing an impressive 37.5-mt lifting capacity. are available. All the rescuer needs to do is simply press the push-to- The elimination of any electrical power supply for drive mechanisms talk button to activate the voice communication through the radio. If a mine is already equipped with communication infrastructure and radio, the Dräger FPS-COM 5000 can be easily integrated and is ready to use for applications underground as well as above ground. In keeping with the Smart Mining vision, the FPS-COM 5000 fits as an integrated part of the communications’ system within the team and fresh air base, which is crucial in order to concentrate on the job at hand. Some mines also require cable-supported communications for its rescue teams to be able to work independently from the infrastructure of the mine. Therefore, a version for such an application is in preparation. It would work independently from any other possible stationary-installed system. This means that operating the Dräger FPS-COM 5000 would be the same as any cable-supported communication system. It would include the voice amplifier, but instead of using a radio cable, it would connect the team to the fresh air base independently. First introduced at the 2016 International Mines Res- cue Competition in Canada, the Dräger FPS-COM 5000 was tested by a total of 27 teams. The communication system was tested and tried under realistic underground rescue scenarios and received impressive, positive feed- The FPS-COM 5000 communica- JD Neuhaus Profi 37 TI hoist successfully handles a 1,000-meter-long pipeline back. It was also commended as a viable and positive tion system has been integrated string weighing 30 metric tons, being positioned within a mining shaft. solution with real benefit for the future of mines rescue. into the Dräger full-face mask.

2018 • VDMA MINING SUPPLEMENT VDMA 35 VDMA 36 GERMAN VENDORMATRIX

VDMA MININGSUPPLEMENT AUMUND • AViTEQ ••• • BARTEC • ••• • • •••• •••• Bauer Maschinen •• • ••••• ••• Becker Mining Systems ••• •••••••• •••••••• Bell Equipment • BEUMER • •••••••••••• BHS-Sonthofen •• Bochumer Eisenhütte • • Bosch Rexroth •• •••• •••• • BRÄUTIGAM • •••• Caterpillar Global Mining ••• • • ••• CFT • • •••• CIV PRÄZISIONSTECHNIK • ••

• Coal Control • • 2018 DEUTZ • •• DMT • • ••• Döpke •••• GERMAN VENDORMATRIX 2018 • VDMA MININGSUPPLEMENT

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware Doppstadt Calbe ••• •••• • Dräger Safety • •••••••••• • ••• ••••• DÜCHTING • • •• Durum • •• • EEP ••• • • • •• ••• Eickhoff •• Eirich •• • EnviroChemie ••• •• ESI ITI ••• FAM •••••••• •••• •• Fagus GreCon • • • FELUWA Pumpen • • • Filtration Group (formerly MAHLE) •• •••• FLSmidth Wadgassen • •• •••• •• FLSmidth Wiesbaden •••• •• GEA Westfalia Separator •• ••• Getriebebau Nord • GHH ••••• • • GOTHE • • •• •• GTA ••• • • HADEF HEINRICH DE FRIES • Hammelmann •• • Hauhinco •• • ••• Haver NIAGARA ••• ••• HAWE HYDRAULIK •• • Hazemag & EPR ••• ••• ••• •••••• H.C. Starck Tungsten • H+E Logistik • ••• •• VDMA 37 VDMA 38 GERMAN VENDORMATRIX

VDMA MININGSUPPLEMENT KSB • ••• Liebherr •• • LOESCHE •• •• ••• marco •• • • MATO • • • • •• MBE Coal & Minerals ••••• •• ••• MTU Friedrichshafen • •••• •• • J.D. Neuhaus •• •• • • Nilos •• ••••••• oddesse • •• • • Paus •• ••• • PFISTER WAAGEN • •••• PFREUNDT • ••• •••••••• PLARAD •

• PRAKLA •• • •• • • 2018 Preinfalk •••••• ••••• •• ••• Pumpentechnik Erkrath • Putzmeister •• • • • • •• GERMAN VENDORMATRIX 2018 • VDMA MININGSUPPLEMENT

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware RWE Technology International ••• • • ••• SAMSON • Sandvik Crushing Technology • SCHADE • Schaefﬂer Technologies • ••• Schäfer Pumpen •• • Schalker Eisenhütte • • Schopf • • Schulte Strathaus • • SEKA • SIEMAG Tecberg • • •• •• ••••• Siemens •• ••••• •••••• •••• SMT Scharf •••• •• • •• STEINERT • Stromag GmbH •••••••••••••••••••••••••• TAKRAF ••• •••••••• ••• Thomas Magnete • • thyssenkrupp Industrial Solutions ••• •••••••••• •• TLT-Turbo • TML Technik •••• • • Tüschen & Zimmermann • • URACA ••• • • VAUDID •••• •••• • •• VELCO •• VOITH TURBO • • • •• ••• ••• VULKAN • •• WILO SE • • ••• • • WIRTGEN ••• ••• VDMA 39 ABB Automation GmbH Andritz Separation GmbH Geschäftsbereich Open Pit Mining Bell Equipment (Deutschland) GmbH Edmund-Rumpler-Str. 6A Hänchener Str. 14 Oberste Elpersweide 4 51149 Köln 03050 Cottbus 36304 Alsfeld www.andritz.com/separation www.abb.com/mining www.bellequipment.com

apc analytics GmbH ABEL GmbH BEUMER Group GmbH & Co KG Daimlerstrasse 17 Abel-Twiete 1 Oelder Str. 40 61449 Steinbach / Ts. 21514 Büchen 59269 Beckum www.apc-analytics.com www.abel.de www.beumergroup.com

AUMUND Fördertechnik GmbH AEM - Anhaltische Saalhoffer Str. 17 BHS-Sonthofen GmbH 47495 Rheinberg Elektromotorenwerk Dessau GmbH An der Eisenschmelze 47 www.aumund.com Daheimstr. 18 87527 Sonthofen 06842 Dessau-Rosslau www.bhs-sonthofen.com www.aemdessau.de

AViTEQ Vibrationstechnik GmbH Alimak Hek GmbH Im Gotthelf 16 BOCHUMER EISENHÜTTE Frauenbrunner Str. 25 65795 Hattersheim HEINTZMANN GMBH & CO KG www.aviteq.de 75031 Eppingen Klosterstr. 46 www.alimakhek.de 44787 Bochum www.be-heico.de

BARTEC Sicherheits- Schaltanlagen GmbH Holzener Str. 35 - 37 58708 Menden Bosch Rexroth AG www.bartec-mining.com Maria-Theresien-Str. 23 allmineral Aufbereitungstechnik 97816 Lohr am Main GmbH & Co KG www.boschrexroth.com Baumstr. 45 47198 Duisburg www.allmineral.com Bauer Maschinen GmbH BAUER-Str. 1 ANDRITZ KMPT GmbH 86529 Schrobenhausen Industriestrasse 1-3 www.bauer.de BRÄUTIGAM Gear & Mining Tech 85256 Vierkirchen GmbH & Co KG www.andritz.com Am Schürmannshütt 8 - 18 47441 Moers Becker Mining Systems AG www.braeutigam-group.com ANDRITZ Ritz GmbH Walter-Becker-Straße 1 Güglingstr. 50 66299 Friedrichsthal 73529 Schwäbisch Gmünd www.becker-mining.com www.andritz.com

VDMA 40 VDMA MINING SUPPLEMENT • 2018 CATERPILLAR Global Mining Europe GmbH Eickhoff Bergbautechnik GmbH Industriestr. 1 Am Eickhoffpark 1 44534 Lünen Maschinenfabrik Heinrich Döpke 44789 Bochum www.cat.com/mining GmbH www.eickhoff-international.com Stellmacherstr. 10 26506 Norden www.doepke-gmbh.de CATERPILLAR Global Mining HMS GmbH Karl-Funke-Str. 36 Maschinenfabrik Gustav Eirich 44149 Dortmund GmbH & Co KG www.mining.cat.com Walldürner Str. 50 Doppstadt Calbe GmbH 74736 Hardheim Barbyer Chaussee 3 www.eirich.com 39240 Calbe (Saale) www.doppstadt.de

CFT GmbH EnviroChemie GmbH Compact Filter Technic In den Leppsteinswiesen 9 Beisenstr. 39 - 41 64380 Rossdorf 45964 Gladbeck Dräger Safety AG & Co KGaA www.envirochemie.com www.cft-gmbh.de Revalstr. 1 23560 Lübeck Web: www.draeger.com ESI ITI GmbH Schweriner Str. 1 01067 Dresden CIV Präzisionstechnik GmbH www.itisim.com Tuchmacherweg 11 DÜCHTING PUMPEN 39288 Burg Maschinenfabrik GmbH & Co KG www.civ-burg.de Wilhelm-Düchting-Str. 22 58453 Witten www.duechting.com FAM Förderanlagen Magdeburg und Baumaschinen GmbH Coal Control Sudenburger Wuhne 47 Gesellschaft für Automation mbH 39112 Magdeburg Reisholzstr. 15 www.fam.de 40721 Hilden DURUM Verschleißschutz GmbH www.coal-control.com Carl-Friedrich-Benz-Str. 7 47877 Willich www.durmat.com

FELUWA Pumpen GmbH Beulertweg 10 54570 Mürlenbach DEUTZ AG www.feluwa.com Ottostr. 1 51149 Köln www.deutz.com EEP Elektro-Elektronik Pranjic GmbH Am Luftschacht 21 45886 Gelsenkirchen www.eep.de Filtration Group GmbH (Formerly MAHLE Industrial Filtration) DMT GmbH & Co KG Schleifbachweg 45 Am Technologiepark 1 74613 Öhringen 45307 Essen www.ﬁltrationgroup.com www.dmt-group.com

2018 • VDMA MINING SUPPLEMENT VDMA 41 FLSmidth Wadgassen GmbH Karl-Koch-Str. 1 GTA Maschinensysteme GmbH 66787 Wadgassen www.ﬂsmidth.com Loikumer Rott 23 HAVER NIAGARA GmbH 46499 Hamminkeln Robert-Bosch-Str. 6 www.gta.eu 48153 Münster www.haverniagara.com

FLSmidth Wiesbaden GmbH Am Klingenweg 4a 65396 Walluf H + E Logistik GmbH www.ﬂsmidth.com HAWE Hydraulik SE Josef-Baumann-Str. 18 Streitfeldstr. 25 44805 Bochum 81673 München www.helogistik.de www.hawe.de

GEA Westfalia Separator Group Werner-Habig-Str. 1 59302 Oelde H. C. Starck Tungsten GmbH www.westfalia-separator.com Landsberger Str. 98 80339 München www.hcstarck.com HAZEMAG Mining Brokweg 75 48249 Dülmen Getriebebau Nord GmbH & Co KG HADEF HEINRICH DE FRIES GmbH www.mining.hazemag-group.com Getriebebau-Nord-Str. 1 Hebezeugfabrik 22941 Bargteheide Gauss Str. 20 www.nord.com 40235 Düsseldorf www.hadef.de

GHH Fahrzeuge GmbH Hammelmann GmbH Emscherstr. 53 hema electronic GmbH 45891 Gelsenkirchen Carl-Zeiss-Straße 6-8 Röntgenstraße 31 www.ghh-fahrzeuge.de 59302 Oelde 73431 Aalen www.hammelmann.com www.hema.de

Gothe & Co GmbH Hauhinco Maschinenfabrik El.-Ap. Elektro-Apparate GmbH & Co KG Kruppstr. 196 45472 Mülheim an der Ruhr Beisenbruchstr. 10 www.gothe.de 45549 Sprockhövel Herrenknecht Mining www.hauhinco.de Schlehenweg 2 77963 Schwanau www.herrenknecht.com

Fagus GreCon Greten GmbH & Co KG Hannoversche Straße 58 31061 Alfeld www.grecon.com HYDAC INTERNATIONAL GmbH Industriegebiet 66280 Sulzbach/Saar www.hydac.com

VDMA 42 VDMA MINING SUPPLEMENT • 2018 Ingeteam GmbH Grand Bateau - Zollhof 6 40221 Düsseldorf MBE Coal & Minerals www.ingeteam.com KSB Aktiengesellschaft Technology GmbH Pumpen & Anwendungen Gottfried-Hagen-Str. 20 Feststofftransport 51105 Köln Johann-Klein-Str. 9 www.mbe-cmt.com 67227 Frankenthal JÖST GmbH + Co KG www.ksb.com Gewerbestr. 28 - 32 48249 Dülmen MESUTRONIC Gerätebau GmbH www.joest.com Hackenfeld 13 94259 Kirchberg www.mesutronic.de KVT Kurlbaum AG Sachsenring 4-6 27711 Osterholz-Scharmbeck KAMAT GmbH & Co KG www.kvt-group.de Salinger Feld 10 58454 Witten www.kamat.de MTU Friedrichshafen GmbH Liebherr-Mining Equipment SAS Maybachplatz 1 49 rue Frédéric Hartmann 88045 Friedrichshafen 68025 Colmar, France www.mtu-online.com Kleemann GmbH www.liebherr.com Manfred-Wörner-Straße 160 73037 Göppingen www.kleemann.info

J. D. NEUHAUS GmbH & Co KG LOESCHE GmbH Windenstr. 2 - 4 Komatsu Germany GmbH Hansaallee 243 58455 Witten Forststr. 29 40549 Düsseldorf www.jdngroup.com 40597 Düsseldorf www.loesche.com www.komatsu-mining.de

Nilos GmbH & Co KG Maschinenfabrik KÖPPERN Reisholzstr. 15 GmbH & Co KG 40721 Hilden Königsteiner Str. 2 www.nilos.com 45529 Hattingen www.koeppern.com marco Systemanalyse und Entwicklung GmbH Hans-Böckler-Str. 2 Krummenauer GmbH & Co KG 85221 Dachau oddesse Pumpen- und Wellesweilerstr. 95 www.marco.de Motorenfabrik GmbH 66538 Neunkirchen Am Pappelwald 12 www.krummenauer.de 39387 Oschersleben www.oddesse.de MATO GmbH & Co KG Benzstr. 16 - 24 63165 Mühlheim www.mato.de

2018 • VDMA MINING SUPPLEMENT VDMA 43 Pumpentechnik Erkrath Schaefﬂer Technologies AG & Co KG GmbH + Co KG Georg-Schäfer-Straße 30 Hermann Paus Maschinenfabrik GmbH Max-Planck-Str. 28 97421 Schweinfurt Siemensstr. 1 - 9 40699 Erkrath www.schaefﬂer.de/ 48488 Emsbüren www.pumpentechnik-erkrath.de rohstoffgewinnung_verarbeitung www.paus.de

Schalker Eisenhütte Maschinenfabrik GmbH Am Eickhoffpark 1 PFISTER WAAGEN BILANCIAI GMBH 44789 Bochum Linker Kreuthweg 9 Putzmeister Solid Pumps GmbH www.schalke.eu 86444 Afﬁng-Mühlhausen Max-Eyth.Str. 10 www.pﬁsterwaagen.de 72631 Aichtal www.pmsolid.com Schenck Process Europe GmbH Pallaswiesenstraße 100 PFREUNDT GmbH 64293 Darmstadt Robert-Bosch-Str. 5 www.schenckprocess.com 46354 Südlohn www.pfreundt.de

SAMSON AG MESS- UND REGELTECHNIK Schopf Maschinenbau GmbH PLAKOMA GmbH Weismüllerstr. 3 Parkstr. 19 - 21 Bahnhofstr. 101 60314 Frankfurt 73760 Ostﬁldern 66809 Nalbach-Körprich www.samson.de www.schopf-mining.com www.plakoma.de

PLARAD Maschinenfabrik Wagner F. E. Schulte Strathaus GmbH & Co KG GmbH & Co KG Sandvik Mining & Construction Fördertechnik - Dichtungssysteme Birrenbachshöhe 17 Crushing Technology GmbH Runtestr. 42 53804 Much Friedrich-Ebert-Str. 75 59457 Werl www.plarad.de 51429 Bergisch Gladbach www.fess-group.de www.sandvik.com

PRAKLA Bohrtechnik GmbH Moorbeerenweg 3 SCHADE Lagertechnik GmbH 31228 Peine Bruchstraße 1 SEKA Schutzbelüftung GmbH www.prakla.de 45883 Gelsenkirchen Im Höger 4 a www.schade-lagertechnik.com 76829 Landau www.schutzbelueftung.de

WOLFGANG PREINFALK GMBH Im Oberen Werk 4 Schäfer Pumpen & Hydraulik GmbH 66386 St. Ingbert Kaiserswerther Str. 74 SIEMAG TECBERG GmbH www.preinfalk.de 40878 Ratingen Kalteiche-Ring 28-32 www.schaefer-ph.com 35708 Haiger www.siemag-tecberg.com

VDMA 44 VDMA MINING SUPPLEMENT • 2018 Siemens AG Process Industries and Drives Division VELCO Gesellschaft für Förder- Schuhstr. 60 Spritz- und Siloanlagen mbH 91052 Erlangen Haberstr. 40 www.siemens.com/mining thyssenkrupp Industrial Solutions AG 42551 Velbert thyssenkrupp Allee 1 www.velco.de 45143 Essen www.thyssenkrupp-industrial- SMT Scharf GmbH solutions.com Römerstr. 104 Voith Turbo GmbH & Co KG 59075 Hamm Voithstr. 1 www.smtscharf.com 74564 Crailsheim Web: www.voith.com

TLT-Turbo GmbH STEINERT Elektromagnetbau GmbH Gleiwitzstr. 7 VULKAN Kupplungs- und Getriebebau Widdersdorfer Str. 329 - 331 66482 Zweibrücken Bernhard Hackforth GmbH & Co KG 50933 Köln www.tlt-turbo.com Heerstr. 66 www.steinert.de 44634 Herne Web: www.vulkan.com

Stromag GmbH TML Technik GmbH Hansastr. 120 Daimlerstr. 14 - 16 59425 Unna 40789 Monheim WILO SE www.stromag.com www.tml-technik.com Nortkirchenstr. 100 44263 Dortmund Web: www.wilo.com

Tüschen & Zimmermann TAKRAF GmbH GmbH & Co KG Torgauer Str. 336 Winterberger Str. 82 WIRTGEN GmbH 04347 Leipzig 57368 Lennestadt Reinhard-Wirtgen-Str. 2 www.takraf.com www.tueschen-zimmermann.de 53578 Windhagen Web: www.wirtgen.de

URACA GmbH & Co KG Thomas Magnete GmbH Sirchinger Str. 15 San Fernando 35 72574 Bad Urach 57562 Herdorf www.uraca.de www.thomas.magnete.com

VAUTID GmbH Brunnwiesenstr. 5 73760 Ostﬁldern www.vautid.com

2018 • VDMA MINING SUPPLEMENT VDMA 45 Equipment & Technology

Caterpillar Launches New Underground Hard Rock Mining Vehicles

deliver the performance and durability of its larger counterparts. It also offers the largest payload in the size class. Developed in response to customer demand for a truck that can work produc- tively in compact spaces, the AD22 is a robust truck capable of maneuvering in smaller mines. Its small operating enve- lope and agile characteristics, including 45-degree articulation and decreased outside turning radius, enhance productivity when working in limited spaces. An oscillating hitch helps absorb haul road irregularities and enables the operator to maintain greater speed and control. Like its larger counterparts, the AD22 makes best use of proven Cat components, such as the Tier 3 equivalent C11 diesel engine. The durable engine delivers gross power of 242 kW. Coupled to the Caterpillar offers a broad line of under- The new traction control system, which C11 is a Cat heavy-duty torque converter ground hard rock mining vehicles includ- uses the new electrohydraulic braking sys- with an automatic lock-up clutch and Cat ing five different sizes of underground tem, limits tire slip going into the pile. The planetary powershift transmission. These loaders and four different capacities of result is longer tire life and reduced tire components are responsible for the nimble underground trucks to accommodate a costs. Also, Auto Dig — fully automated performance, speed on grade and all- wide range of mine openings and produc- bucket loading — helps new operators be wheel drive capabilities of the truck. tion requirements. All of the vehicles use productive the first day and reduces fatigue The truck is available with an open proven Cat engines and drive trains for for experienced operators. The R1700 also operator compartment or an optional efficient, reliable operation and extended features operator presence and door latch enclosed cab. The sweeping deck design durability. Each of the machines comes monitoring for enhanced safety. provides the operator with good sight lines with the product support capabilities of The new R1700 also delivers signifi- around the front of the truck. An operator the local Cat dealer — to keep machines cant technology enhancements. Three dif- present system automatically sets the park- producing at lowest cost per ton. ferent engine emissions configurations can ing brake and shuts down the engine if the The Cat underground loader, or LHD, be tailored to the mine’s ventilation needs. operator fails to apply the brake before line ranges from 6,800-kg payload to The new Cat line-of-sight remote control exiting the cab. 20,000-kg payload. In the middle of the console promotes productive operation. Multiple dump body sizes are available range is the 15,000-kg-payload R1700, The R1700 also is equipped with multiple to optimize the truck for every applica- which was recently commercially launched subsystems for fast technology implemen- tion and to help mines achieve the tar- after proving its capabilities in extensive tation. Remote machine health monitoring, get payload based on material density. field trials. payload monitoring and other technology Dump bodies come in 9, 10, 11 and A completely new Caterpillar design, options are available. 12 cubic-meter sizes. An ejector body the R1700 loader benefitted from the use of The Cat line of underground articulat- of 9.7 cubic meters is also offered. The engineering talent from across the company ed trucks is well matched to Cat loaders. AD22 offers a three-pass match to the Cat to bring new levels of productivity, operator Four truck models offer payload capacities R1300G underground loader or a two- comfort and serviceability to underground ranging from 22,000 to 60,000 kg. pass match to the R1600H. miners. Compared to the previous model, Caterpillar recently introduced the the new R1700 carries 20% more material AD22 Articulated Truck with a 22-met- Loesche Sells 32 with each pass. Increased digging forces ric-ton (mt) capacity. The newest addition Coal Mills to India add further to its production capabilities as to the Cat underground truck line is Jawaharpur — In one fell swoop, Loesche does superior machine balance. Caterpillar’s smallest, but it’s designed to has sold 32 coal mills to India and gained a

+-INDIA 2018 Equipment & Technology

new end customer in the process. The large ity to Doosan Power Systems India (DPSI). our own manufacturing facilities as well as vertical roller mills (VRM), with two rollers Loesche recently established LESI in India through our supplier network.” each and a performance of 79.2 metric with a connected workshop, in order to The foundry development will begin as tons per hour (mt/h) or 75.6 mt/h, will be strengthen and expand its market activities soon as the acquisition of the foundry assets used in the coal-fired power plants “Super in the thriving subcontinental energy sector. has been completed. The first product Thermal Power Station” in Jawaharpur and The Indian energy market is the second deliveries from the Vadodara foundry are “Obra-C” in the Sonebhadra district of largest in the world, after China. Energy expected by the end of 2019 and the pro- Uttar Pradesh state in North India. At both production in India is currently primarily duction will ramp up quickly in 2020. The locations, the end customer Uttar Pradesh dependent on coal power plants. Experts new foundry will be built to follow Metso’s Rajya Vidyut Utpadan Nigam Limited predict an average increase of 18 GW per sustainability and quality principles. (UPRVUNL) will operate four power sta- year until 2020 in coal power plant output. In related news, Metso has won a signif- tion blocks from 2020/21 onwards, with For this reason, the construction of a icant order to deliver a pellet plant, includ- 660 MW of power each. Delivery of the large number of coal-fired power plants is ing grinding, filtration and a pyro-process- Loesche mills should be made by Autumn planned. With its new subsidiary, Loesche ing pellet plant to a large-scale steel oper- 2019 and will include electric drives, slide can better provide the local energy sector ation of JSW Steel Ltd. in India. This new gates, instrumentation and junction boxes. with Loesche mills and maintenance ser- order is Metso’s largest global pellet plant The contractor and constructor for vices in future. delivery, and the single largest installation the power plants is the Indian company The 32 coal mills for the new UPRVUNL for Metso 2040-60 Vertical Plate Pressure Doosan Power Systems India (DPSI). DPSI, power plant are distinguished by their mod- Filters VPA, which are used in heavy-duty a subsidiary of the Korean Doosan Heavy ular construction, which has been tried and dewatering applications. Industries Group, was commissioned by tested by Loesche in the cement industry. “Metso has a proven track record of the state electricity supply company of The principle of these grinding plants is delivering sustainable performance and reli- Uttar Pradesh, to the value of $2.3 billion. based on a horizontal grinding table with ability to the mining industry globally. We With its efficient VRM technology and com- segmented grinding plates and conical are very proud of this order, which further petitive prices, Loesche was able to assert rollers (M) which are arranged at a 15° strengthens our position in the Indian min- itself among international competitors and angle to the grinding table. The hydraulic ing market,” said Victor Tapia, president, once again win over its long-standing part- swinging device for the rollers (M) ensures Metso Mining Equipment business area. ner in joint projects. a simple and fast change of grinding parts. Metso established its operations in It is worth noting that this is the first large Loesche mills guarantee consistent through- India in 1992, and has been developing order obtained by the Loesche subsidiary put and fineness product quality using an a strong footprint in the market ever since. Energy Systems India Private Ltd (LESI) in efficient hydraulics system to regulate grind- Today, Metso says it’s the leading player the Indian power plant market. LESI has its ing pressure, and a speed-controlled grind- in pelletizing in India. head office in Chennai — in direct proxim- ing table and high efficiency classifiers. Thyssenkrupp Installs Metso to Increase its Material Handling Foundry Capacity in System India thyssenkrupp also won a contract from Metso is investing in the development of its Doosan Power Systems India (DPSI) to foundry capacity in Vadodara, India. The supply material handling plants for the initial investment includes the acquisition same two power projects in Uttar Pradesh, of the property and foundry assets of a pri- India. The order is worth a total of around vately-owned foundry project, Mega Cast. $115 million and includes engineering, Metso expects to invest a total of approx. delivery and installation of two complete EUR 25 million to purchase the assets and coal handling systems, including associated to develop the foundry by 2020. With structural and electrical works. The plants this investment Metso is responding to will be part of the Obra C and Jawaharpur the global market demand by increasing coal-fired power stations in Northern India. production capabilities in cast wear parts Malay Das, Managing Director and for the aggregates and mining industries. CEO of thyssenkrupp Industries India: “In “This investment fully aligns with our prof- India, thyssenkrupp has more than 40 itable growth strategy. It further expands years of experience in material handling our global manufacturing footprint in found- technology and the execution of coal ry products, improving our operational handling plants. We are very proud to put capabilities and allowing us to meet our this experience to work with DPSI for the customers’ growing needs both in terms of Jawaharpur and Obra C power projects. availability as well as reduced lead times,” Our innovative and reliable technologies said Sami Takaluoma, President, Minerals combined with a strong local setup that Consumables business area at Metso. “We provides engineering excellence as well as are continuously investigating new ways commissioning expertise were key factors to develop our supply capabilities through in winning this contract.”

INDIA 2018 + . Equipment & Technology

Dilip Vaidya, president and director of technology of BKT, said the 51-in. tire will be released to the market in the second quarter of 2019, with the 57-in. tire following in the second quarter of 2020. Vaidya described the advantages of latest-generation machinery that was purchased for improved compounding, steel cord processing and steel cord cutting along with a new tire building machine to complete and enhance the complex tire manufacturing process. “We have reached a stage of advanced engineering,” Vaidya said. He also touched on the changes in technology and what BKT is doing to continue to move forward on a global level. BKT has entered into a joint research Part of the material handling package includes four twin wagon tipplers. agreement with KULTEVAT Inc., a biotech- nology company that specializes in the Effective material handling systems must coal to the stockpile. When needed the cultivation of TKS dandelion as a renew- be individually designed and fully inte- material is reclaimed and transported to able and sustainable alternative to natural grated so as to achieve a smooth flow the boiler plant on belt conveyors. rubber, he added. of material from one section of a plant to the “We will develop new compound- next. To meet these requirements, thyssenk- BKT Celebrates 10 Years ing methods to be integrated in the tire rupp will take care of the whole value chain of EARTHMAX Tires manufacturing process, and TKS rubber from engineering to procurement and con- In early June, off-highway tire manufactur- will gradually replace the use of natural struction for the complete material handling er Balkrishna Industries Ltd. (BKT) celebrat- rubber,” he said. system. From coal unloading and conveying ed 10 years of its EARTHMAX tire line-up They expect to receive samples by to crushing and storage all key equipment in Heraklion, Crete, Greece. At the event, October, with the supply of 1 metric ton of will be manufactured in the company’s own BKT announced its objective to achieve a stabilized TKS rubber by October 2019, facilities in Pune and Hyderabad. 10% market share in the all-steel radial he added. The scope of supply includes numerous segment of the global off-the-road (OTR) Another area they are focusing on is belt conveyors with an overall length of 17 market by 2025. the use of nanomaterials or nanocompos- km, four twin wagon tipplers, screens and “It will be challenging as always and ites, which can provide enhanced perfor- crushers as well as four combined bucket we will master it as always,” said Joint mance, Vaidya said. Under this area, they wheel stackers/reclaimers and one buc- Managing Director Rajiv Poddar. The have done research into graphene, which ketwheel reclaimer. Both systems with an company currently has a 6% market is wear and puncture resistant. overall coal handling capacity of 3,000 share, he added. In addition to new technologies, BKT has mt/h each will be fully operational by the BKT first launched the EARTHMAX tire set up its own carbon black manufacturing first half of 2021. for loaders in 2018 and now has an exten- plant at the Bhuj plant site, which will begin Coal will be delivered to the site by rail sive range of 25 all-steel radial OTR tires production in the first quarter of 2019. either to a track hopper area or a rail car and plans to add even more, all produced “Especially, with the focus on giant unloading station which will be equipped at its Bhuj plant in India. Chairman and tires, large quantities of carbon black with two twin wagon tipplers each. A Managing Director of BKT Arvind Poddar and a variety of specialty formulations to 2-m wide conveyor system will transport described the start of EARTHMAX as a satisfy specific performance criteria are the coal to the crushing and screening “milestone in BKT’s history.” required,” Vaidya said. complex equipped with a total of four pre- To continue to gain a larger percent- As a carbon black manufacturer, BKT viously mentioned Loesche mills and four age of the OTR tire market, the company will be able to produce customized carbon vibrating screens each. Two combined will roll out 51-inch (in.) and 57-in. tires in black of non-ASTM grades that are not bucketwheel machines stack the processed the near future, said Poddar. available on the market, he added.

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+/INDIA 2018