CAIndiaC2012_Covers_CA India 11/16/12 3:14 PM Page 1 CAIndiaC2012_Covers_CA India 11/16/12 2:23 PM Page 3
The problem? Pump hoses were getting chewed up at Barrick Gold’s Lawler operations near Kalgoorlie, Australia. Sometimes failing after just ten days on the job. Fact is, the hoses weren’t tough enough to handle the abrasive sulphides. Then they turned to Weir Minerals for something that was. Hoses with Linatex® latex lining. Now they’re going 12, 16, even 18 months without maintenance. Linatex® latex liners simply outwork and outlast anything that they had tried before.
Turning rubber into gold. A job-report from Barrick Gold
And turning gold into profi t. no hose “patch jobs” and increased R&D. For a real world. It adds up to over $700,000 savings safety. And big cost savings. Linatex® liners are a product of the Weir per year in production costs for “The long life, the monitoring Minerals Advanced Research Center in Barrick. Plus, the exclusive Wear capability and the quality of the Malaysia. It’s where we simulate the Indicator Technology has turned hoses set them apart from the rest,” toughest mineral processing conditions maintenance from a reactive process says Maintenance Planner Dave on the planet. And build products accordingly. Linatex® liners are 95% into a totally predictive one. Long. Material Matters.™ And at latex for superior resistance to cutting, It’s a built-in early warning system, Barrick Gold’s Lawler plant, what tearing and abrasion. And when they featuring a wireless transmitter that matters most is Linatex® liners from do start to show wear, they even tell sends wear information to a remote Weir Minerals. For them, it’s the you about it. In advance. With a built-in wear indicator. Material Matters™. In receiver, ensuring fewer shut downs, gold standard. everything we do. And it all starts at our Advanced Research Center. To learn more about this story and other Weir Minerals products, visit whatismaterialmatters.com
Copyright © 2012, Weir Slurry Group, Inc.. All rights reserved. LINATEX is a registered trademark of Linatex Ltd; MATERIAL MATTERS and the M2 Material Matters logo are trademarks of Weir Minerals Europe Ltd; WEIR is a registered trademark of Weir Engineering Services Ltd. Aspects of the Wear Indicator Technology described in this publication are protected by patents pending and registered. CAIndia_pg1_India_pg01 11/16/12 2:51 PM Page 1
News Briefs
20122012 COALCOAL AGEAGE IndiaIndia WWW.COALAGE.COM
News Briefs CIL constrained by red tape and poor infrastructure...... 4 NTPC increases total installed capacity ...... 5
Features The Benefits of Slurry Pump System Optimization Improved energy efficiency and reliability enhance the bottom line ...... 6
Coal Handling System...... 8 The Growing Popularity of Sustainable Mine Reclamation...... 10 Couragous Leadership...... 12
Mining Equipment and Technology Best of Germany 2012 A Supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age Chinese Edition, Best of Germany 2012 Coal Age Russian Edition, Coal Age India,
A Supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age Chinese Edition, Coal Age Russian Edition, Coal Age India, Coal Age Asia and The ASIA Miner ...... 13 Coal Age Indonesia and The ASIA Miner
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COAL AGE INDIA 2012 1 2-3 CAIndia_India_pg02-03 11/16/12 3:12 PM Page 2
Editor’s Note
Preparing for the Future By Steve Fiscor, Editor-in-Chief www.mining-media.com
Mining Media International In some ways the situation with the U.S. and Indian elec- Editorial Office 11555 Central Parkway, Suite 401 trical infrastructure is similar and in other ways it’s a Jacksonville, Florida 32224 U.S.A. world apart. Both countries rely on coal and have mas- Phone: +1.904.721.2925 sive reserves. American mines are highly productive and Fax: +1.904.721.2930 the Indian mines are hoping to achieve that status. Coal Editor-In-Chief – Steve Fiscor, is shipped by rail long distances to the power plants. [email protected] Production in both countries is being restrained. India Western Field Editor – Russ Carter, has infrastructure issues while coal in the U.S. faces stiff [email protected] competition from inexpensive natural gas and resistance Steve Fiscor/Editor-in-Chief due to environmental activism. The coal-fired power European Editor – Simon Walker, [email protected] plants in the U.S. have ultra-high availability rates and
healthy stockpiles; India’s power sector, as we saw this summer is unreliable and Latin American Editor – Oscar Martinez, stocks are running short. [email protected] As this edition of Coal Age India goes to press, India is worried that massive Associate Editor – Gina M. Tverdak-Slattery, blackouts will reoccur with the slightest disruption in supply. According to the [email protected] Central Electricity Authority, 35 power plants have reached a “super critical” stage. The CEA classifies super critical situations as those plants with less than a Graphic Designer – Francesca Peeples, [email protected] four-day coal supply. Eventually India will work through these problems, as peo- ple demand a more secure energy supply. The positive message is that coal demand is high and will only continue to grow. Each year, Mining Media produces several regional editions by repurposing Mining Media International technical information from Engineering & Mining Journal (E&MJ) and Coal Age, Corporate Office the two leading mining trade journals. E&MJ covers the metal mining and miner- 8751 East Hampden, Suite B1 Denver, Colorado 80231 U.S.A. al processing business worldwide. It has about 20,000 readers who are mostly Phone: +1.303.283.0640 mine engineers, metallurgists and geologists. Coal Age covers the U.S. coal min- Fax: +1.303.283.0641 ing and processing sector. It has more than 16,000 readers who are mostly mine President/Publisher – Peter Johnson, engineers, mine managers and prep plant managers. [email protected] This edition of Coal Age India includes a special section, the Best of Germany, which was produced in cooperation with the German Engineering Federation U.S. & Canada Sales Manager – Victor Matteucci, [email protected] (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 Scandinavia, UK and European Sales around the world. In this special section, VDMA members talk about how they are Manager – Colm Barry, [email protected] improving equipment and technology. German Sales Manager – Gerd Strasmann, Monthly, Coal Age and E&MJ offers readers ideas on how to operate mines [email protected] and plants more safely and efficiently. Society has made some huge strides, but we are still far from perfect. I watch sadly as the U.S. abandons coal and regu- Ad Traffic Manager – Erica Freeman, [email protected] lates itself out of the mining business. Similar to the Germans, we have a great mining heritage. They say those that do not learn history are destined to repeat the mistakes. Hopefully you can learn from our experience and avoid repeating
our mistakes. COPYRIGHT 2012: Coal Age. ALL RIGHTS RESERVED. Our goal is to inform India’s mine and prep plant managers about many of the new developments taking place. If one reader gets an idea from reading this This publication was printed by: Starling Media magazine that makes a mine safer or saves time or money, then we consider this Kolkata, India. exercise in trade publishing a success. Enjoy this edition of Coal Age India. Phone: +91-98300 53601 Thank you. E-mail: [email protected] 2012 COALCOAL AGEAGE Steve Fiscor, Editor-in-Chief, E&MJ/Coal Age IndiaIndia
2 COAL AGE INDIA 2012 2-3 CAIndia_India_pg02-03 11/16/12 3:12 PM Page 3
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Liebherr Mining Equipment Newport News Co. 4100 Chestnut Avenue Newport News, VA 23607 Phone: (757) 245-5251 E-mail: [email protected] www.liebherr.com The Group 4-5 CAIndia_News_News Briefs 11/16/12 2:14 PM Page 4
News Briefs
CIL constrained by red tape and poor infrastructure
During November 2012, Coal India Ltd. During October, as many as 19 thermal (CIL), one of the world’s largest coal produc- plants in India were reportedly reaching the ers, reported it will unlikely be able to “super critical category” for having coal increase coal deliveries significantly for at stock for less than four days and 11 thermal least three years due to bureaucratic red tape plants figure in the “critical category” with and a lack of transport infrastructure. This is coal stock availability for less than a week. not good news for India’s power sector, A report issued by the Operation which is also suffering availability problems. Monitoring Division of the Central Electricity At the end of July, two days of consectuive Authority (CEA) on September 4 said that out
Soon after taking control, Rao said the immediate priority was Narsing Rao took over as chairman of the CIL during April to increase coal production and step up the coal supply. Now he 2012. Prior to the top post at CIL, he was chariman of Singareni Collieries Co. Ltd. (SCCL). says he can raise production, but without adequate rail serv- The latest figures by Punjab State Power ice, stockpiles will only build at the mines. Corp. Ltd. (PSPCL) reveal Bathinda thermal plant has coal stock for 22 days (for three units, one is non-operational at present), blackouts left more than 600 million people of 89 thermal plants, monitored by the CEA, against the normal requirement of 30 days. without power. 30 have less than a week’s coal stock. The Ropar thermal plant has coal availability for A lack of railway infrastructure to trans- report states none of the thermal plants of 17.5 days against the normal requirement of port coal from mines to power stations is the Punjab figures in the super critical category, 25 days. Similarly, Lehra Mohabbat thermal greatest hurdle to growing coal stocks, said but all of these are having less coal stock plant has coal stock for 17.5 days, against S. Narsing Rao, chairman, CIL. CIL’s produc- than required as per norms. 30 days. tion alone will not be enough to meet rising demand, leaving power generators with little option other than to import coal. In 2011, India mined more than 550 mil- lion metric tons (mt) of coal per year and imported more than 100 million mt. Coal imports into India are expected to grow to more than 190 million mt in 2012. Unreliable domestic supplies threaten the country’s long-range plans to increase power generation. The government intends to increase total power generating capacity by 44% to 288 gigawatts by 2017--most of that will the coal-fired power. Rao blamed the Indian government for the slow pace of permitting for mining projects. Stockpiles among the country power plants have depleted to seriously low levels. India’s top coal-producing states, Jharkhand and Orissa, which together account for over half of the country’s production, suffer from rail-related issues. Eevn though imports are seen as way to alleviate rail-related stress, an ongoing crisis at Haldia Dock Complex has already started having an impact on industry in the region. Anticipating a shortage in supplies, the National Thermal Power Corp. (NTPC) has started unloading imported thermal coal for its power plants at Farakka and Kahalgaon on barges from ships waiting at the Sandheads. The plan is to sail these barges to HDC, unload the thermal coal and trans- port them to the power plants.
4 COAL AGE INDIA 2012 4-5 CAIndia_News_News Briefs 11/16/12 2:14 PM Page 5
News Briefs
NTPC increases total installed capacity
The total installed capacity for India’s National Thermal Power Corp. (NTPC) has increased to 39,674 MW with the commis- sioning of the third 500 MW unit of at its Indira Gandhi Super Thermal Power Project at Jhajjar. NTPC currently has more than 16,000 MW capacity under construction in different parts of the country. Addressing employees at the program to celebrate the 37th raising day of the compa- ny Shri P. Uma Shankar, secretary power, appreciated the performance of NTPC and congratulated them on the achievements. He also presented the Swaran Shakti Awards to the best performing stations of the company. NTPC Ramagundam was given the rolling trophy as the best performing NTPC station. Shri Arup Roy Choudhury, CMD, NTPC, and the directors of NTPC were present with him on the occasion. The NTPC board of directors has also approved an investment for the first stage 1,600 MW of the Lara Super Thermal Power Project in Chhattisgarh recently. The first stage of the Lara Project having two units of 800 MW each is to be implemented at estimated cost of Rs 11,846 crore. The project shall have an ultimate capacity of 4,000 MW. Electricity generated from the Lara project shall be sup- plied to the states of Chhattisgarh, Maharashtra and Goa. NTPC has recorded highest ever growth in its history in 2011-12 and operates its units with high levels of capacity utilization and reliability. The company’s robust growth has translated into sound financials and its management has ensured that the fundamen- tals of the company remain strong and are leveraged for further growth and higher returns. NTPC is India’s largest power utility with an installed capacity of 39,674 MW through 16 coal–based, seven gas/liquid fuel and seven joint venture/subsidiary power stations.
Shri P. Uma Shankar, secretary power, presented the Swarn Shakti Awards to the Best Performing NTPC Stations. NTPC Ramagundam was given the rolling trophy as the best per- forming NTPC Station. A cultural program “Meghdoot and Aina- e- Mughal" was presented by NTPC Employees and their family members on the occasion.
COAL AGE INDIA 2012 5 6-9 Slurry_Conveyor_India_pg02-03 11/16/12 2:56 PM Page 6
Slurry Pumps
The Benefits of Slurry Pump System Optimization Improved energy efficiency and reliability enhance the bottom line
For most mineral processing applications, this wasted energy, some is lost by internal slurry pumps represent a key component. Too recirculation within the pump and some as often, however, many plants will take a “fit heat or vibration or any combination of them. and forget” approach to maintenance of These are erosive forces, and so the relation- these vital pieces of equipment--at least until ship between reliability and energy efficien- a critical repair is needed. There can be cy is clear--as more energy is wasted, erosive severe cost penalties associated with this forces increase in intensity, so reliability is approach. Some of the most significant reduced. include reduced productivity, and higher than necessary energy and maintenance costs. A Energy savings with carefully planned and implemented opti- alignment optimization mization program can help alleviate these in pumps unnecessary costs. A plant recently experienced high vibration Generally speaking, optimization leads to levels on 12 pumps, resulting in excessive reductions in energy consumption, thereby consumption of both energy and spare parts. resulting in lower operating costs. And while An SKF condition monitoring program with it is often the anticipated energy cost savings Microlog Analyzer showed that the high that are used to justify a slurry pump improve- vibration levels were clearly due to misalign- ment project, the fact is, benefits often extend ment. Using the SKF TKSA 40 system techni- well beyond energy savings. cians corrected the misalignment to help For example, shaft misalignment is improve the operation of the electric motor. responsible for up to 50% of all costs related Measuring energy consumption before and by SKF @ptitude software. This is based on to rotating machinery breakdowns. after alignment for the 12 pumps demon- the company’s Operator Driven Reliability Accurately aligning shafts can prevent slurry strated an average of 8% energy savings concept and provides plant operators with pump breakdowns and reduce unplanned (maximum of 20% in some cases) or approx- the information they need to establish the downtime that results in a loss of production. imately 180 MWh/year, along with reduced optimization opportunities available within The point at which the highest proportion of vibration levels and increased reliability. their pump systems. In addition, it can be energy from the shaft of a pump is transferred In addition to higher maintenance costs, the incorporated into any condition monitoring to the fluid being pumped is the Best costs of unreliability due to forced shut downs program. In fact, SKF recommends that con- Efficiency Point (BEP) of that pump. At this can be high. The costs of unplanned shut- dition monitoring programs be adapted to point, internal forces in the pump are at a downs vary, and in many cases are difficult include this data, as condition monitoring minimum. As the operating point of a pump to quantify. alone does not provide all the information moves away from the BEP, this energy trans- The SKF Energy Monitoring Service--Pump needed to assess the health of a pump: ener- fer efficiency falls and axial and radial forces Systems is designed to help pump operators gy efficiency is a key component of the infor- increase. Although some energy loss is track efficiency, as well as actual operating mation needed. inevitable (for instance, friction at wetted sur- efficiency relative to BEP. Periodic measure- Pump system optimization provides real faces, at seal faces and within bearings) ments of pressure, flow and power for each opportunities to improve reliability and to some of the energy that is not being trans- pump being tracked provide the data need- reduce costs. There are many tools and train- ferred from the shaft to the fluid is wasted. Of ed for the analysis, which is conducted using ing courses available to help provide the knowledge needed to implement a program to realize these opportunities. Where invest- ment is needed to capture the benefit, the full array of cost savings should be estimated to provide a realistic return for that investment. Given that energy costs are by far the largest component of the life cycle costs of owning a pump, plant operators owe it to themselves to assure the highest level of pump optimization attainable. By incorporating the right tools and services into their condition monitoring programs, plant operators can go a long way toward maximizing the energy efficien- cy of their pump operations.
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Slurry Pumps
MDX Technology Cuts Pump TCO by Millions
GIW Industries, a leader in the design, manufacture and appli- When the pump stops, the mill stops. And the cost of that cation of heavy duty, centrifugal slurry pumps, announced that downtime is dramatic at a large mining installation. For this its installation of MDX pump technology at a major copper mine mine, every hour of downtime represented $150,000. To in Chile has resulted in a dramatic reduction of total cost of replace a slurry pump, the mill has to be down 10 hours. And ownership (TCO) for those pump applications--amounting to mil- with the previous pump, the mill engineers were performing lions of dollars in savings for the mining company. pump replacement eight times per year. Elias Aho, global sales and projects manager for GIW, said But the application presented its own challenges: This mine that a sulfide concentrator, owned by BHP Billiton, reports operates the largest cyclone-feed pump in the world. increased revenue of $8 million due to productivity increases, However, working with GIW had advantages for the compa- with an additional savings of $1 million in energy costs. ny. Because GIW operates its own foundry, it can produce “TCO for slurry pumps includes not only the initial cost of the parts cost- and time-effectively — even a pump as large as this pump,” Aho said, “but also factors such as wear life, annual one. The new GIW MDX pump, with an 84-inch impeller and cost of parts, labor, energy and downtime for maintenance.” All weighing 100,000 lb, replaced the 150,000-lb competitor of these factors are addressed by the advanced engineering, pump, providing a lighter, more durable pump that runs on materials and technology provided by GIW MDX pumps. significantly less energy. The mine relies extensively on slurry pipelines to transport copper The new MDX pump has already surpassed the mine’s goal ore. But the hard rock slurry is brutal on pumps and equipment. of doubling the wear life of the pump. GIW engineers are Wear parts suffer under the constant abrasion of the ore, and most now working on a program of continuous improvement, aim- competitor pumps require frequent maintenance and replacements. ing to extend the pump's wear life another 40% to 50%. By The company had GIW installations for other applications and real- cutting its maintenance downtime in half, the mine has real- ized it was seeing greatly improved wear life with those pumps. ized an $8 million increase in revenue. In addition, it has The mine decided that replacing its lower-performing pumps with reduced its energy cost by an additional $1 million annually. GIW MDX technology was the right move.
Tailings Pond Elimination Polyurethane screens down to 0.18mm
Solids recovery down to 45 microns Solids contain 23-25% moisture Solids in a stackable/conveyable form
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Conveyors
Armstong’s Coal Handling System A well-engineered network of conveyor allows coal to be loaded and unloded from barges on the Green River
Overland Conveying Systems, based in key equipment during a flood would be to Madisonville, Kentucky designs and builds walk a narrow catwalk 20 ft off the ground all conveyor systems for the coal industry. One of the way from the mine to barge load-out. its customers, Armstrong Coal, a coal opera- What Daniel wanted for this project was a reli- tors base in Western Kentucky, decided to able gearbox that wouldn’t require a lot of install a new coal-handling system at its attention, small enough to fit in a confined Equality Boot mine, located approximately 8 space, but powerful enough to do the job. miles from the company’s prep plant. As luck would have it, about the time Trucking coal over county roads was not Daniel started the project, Baldor introduced an option, and when Armstrong learned it the full line of MagnaGear XTR high horse- could not convey the coal overland, its only power speed reducers; a compact, power- option was to transport the coal by barge on dense design in a heavy-duty package. Based the Green River. The project involved thou- on his experience with other BaldorDodge sands of feet of conveyors down to the river for gearboxes, Daniel says he was eager to see load-out, plus a new system to off-load the coal the new gear reducer and get more details. from the Armstrong dock up to the prep plant. “I have used the company's Torque- Arm At the mine site, David Daniel, chief engi- reducer for years on many projects with a lot neer, Overland Conveying Systems, had the of success,” said Daniel. “This product sets the challenge of building a nearly 4,000-ft long standard in our industry because they do the conveyor high enough off the ground to evade job, they are user-friendly, and they last a the annual river flood. The only way to reach long, long time. With a reputation like that, it
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8 COAL AGE INDIA 2012 6-9 Slurry_Conveyor_India_pg02-03 11/16/12 2:31 PM Page 9
Conveyors
was not a stretch for us to take a serious look built us a product that we needed.” The first coal from the Equity Boot mine was at a new gearing product because we natu- MagnaGear reducers are available in loaded and unloaded in September 2010. rally expected it to be just as good.” parallel shaft or right-angle configurations Since then Daniel says the reducers have done Convinced that the MagnaGear was the with solid or hollow output shafts. They also the job everyone expected them to do, moving right product, Daniel said he worked out all come in several mounting configurations, coal with no issues. Both Overland Conveying the designs and product specifications to pres- including tunnel housings. For Daniel, the Systems and Armstrong Coal are so pleased ent to company officials at Armstrong Coal for reducer’s universal housing design also with the performance of the product that final approval. His plan included a total of 10 means the customer doesn’t need to keep Daniel has purchased seven MagnaGears for MagnaGear reducers, coupled to multiple spares on-site. a new Armstrong Coal project. Baldor•Reliance motors. Despite the newness “The reducer is set up to work on either “All I can say is that if the MagnaGear of the product, Daniel said Armstrong gave its side, so I have the option of right-hand or left- product didn’t work, or if we had any prob- OK to the plan based on the reputation of hand mounting,” said Daniel. “Now, I only lems, I would not be using them again,” says BaldorDodge gearing. need one spare that can work anywhere on Daniel. “But it’s a good product, and I had a “Like me, they knew that the gearing is well the project. Other products out there do not good experience working with Baldor on the respected in the marketplace,” said Daniel. offer this same kind of flexibility.” Boot project, and that’s why I’m back.” “Your company is not new to this industry, and you have been cutting gears for a long time. We didn’t hesitate because we trusted that this gearbox would be a good product and that INNOVATIVE SOLUTIONS FOR DEMANDING OPERATIONS we would get good support.” Some of that support came from Baldor’s System-1 group, a team that facilitates the design, quotation and order processing of multiple power transmission and electrical products into a complete packaged solution. While Daniel performed all his own calcula- tions and made his own motor and reducer Keep on rocking! selection, he did appreciate the System-1 team confirming his selections, plus the help they provided on other products required for the job. “I don’t have the same level of knowledge on couplings, sheaves and guards,” said Daniel. “I simply let the System-1 team handle all of those details, and when the equipment shows up at our shop in a complete package, my shop manager doesn’t have to worry about it either.” Installation & Commissioning Daniel said the reducers have delivered every- thing he expected, from installation to per- formance. And he points to several design ele- Together, we can move mountains, ments that he believes make this reducer an ideal choice for high torque applications, even in the roughest conditions. including the power-dense design. “The way engineers designed this product Your operation’s no walk in the park. Every day, you hit the wall hard. means we get more torque out of a smaller But bottom line: You’ve got to keep it running. Tsubaki understands. reducer,” explained Daniel. “This makes the MagnaGear very appealing because you We engineer heavy-duty chains to meet the heavy-duty demands of get more torque for the money compared to industries like yours. Like a rock, we’re here for the long-haul. others in the market. It’s a very cost-effective Time to get tough on downtime and rock on with Tsubaki. package.” Daniel said the compact design of the www.ustsubaki.com reducer has also been a plus on the Armstrong project, especially when you consider many of the units are located along a catwalk or in other confined spaces. “Not only are the units compact, I also like the way the reducer is coupled to the motor,” said Daniel. “The coupling housing is only 20 © 2012 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved. inches long; others in the marketplace are up to 3 ft long, which causes a lot of problems. LONGER LIFE LESS DOWNTIME LEADING SERVICE & SUPPORT The engineers who designed the MagnaGear s s must understand the industry because they
COAL AGE INDIA 2012 9 10-11 CAIndia_India_pg02-03 11/16/12 2:36 PM Page 10
Sustainable Development
The Growing Popularity of Sustainable Mine Reclamation Companies may reap potential rewards by considering the Triple Bottom Line business model, which bolsters sustain- ability through financial prosperity, environmental steward- ship and social responsibility By Wendy Schlett
The concept of sustainability continues to Simple Principle gressive companies that focus on technolo- gain traction in every industry, including min- This aspect of sustainability is often unrec- gy, information and new forms of value cre- ing. Even though mining typically brings up ognized, but in fact the definition of sus- ation. The Triple Bottom Line incorporates ideas that conflict with the tenets of sustain- tainability is much more pragmatic. The the three pillars of sustainability—financial ability, specifically extracting non-renewable concept of sustainability is not based on prosperity, environmental stewardship and resources from the earth, it is becoming more uncompromising idealism that requires the social responsibility—and in this model and more possible to reconcile the two. land to be left untouched by humans. In these pillars work together to simultaneously Sustainable mine reclamation ensures fact, the United States Environmental influence business decisions. that the surface of the earth is not left to reju- Protection Agency describes sustainability By paying attention to the Triple Bottom venate itself, thereby mitigating potentially as “based on a simple principle: Everything Line, organizations can effect positive contaminated and unusable land that previ- we need for our survival and well-being change that includes enhanced public sup- ously lay fallow for ages by past mining depends, either directly or indirectly, on our port, increased profitability, reduced and reclamation practices. Now, new uses for natural environment. Sustainability creates better controlled risk, minimized environ- mined land are being considered before and maintains the conditions under which mental impact, increased brand value and mining even commences, and more oppor- humans and nature can exist in productive reputation, and overall improved global tunities and emphases are being placed on harmony, that permit fulfilling the social, standing to operate and grow. Given all of thinking about these future uses with sus- economic and other requirements of present these positive outcomes, it stands to reason tainability in mind. and future generations. Sustainability is that sustainable business models are grow- Sustainable practices are growing in important to making sure that we have and ing in popularity. popularity, and not just for altruistic rea- will continue to have, the water, materials Once it is understood that sustainable sons. While these practices incorporate the and resources to protect human health and practices work to meet several goals, it pace of a growing population that is our environment.” becomes easier to recommend and imple- informed and active in ensuring a thoughtful A new business model, commonly known ment such practices. Mine reclamation can and careful approach to natural resources, as the Triple Bottom Line, has evolved from and should be re-examined from a sustain- they can also simply be more practical and the sustainability efforts pursued by pro- ability framework. Especially given the cur- fiscally sensible. rent economic climate that has effectively narrowed the possibilities for viable mine reclamation projects, incorporating sustain- able practices in mine reclamation will offer mineral producers financial, environmental and social benefits. While not always possible, greater effi- ciencies can be realized if mine operators think about the reclamation process before mining even begins. This allows for the pos- sibilities of re-using certain materials and doubling positive outcomes. Understanding the natural footprint of the land to be mined is also helpful toward achieving sustainabil- ity goals—by being more realistic about what the land can and cannot accomplish once it is mined will help to keep costs low and overall production and post-production efforts less arduous.
Identifying Specific Needs In this line of thought, it makes sense that Afforestation or reforestation of a mining area are both specific types of carbon offset projects well-suited for sustainably reclaim- there is a movement within sustainable mine ing mined areas. reclamation to return the land to something
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Sustainable Development
set their own greenhouse gas emissions that result from everyday activities. Afforestation and reforestation of a min- ing area are both specific types of carbon offset projects well-suited for sustainably reclaiming mined areas. In addition to the environmental benefits these projects pro- duce—improved air and water quality, reduced soil erosion, and a generally less- ened impact of global warming through car- bon storage—afforestation or reforestation projects can also offer new jobs, new streams of revenue, and improved local economies. In one example, abandoned and previ- ously reclaimed coal mines in the Appalachian region were reforested through a project that brought together the University of Kentucky, the U.S. Forest Service and the Office of Surface Mining and Reclamation Enforcement. These sites proved excellent locales for enhanced ter- Afforestation or reforestation of a mining area are both specific types of carbon offset projects well-suited for sustainably reclaim- restrial carbon sequestration. ing mined areas.
not unlike its former self, rather than ters the growth of local but rare plant Financial Rewards attempting to create something brand new species. These organizations can offer plan- Sustainably reclaiming a mine can also and unrecognizable. In many cases, this ning and expertise, and can also help with benefit mine producers financially through can be achieved by working in concert with providing volunteer labor. their eligibility for other tax credits (espe- the local community to determine what their Additionally, partnerships between mine cially the Brownfields tax credit), and needs might be, and then repurposing the operators and nongovernmental organiza- through an increased value of the land. In mined site to meet those needs. tions can provide economically positive out- one example, by transforming the land into As an example, the community surround- comes. These partner organizations offer an ecological landscape that promotes ing a mined site may identify a new neigh- grant funding and tax or impact mitigation long-term preservation through land restric- borhood park as a local need. By knowing credits and incentive knowledge that can tion and charitable donation, the land qual- this at the outset of developing and/or help make a sustainable mine reclamation ifies for a tax credit that can offset corpo- reclaiming the mined land, the organization project that much more financially feasible. rate profits. This type of project will also and the community can work together har- In addition to the options already men- positively restore the land’s ecosystem, moniously to determine the vision and tioned, another option for reclaiming mined which will in turn increase the overall value potential limitations of the project. Other land sustainably is by creating a wetland of the land. If the land is then donated to options a community might consider as bank. This could qualify the land to gener- the local community or a charitable organ- helpful alternatives to a former mined site ate wetlands credits. In this scenario, a pre- ization, a higher tax credit for the land could include a water reservoir, viable approved wetland bank would allow devel- could be realized. industrial park, public recreational trails opers and/or mine operators to secure wet- With the multitude of possibilities avail- through a reforested area, or a similar proj- land mitigation credits for developments able toward reclaiming mined lands sus- ect. For a mineral producer that can devel- that impact wetlands in other locations. The tainably, it is no wonder that sustainable op a positive relationship with the commu- credits finance the development and main- mine reclamation is growing in popularity. nity in which it operates, and can identify a tenance of the sustainably reclaimed mine Sustainable mine reclamation projects allow project that mutually benefits that communi- as a wetland bank. Once established, the a mine producer to develop something new ty as well as the producer, more benefits wetland bank could then be donated to a and worthwhile, that supports the organiza- abound. Good will and a reputation for non-profit organization such as the U.S. tion’s goals and the betterment of the com- social responsibility go a long way toward Army Corps of Engineers, the U.S. munity in which they operate. Sustainable company growth and market advantage. Environmental Protection Agency, or the mine reclamation projects also create finan- In addition to partnering with the local U.S. Fish and Wildlife Service for long-term cial prosperity, environmental stewardship, community, non-profit organizations should maintenance and operation. and social benefits—thereby creating a pos- be considered, as they offer resources Carbon-offset opportunities are another itive Triple Bottom Line for the producer, the toward sustainable mine reclamation proj- sustainable end-use in the reclamation of community and the environment. ects as well. Working with groups such as mined land. Carbon offsets reduce carbon The Wildlife Federation, The U.S. Fish and dioxide or other greenhouse gas emissions ------Wildlife Service, The Nature Conservancy in a balancing act to compensate for a car- Wendy Schlett is a project manager for and other federal, state or local nongovern- bon emission made elsewhere. Companies, Sustainability, Environmental Management mental agencies can help identify the best governments and other organizations that Systems and Environmental Regulatory possible end use for the reclaimed mine— need to comply with carbon dioxide caps Compliance at GZA GeoEnvironmental, whether that be the creation of habitats that make up one of the markets for carbon off- Inc. (www.gza.com). For more information, encourage biological diversity, endangered sets. Companies, governments and individ- contact Ms. Schlett at 616-956-6123 or by wildlife protection, or an ecosystem that fos- uals can also purchase carbon offsets to off- email: [email protected].
COAL AGE INDIA 2012 11 12 CAIndia_minesafety_India_pg02-03 11/16/12 2:37 PM Page 12
Mine Safety
Couragous Leadership Instilling a Culture of Safety By Bruce Huber
A few years ago, Barrick Gold Corp. was trying Some experts maintain 70% of communication to realize a step-change improvement. to determine how it could make a step-change is LISTENING. Listening is not generally a strong Note the reference to ‘time’ in this quote wide- improvement in safety performance across the management trait. ly attributed to Abraham Lincoln: “Commitment is company. After analyzing the various safety sys- We helped our supervisors understand the dif- what transforms a promise into reality. It is the tems and tools in place at sites, we realized that ference between management and leadership. words that speak boldly of your intentions. And the continuing to focus on what I call the ‘technical Some companies treat these two as the same. We actions which speak louder than the words. It is side of safety’ might achieve some modest and believed there was a distinct difference and achiev- making the time when there is none. Coming regular performance improvements. However, ing a balance between the two was essential. through time after time after time, year after year we were never going to see dramatic improve- It takes some emotional experience to drive a after year. Commitment is the stuff character is ment using this approach and further, it would behavioral change. Why do people continue to made of; the power to change the face of things. take 40 years or more to approach zero injuries. use a cellphone while driving, even though it is It is the daily triumph of integrity over skepticism.” We observed that the same tool being used widely known this is a very dangerous practice? It When we take the time the results we want are effectively at one site had very little impact at is because they do not want to lose their social con- evident. Take the time. another mine. The tool was the same; it was the tact. There is no reward for giving it up other than As part of the safety culture, Barrick also asked people using the tool that made the difference. the intangible ‘safety.’ Unless we can communicate leaders to demonstrate ‘visible, felt leadership.’ You We had to shift our focus to achieve a better what is in it for them, they will not change their cannot create a safety culture by sending safety balance between technical safety (policies, proce- behavior. We have to connect emotionally with messages to the field from your office. You must be dures, training and auditing) and the people side them so they “feel” the consequences of an inci- in the field, interacting with people, walking of safety (leading, motivating, coaching and inspir- dent. Courageous Safety Leadership is transparent around, coaching, checking compliance, and ask- ing). With the help of Jim Clemmer, a recognized and shows the terrible toll incidents and fatalities ing questions. Your words and actions must com- leadership consultant, Barrick’s Courageous Safety have on co-workers, families and friends. The municate the sense of urgency around safety, as Leadership program was born. impact of these situations reaches people on an well as the vulnerability that exists around the work The foundation of the program is a two-day emotional level, changes what they believe and being done. Keep stressing the vision with a focus training program for every supervisory level ultimately results in a behavior change. on caring for people—employees, contractors, employee and a one-day course for every worker. Safety was always in the forefront. “Safe pro- suppliers—not statistics. The course is designed around people. It is highly duction” became our mantra. We measured, com- Go out of your way to acknowledge good motivational, very inspirational and requires a lot pared and published results from each site regu- safety performance. Respond to any safety inci- of participation. There are roughly three hours of larly. We presented awards to sites that achieved dent or near miss with a “what can we learn” teaching (lecture) in the two day version. The rest good safety performance. We also presented approach. Take immediate action to correct any of the time, the participants are engaged in work- awards to individuals who contributed to the safe- substandard condition or behaviors, challenging group or individual activities, all focused on spe- ty culture. We celebrated safety achievements negative attitudes or hierarchies if necessary. As cific people issues. When I left Barrick, more than throughout the year. The senior leadership of the managers, leaders should assess safety activities 30,000 employees and contractors had taken this company was actively engaged in the recognition as part of performance reviews and compensa- training. We experienced a 65% reduction in total process so that employees could see safety was a tion, and promote only those individuals with recordable incidents. Everyone in the company priority for the organization. proven safety performance. Hold yourself and credited Courageous Safety Leadership with When we look at companies with world- others accountable for following through on safe- changing the company culture. class safety performance, we see they have ty-related commitments. Make safety discussions We developed the vision “every person going leaders who are personally committed and part of every meeting. home safe and healthy every day” believing it was engaged. We cannot expect others to act with Good leaders build a safety culture, maintain possible to achieve that vision. Courageous Safety safety in mind if we do not model the right people’s trust, control risks and position the organ- Leadership focuses on people skills, communica- behaviors ourselves, both on and off the job. ization for enhanced success. We have the oppor- tion, openness and transparency, honesty and While the traditional approach to safety has tunity to improve safety performance if we have the integrity. It is also about empowering people to resulted in improvement over the years, consider right attitude. We must believe that we can create speak up when things are not right as well as that the structured method may also be one of our safe, incident-free workplaces, and we must work accepting responsibility. That sometimes means failings. Safety has often been about procedures toward this objective. Yes, zero is possible, and we confronting people and hierarchies, rather than just and training—trying to get everyone to do the can achieve that with committed, engaged leader- “going along to get along.” Sometimes we must same jobs the same way, repeatedly. Fortunately, ship in our organizations. have the courage to do what is right regardless of most people conform. For those who do not, the the consequences to ourselves. At the same time, to traditional approach has been harsh discipline, ------encourage people to speak up, we need to create and that has not achieved much success. Huber currently serves as vice president of safety an open atmosphere and show them we will We have to work with our employees on an services at inthinc technology solutions respect their opinions, listen to their ideas, and individual basis, applying and delivering what (www.inthinc.com). Previously, he was the director enlist their support in finding solutions. they needed—not what we think they must of safety and health at Barrick Gold and was cred- Courageous Safety Leadership is about treat- have. This means a different approach with ited for implementing the company’s Courageous ing people like people, building relationships each of them and a lot of communication. That Safety Leadership program. In 2009, the and trust, and empowering people to become takes time, a precious commodity that none of International Society of Mine Safety Professionals part of the solution rather than remain as part of us seem to have enough of. We had to commit recognized Huber with its Highest Degree of the problem. We mentioned communication. to this leadership approach if we were going Safety Award.
12 COAL AGE INDIA 2012 VDMA_pg13-15_VDMA_pg01 11/16/12 11:12 AM Page 13
VDMA Mining Equipment and Technology
Best of Germany 2012
A Supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age Chinese Edition, Coal Age Russian Edition, Coal Age India, Coal Age Indonesia and The ASIA Miner
In Co-operation With VDMA
2012 • VDMA MINING SUPPLEMENT 13 VDMA_pg13-15_VDMA_pg01 11/16/12 11:12 AM Page 14
Mining More for Less.
Liebherr India Private Limited R@ys IT Park 6th Floor, Block En 9, Sector V Saltlake City, 700 106 Kolkata Tel.: +91 22 67957500 E-mail: [email protected] www.liebherr.com The Group VDMA_pg13-15_VDMA_pg01 11/16/12 11:12 AM Page 15
Foreword: Technology Serves the Global Mining Industry
As we move into 2012, there is widespread growing demand for energy and steel, especially in VDMA emerging markets such as China, India, Brazil and Russia. Germany’s mining-equipment man- ufacturers are ready to respond to the new surge in demand for high technology—combined with better safety standards—as the key to higher production and greater efficiency. Germany leads the world in engineering expertise, especially in mining equipment and tech- nology. German technology has a long tradition, having been designed to handle the difficult geological conditions found in the hard-coal mines in the Ruhr area, the Saarland and at Ibbenbüren. Over time, this technology has been developed further, so as to satisfy the require- ments of a worldwide market. Today, almost 90% of German mining-equipment sales are generated in countries other than Germany. While China, Russia and the United States are currently the main export destinations, other parts of the world such as Southeast Asia, Latin America and Australia are growing mar- kets for Germany’s mining equipment manufacturers. German mining technology has been field- proven in both underground and surface mines in each of these markets, firmly founded on the strength of its technical design, safety measures and environmental features. The VDMA-Mining Equipment Association welcomes all readers of the 2012 Mining Supplement, with its emphasis on how today’s German mining technology is designed with the emphasis on operational and personal safety. We hope you will enjoy this publication.
Glückauf!
Dr. Paul Rheinländer President of the VDMA-Mining Equipment Association
VDMA, the German Engineering Federation, Mining Equipment Association Lyoner Strasse 18 D-60528 Frankfurt Germany
Table of Contents:
A Special Supplement to German Equipment Sales Go from Strength to Strength with Record Export Demand ...... 16 Engineering & Mining Journal (E&MJ) Surface Mining Technology: Safety and Productivity Going Hand-in-Hand ...... 18 Produced by Mining Media International 11555 Central Parkway, Suite 401 Materials-Handling Technology: Keeping Minerals Moving Around the World ...... 20 Jacksonville, FL 32224, USA Underground Mining Technology: Safer Working Conditions and Higher Productivity ...... 22 Tel: +1-904-721-2925 Fax: +1-904-721-2930 Coal and Mineral Processing: www.mining-media.com Getting Out the Most, Safely and Economically ...... 26 Copyright 2012 Mining Media Safety and Productivity Across the Board: Completing the Portfolio...... 30 Drives Technology: Placing Power Where it’s Needed ...... 32 Sponsor: German Engineering Federation Vendor Matrix and Buyers Guide ...... 36 Verband Deutscher Maschinen- und Anlagenbau (VDMA) e.V. Lyoner Str. 18, D-60528 Frankfurt/Main Articles in this publication were researched and written by Simon Walker, European Editor for Engineering & Tel: +49-6966-031262 Mining Journal. For additional information about the articles or the manufacturers highlighted here, please Fax: +49-6966-032262 contact Mining Media ([email protected]) or one of our regional representatives. www.vdma.org
Published by Mining Media Int’l in cooperation with the VDMA EQUIPO | INGENIERÍA | TECNOLOGÍA
2012 • VDMA MINING SUPPLEMENT 15 VDMA_pg16-17_Intro 11/16/12 3:02 PM Page 16
German Equipment Sales Go From VDMA Strength to Strength With Record Export Demand
With the world showing a gradual recovery from the worst of the eco- importance as time goes by. nomic crisis, Germany’s mining-equipment manufacturers reported a Responding to a question at the meeting’s press conference, modest increase in sales during 2010. Although sales during the first Dr. Rheinländer noted that while the sector’s domestic market was part of the year had been slow, demand fortunately began to grow dur- bound to shrink in the future, some companies are already being ing the final few months of 2010, with the upturn then accelerating proactive in their approach. Citing his own company, coal mining to form a spring-board for a bumper 2011. equipment manufacturer Eickhoff, he said that it will be taking its This was the message given to VDMA member companies at the R&D operations to one of its main markets—Australia—in order to mining branch’s annual meeting in Essen in late November. Speaking be closer to its customers there, while continuing to rely on the exper- at the meeting, branch president Dr. Paul Rheinländer was able to tise of its skilled workforce in Germany to produce its equipment to predict that Germany’s mining-equipment suppliers were expecting to the high standards expected of it. achieve total sales of just over €5 billion during 2011, representing not only a 32% increase over 2010, but also a new annual record. Exports Underpin Record Sales Not only is this a significant achievement in its own right, With sales worth around €4.66 billion expected from export markets Dr. Rheinländer said, but the fact that the mining-machinery sector in 2011, Germany’s mining-machinery manufacturers had a bumper had managed to increase its sales for the past three consecutive year. China continued to be the largest individual export destination, years meant it was one of the few in Germany that had shown unin- with sales totalling some €400 million, up from €323 million in terrupted growth throughout the period of economic crisis. 2010. And, said Dr. Rheinländer, it was not only orders from the coun- Dr. Rheinländer cited the strength of demand around the world for try’s coal industry that were important; China is developing its miner- raw material commodities as being the driving force behind this suc- al resources across the board, providing export opportunities for the cess, not only from industrialized countries but also increasingly from whole range of mining equipment. emerging markets. “For example in India, we expect revenues from Second in importance as an export destination, Russia also pro- equipment sales will be up by almost 50% this year,” he said. duced an upturn in equipment orders during the year, with sales ris- The world’s main commodity exporters have been taking advan- ing from €264 million in 2010 to €299 million in 2011. As tage of the continuing strength in demand to both expand existing Dr. Rheinländer pointed out, liquidity in the Russian economy has mines and bring new ones on stream. “In addition, rising commodity improved, with better opportunities for financing new equipment pur- prices have increased the attractiveness of new mining projects, even chases. In addition, he said, coal is increasingly replacing natural in Germany, with the opening of a barite mine at Wismut and plans gas as a fuel in Russia, given the country’s need to maximize gas for the development of a big new copper mine in the Lausitz region of export earnings, with more coal being mined for export as well. eastern Germany,” he said. German equipment exports to the U.S. market also rebounded “Germany’s potash producer, Kali & Salz, is also thinking seri- strongly in 2011, to stand at around €197 million, while exports to ously about either re-opening two old mines or developing two new Australia reached a new value high of €76 million. This, ones. While mining-machinery manufacturers are watching with Dr. Rheinländer told Best of Germany 2012, was excellent news, with interest plans being developed by RAG to use old hard-coal mine sales volumes in both major markets having returned to—or sur- shafts and infrastructure as a new generation of environmentally passed—levels achieved before the economic crisis broke. friendly pumped-storage power stations,” Dr. Rheinländer said. With And, while much of the equipment sold into these markets was sales of some €480 million anticipated for 2011, Germany remains orientated toward the coal industry, most of the sales made to opera- the sector’s largest single market, although the scheduled wind- tions in South America have been into hard-rock mining, illustrating down of the hard coal industry by 2018 will inevitably reduce its just how versatile Germany’s manufacturers really are. With the value of exports rising by more than 25% to an estimated €91 million as metal-mining companies expanded their operations, and brought new mines on stream, this was a major achievement, Dr. Rheinländer said. VDMA Participation at “Germany’s mining-equipment sector is very stable, and this is Mining Exhibitions During 2012 due in no small measure to the very wide spread of the technologies covered by VDMA member companies. It’s a good position to be in, and Date Show Location so far as we can tell, companies have strong order books well into 9-13 April Expomin Santiago, Chile 2012. Orders are coming in on a very regular basis, and we are pre- 24-26 April Mining World Russia Moscow, Russia dicting that the sector will increase its turnover by between 8% and 2-5 May Conbuild Indonesia Jakarta, Indonesia 10% next year,” he said. 16-19 May Future Mongolia Ulan Bataar, Mongolia “There is great potential to develop bigger markets in South 10-14 September electra mining africa Johannesburg, South Africa America, and in countries such as Indonesia and Mongolia,” he said, 16-18 September CIEI Taiyuan, China noting the organization hosted a visit by a delegation from Colombia’s 24-26 September MINExpo International Las Vegas, USA mining industry during 2011, with preparations for a similar group 5-8 December IMME Kolkata, India from Peru already under way. His enthusiasm for creating stronger links with the rapidly devel-
16 VDMA MINING SUPPLEMENT • 2012 VDMA_pg16-17_Intro 11/16/12 3:02 PM Page 17
oping mining industry in Mongolia were echoed by the country’s ambas- sador to Germany, Baldorj Davaadorj, in a presentation to the Essen meeting. Making mention of work that German companies have already done, for example, in the fields of coal-to-liquids projects and supply- ing mineral-processing equipment, Davaadorj also pointed to the visit that Germany’s Chancellor, Angela Merkel, made to Mongolia in October 2011. Positive results from Merkel’s trip included the signing of a com- modity partnership agreement that provides for increased bilateral min- eral and equipment trade. “We have the raw materials while Germany has the latest tech- nology and the know-how,” Mongolia’s Prime Minister, Sukhbaatar Batbold, was reported as saying during the visit, while Merkel said: “I am convinced that we have laid the foundations for a long-term partnership in the energy and extractive sectors that will benefit both countries.”
Mining for the Future Over the past three years, the VDMA has been at the forefront of moves to involve Germany’s mining industry, its equipment suppliers and its mining universities in understanding what the next generation of min- ers will need in terms of technology. Having already run workshops at Aachen and Clausthal technical universities, the third Future Mining workshop was held in July 2011 at the Bergakademie Technische Universität Freiberg, which was founded in 1765 and is the oldest min- ing faculty of the world. The questions posed at the workshop were: “what equipment will be required?” and “what is needed for Germany to remain a world leader in terms of technology?” To generate discussion and to help workshop par- ticipants gain knowledge from the open forum, the event focused on questions such as: “how can we create new ideas?” while challenging people to change their points of view. Helping them to do this, the work- shop also included an introduction to the most appropriate ways of get- ting new and different viewpoints. SOME THINK Having held three events that provided engineers with the inspira- tion to find different ways to innovate, the VDMA is now challenging LONG-DISTANCE manufacturers to create new ideas and new R&D projects. During 2012, its mining equipment branch will be organizing workshops with univer- TRANSPORT IS sities and companies to discuss proposals for the new technologies and procedures that have been outlined in the previous events. The aim, it INFRASTRUCTURE- says, is to decide the best way of taking these ideas forward to the next stage, as development projects. INTENSIVE. Promoting German Equipment Worldwide WE THINK One of the VDMA’s key functions is to support its member companies in international markets, in a sales environment that is becoming increas- ingly competitive. Publications such as Best of Germany play an impor- DIFFERENT. tant role here, and are readily available at all of the international exhi- bitions that the VDMA attends. Transporting materials from remote locations has tradition- During 2012, for instance, the VDMA will be at no fewer than eight ally required signifi cant infrastructure investments in road major mining sector exhibitions around the world, as shown in the or rail links, vehicles, personnel and fuel. BEUMER off ers adjoining table. The truly international effort it places on marketing an economical, effi cient and environmental alternative – activities for its members is clear to see, with its presence at trade long-distance overland conveying. This gives you a dedicated, shows in Asia, the United States, South America, Africa and Europe around-the-clock transport link at the fraction of the cost aimed at promoting the high quality and technical expertise of German of infrastructure development. The reduced noise and air equipment to new markets. pollution minimises environmental impact and improves Looking ahead even further, 2013 will bring the return of bauma, personnel safety. Add to that a high degree of design fl exi- with the VDMA’s mining and construction equipment branches being bility and customisation and you can see why overland among the principal sponsors. Running from April 15 to 21 at the main conveying makes a big diff erence to operational effi ciency Munich fairground, bauma 2013 aims to build on the success of the last and environmental protection. show in 2010 when, despite the volcanic disruption to Europe’s trans- For more information, visit www.beumergroup.com port links, over 420,000 people attended from more than 200 countries. Since 2004, bauma has included a specific mining component that in 2010 had 605 exhibitors, with a promise for 2013 of a dedicated hall for mining-sector suppliers.
2012 • VDMA MINING SUPPLEMENT 17 VDMA_pg18-19_Surface 11/16/12 11:18 AM Page 18
Surface Mining Technology:
VDMA Safety and Productivity Going Hand-in-Hand
With its history of large-scale surface mining that goes back into 1907, Carlshütte AG built the first electric-driven rope shovels for the 19th Century, Germany has built up a strong presence in the the Lizenz open pit, which was controlled by Demag (Deutsche world market for equipment that does the job efficiently, cost-effec- Maschinenbau AG). In 1925, Demag took over Carlshütte and relo- tively and—as is ever more important these days—as safely and cated the company to Duisburg. The Düsseldorf plant, where pro- with as little environmental impact as possible. Orders for massive duction is centered today, was built in 1939. machines for lignite mining may be few and far between, but the Over the years, KMG notes, Demag again and again set mile- machines that are out there in the field need upgrading from time stones in the mining sector worldwide. In 1949, the BL 335 rope to time, making them more energy-efficient and productive. shovel was the biggest such unit in the world, and in 1954 Demag German expertise has led the world in the design of hydraulic caused a sensation at the Hannover industrial fair when it intro- mining excavators, with three of the major suppliers located in duced the first fully hydraulic, diesel-driven excavator in the world. Western Europe. Where engines are concerned, manufacturers have The company followed that in 1972 when it developed the first risen to the challenges set by national and international regulators, hydraulic excavator with a total machine weight of more than 100 t. thereby ensuring that earthmoving equipment of all types and In 1978 Demag was integrated into the global Mannesmann capacities meets the evolving environmental emission standards. group, and was renamed Mannesmann Baumaschinen GmbH. Control systems have become increasingly sophisticated, squeezing However, it maintained its pioneering role in world mining, with the the last pennies and cents of productivity out of a machine’s per- introduction and commissioning of what was then world’s biggest formance; yet Germany’s equipment companies continue to come up hydraulic excavator, with a machine weight of more than 500 t. with new solutions that give the surface-mining community even Another important milestone came in 1999 with the company’s more for their money. acquisition by Komatsu Ltd, and its renaming as KMG. Today, the company claims around a 30% share of the substan- A Long-time Heavyweight in tial world market for mining excavators, and is continuing to Hydraulic Excavator Design expand and strengthen is position as a manufacturer of extra-large With its headquarters in Düsseldorf, Komatsu Mining Germany excavators for open-pit mining. Its Düsseldorf plant produces four GmbH (KMG) is part of the international mining- and construction- different types of excavator, with weights of 250 to 760 t for its flag- equipment supplier, Komatsu Ltd of Japan. Within the group, KMG is ship machine, the PC 8000. Depending on the model, bucket sizes responsible for the development, production and marketing of vary from 16 to 42 m3. In addition to standard configurations, KMG super-large hydraulic excavators for open-pit mining world-wide. offers machines that are tailor-made to customer requirements, The company says that the KMG brand is recognized around the with users able to chose between diesel or electric drives as well as world as a synonym for high quality that is achieved through con- between backhoe and front shovel equipment. tinuous product development and innovation, combined with long- KMG says that its machines are now at work all over the world, term reliability. operating day and night under very tough conditions. One example The company’s history goes back to the early 20th Century. In of this is the environment in the Department of Cesar in Colombia,
The team of mechanics responsible for looking after two Komatsu PC 4000s and a fleet of 730E haulers at Vale’s Bayóvar phosphate mine in Peru. Weighing in at 390 mt (430 ton), these PC 4000s carry a 29 m3 bucket because of the low density of the rock.
18 VDMA MINING SUPPLEMENT • 2012 VDMA_pg18-19_Surface 11/16/12 11:18 AM Page 19
with humidity close to 75%, daytime temperatures ranging up to 50°C and high dust concentrations. Moreover, another big advan- tage Komatsu claims is working in high-altitude operations, which are tough on excavators. At Barrick Gold’s Pascua Lama project on VDMA the border between Chile and Argentina, three PC 8000s will work at an altitude of 5,200-5,800 m, in one of the highest surface-min- ing operations in the world. KMG reports that the PC 8000 is the best-selling excavator in his class, with over 90 units supplied worldwide. In addition, it claims market leadership in supplying electric-driven excavators, and to be the only OEM able to supply this power source in the plus- 700 t heavyweight excavator class. It also says that its design philosophies are guided by safety regulations together with the requirements of the EMERST (Earth Moving Safety Round Table) group, and that in October 2011 it became the first hydraulic min- ing shovel OEM to offer a specific OMAT training course. Liebherr’s flagship truck, the 363-mt capacity T 282 C. Supplying the Big Tools for Mining Key safety features on new Liebherr excavators include a From small beginnings in 1949, the decentralized Liebherr Group of redesigned operator’s cab, which is positioned further forward than companies has grown to offer hundreds of products and services in the past, to give better visibility. worldwide. With more than 32,000 employees in over 100 countries, Meanwhile, the company’s other contribution to surface-mining the group states that it is recognized by customers throughout the technology is its T 282 C mining truck, produced in its plant in world for its top quality, user-orientated products and services in a Newport News in the USA. Liebherr reports that its trucks are now in wide range of technological fields. operation in coal, copper, iron-ore, oil-sand and gold mines in the The range of loading equipment manufactured by Liebherr at USA, Canada, South America, South Africa, Australia and Colmar, France, currently covers seven different sizes of mining Indonesia. excavators, with electric and diesel drives of up to 3,000 kW and The T 282 C can carry a payload of up to 363 t (400 st) at operating weights up to 800-plus tonnes. This broad range of types speeds of up to 64 km/h (40 mph). Available with a 2,800 kW MTU provides the right equipment for every application, the company engine or a 2,610 kW Cummins, the truck is engineered to be suggests, while offering a selection of mining buckets specially strong, durable and light-weight, Liebherr says, while claiming that matching the properties of the material. Liebherr’s most recent it also offers the highest payload-to-empty vehicle weight ratio in additions in this product category, the R 9100, R 9400 and the R its class. 9800, have extended the lower, middle and upper ends of the range. The smallest mining excavator, the R 9100, which was first Specialised applications for big breakers introduced in 2010, weighs between 110 and 114 t. It is powered by Based in Essen, Atlas Copco’s heavy-duty hydraulic-breaker divi- a new Liebherr V12 diesel engine that develops 565 kW (757 hp), sion now has a 14-model range, covering the 2,000 kg HB 2000 to complies with USA/EPA Tier 2 emission limits, and make highly effi- the 10-t operating weight HB 10000. Recent upgrades to the prod- cient, economical use of fuel, the company claims. The Liebherr uct range have given an improved power-to-weight ratio, the com- bucket of the R 9100, with a nominal volume of 6.8 m3, has an opti- pany says, so that the same performance can be achieved with a mized pattern for mining work, designed for improved penetration smaller attachment and carrier unit–leading to reduced investment and a high fill factor. The R 9100 incorporates proven systems and and maintenance costs. components that Liebherr itself has developed; together with the Two applications that spring to mind for big hydraulic hammers revised single-line lubrication circuit and the fuel and oil filter sys- are the secondary breaking of oversized rocks and clearing block- tems, they are part of the key to the machine’s reliability and per- ages on scalping grizzleys and in crusher throats. However, the formance potential, Liebherr says. Cost-effectiveness is enhanced quarrying industry is also a major user of this type of technology. by the reduced volume of maintenance work. A wide catwalk makes Throughout the industry, Atlas Copco says, increasing demand it easy to reach the individual assemblies for rapid and reliable ser- for smaller, more mobile carriers has emphasized the gap between vicing, while all maintenance points are accessible at a practical the 3000 and 4200-sized breakers; hence its decision to introduce height from one side of the machine. the HB 3600 machine. The upper end of the Liebherr range is marked by the R 9800, introduced in 2008. With up to 810 t operating weight and powered by two 1,492 kW (2,000 hp) diesel engines in Tier 2 configuration, the R 9800 is the largest backhoe excavator in the world. The machine is fitted with a nominal 42 m3-capacity bucket as a back- hoe and 42.7 m3 as a face shovel, with breakout and digging forces being optimized for the best possible penetration. Other mining excavators from Liebherr include the R 984 C (120-125 t; 504 kW/685 hp); R 9250 (250-253 t; 960 kW/1,287 hp); R 9350 (302-310 t; 1,102 kW/1,500 hp); R 9400 (345-353 t; 1,250 kW/1,675 hp), R 995 (441-450 t; 1,600 kW/2,140 hp); and R 996 B (672-676 t; 2,240 kW/3,000 hp). The R 9400 will be officially launched at the 2012 MINExpo in Las Vegas, the company says, although it already has eight machines working on site, while the R Atlas Copco’s heavy-duty hydraulic-breaker division now has a 14- 9250 and R 9350 can be supplied with Tier 2-compliant engines for model range, covering the 2000 kg HB 2000 to the 10t-operating the US market. weight HB 10000.
2012 • VDMA MINING SUPPLEMENT 19 VDMA_pg20-21_Materials Handling 11/16/12 11:19 AM Page 20
Materials-handling Technology: VDMA Keeping Minerals Moving Around the World
Moving minerals from mine to plant; moving overburden; crushing, stack- ing and reclaiming; German companies are at the forefront of materials- handling technology. And, of course, that is not really surprising, given the country’s background in the large-scale opencast lignite mining that has kept its power stations fueled for decades. German materials-handling systems think big, and can move millions of cubic meters of material safely and economically while minimizing their impact on the environment. Reliability is a key feature, with no room for complacency when it comes to keeping the belts running, the screens clean and the rock flowing.
Bending Belts for Environmental Protection Based in Beckum, Beumer Maschinenfabrik GmbH & Co. KG offers its materials-handling capabilities right across the mining and minerals sec- tor. The company states it is an international leader in the manufacture of intralogistics for conveying, loading, palletizing, packaging, sorting and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Ltd, the Beumer group employs about 3,000 people and has an annu- al turnover of about €450 million. Heavy-duty vibrating screens is one area of Jöst’s specialization. Having been in business for 75 years, Beumer began developing curved belt conveying systems some 50 years ago, claiming to have origi- With more than 90 years’ experience, the company manufactures sophis- nated the theoretical dimensioning fundamentals for these types of instal- ticated machines and systems mainly based on vibration technology, lation. Since then, the company says, it has continued to develop the tech- together with solutions for thermal processes. nology, both for open troughed belts and for closed, tubular belt conveyors. Looking specifically at Jöst’s vibration technology for the handling of The company has been involved with various aspects of conveyor bulk materials in primary industries, it has a wide product range that design since its formation with its founder, Bernard Beumer, having invent- includes the Extrovib system, grizzly screens and feeders, scalping screens, ed and patented a conveyor idler that featured a labyrinth seal. From that banana screens, classifying screens, dewatering screens, vibrating feeders starting point, successive generations of the Beumer family have built the and drying systems. Its special screens include its Grecco screens, company to be a significant player in the international market. Trampolin flip-flow screens, fine screens and non-blinding screens among Under a recent contract, the company is supplying a troughed belt con- others, while it also has expertise in the design and supply of electric con- veyor, capable of negotiating horizontal curves, to Nordkalk, one of Europe’s trol and regulation for machines and complete systems. major manufacturers of lime products. A key feature of Nordkalk’s require- The company says that screening technology is the centerpiece of its ments was for the limestone-transport system to be environmentally friend- product range for the primary industries, handling materials as diverse ly, Beumer explains, with the 8.7-km long conveyor being installed in the as coal and diamonds as well as industrial minerals such as limestone, north of the island of Gotland in the Baltic Sea. This, the company adds, is hard rock and mineral sands. Aside from its main plant in Germany, Jöst the largest limestone-production operation in Scandinavia, supplying lime- manufactures its machines and systems in Australia, China, France, stone to customers around the Baltic Sea, with part of the quarry’s output India, South Africa and the U.S., with the Australian, Chinese and South being processed into quicklime by Nordkalk’s subsidiary, KPAB. African activities being mainly focused on the production of heavy-duty Every hour, 1,500 mt of limestone will be transported from a new quar- vibration screens and vibrating feeders. ry at Bunge to the plant in Storungs, where it will be graded and stockpiled. During 2011, Jöst won a major order for seven large feeders and “The Beumer troughed belt conveyor was a clear favorite of ours compared screens for Rio Tinto’s iron ore operations in the Pilbara region of Western to other transport options,” said Mikael Lindberg, plant manager for Australia. The screens will be used at the Cape Lambert Port B facility to Nordkalk. “It uses little energy, is quiet and environmentally friendly.” sort lump ore and fines ahead of ship-loading. The new port facility will Beumer notes it was crucial for Nordkalk to preserve the island’s coun- add 50 million mt/y of iron-ore capacity in phase 1, with a second phase tryside during transport. This goal was achieved, it says, because the proposed to duplicate capacity to 100 million mt/y. troughed belt conveyor can navigate particularly tight horizontal curves. Each double-deck screen, fully assembled and tested at Jöst This allows for flexible, continuous routing, and the opportunity to bypass Australia’s Welshpool facility, has a vibrating mass of 37.9 mt mount- sensitive areas or to negotiate obstacles such as rivers, streets, railways ed on an isolation frame weighing 19.2 mt. Measuring 4.27 m wide, the and so on, while preserving the existing terrain. screens will be fed using diverging feeders to spread the ore over the full width of the screen, thereby using the maximum available surface Vibration Expertise for the World Market area. The screen design was developed ‘in-house,’ Jöst says, using Headquartered in Dülmen, Jöst GmbH & Co. KG specializes in applying finite element models that were checked against factory test results vibration technology to handling and processing a wide variety of bulk using strain-gauge recordings for verification. Fully modal analysis materials for primary industries and also for other end-users such as the was also undertaken to ensure a full understanding of the frequency foundry, steel, environmental, recycling, chemicals and food industries. responses of the screens.
20 VDMA MINING SUPPLEMENT • 2012 VDMA_pg20-21_Materials Handling 11/16/12 11:19 AM Page 21
VDMA VDMA_pg22-25_Underground 11/16/12 11:20 AM Page 22
Underground Mining Technology: VDMA Safer Working Conditions and Higher Productivity
German companies have been at the forefront of underground mining tech- long chair-lift system for a coal mine in Mexico. A challenge here was to nology for well over a century, and even during the gradual run-down of the keep the system separate from an existing monorail network, for person- country’s hard coal mining industry, they are still showing just how innova- nel safety reasons, the company said. tive they can be in supplying state-of-the-art equipment to export markets Scharf also reports having been successful in transferring its monorail around the world. German underground mining technology is not, of course, technology from the coal industry to hard-rock mining, with several systems focused exclusively on the coal industry, with its suppliers continuing to win delivered to mines in South Africa. The company claims that independent an increasing share on world markets with machines for hard-rock and reports have shown that mining companies can cut both their costs and evaporite mining. cycle times for handling materials underground by using monorails, with For instance, Hauhinco has been supplying equipment to the mining savings coming from lower ventilation requirements and the use of small- industry for over 100 years, having become one of the world’s leading sup- er-diameter headings for their transport infrastructure. pliers of water hydraulic systems, with an extensive range of valves, pumps and electronics. Hauhinco supplies individual and tailor-made high-pres- Caterpillar: Bringing Germany’s sure and spray systems for longwall installations. As well as single-face Coal Mining Heritage Up-to-date systems, the company says, it can design and install centralised networks As predicted in the 2011 edition of Best of Germany, there is a new name that can supply up to four faces within a single mine, with its infrastruc- within the German mining-equipment sector: Caterpillar. Today, Bucyrus ture covering distances of up to 5 km. Europe GmbH is part of the Caterpillar Global Mining Division, which offers From its headquarters in Dortmund, the Deilmann-Haniel what the company claims to be an unparalleled range of mining and sup- International group encompasses specialist shaft-sinking contract ser- port equipment and technologies for all types of underground mining. vices and underground mining equipment from its German subsidiaries, As most people within the mining industry will recall, the former DBT with shaft-sinking and mine construction services being supplied through company brought together a huge pool of German expertise in mining its Redpath and Frontier-Kemper companies in North America. equipment design and manufacture, with the subsequent acquisition of Deilmann-Haniel Shaft Sinking GmbH claims to be one of the world’s DBT by Bucyrus merely adding to the company’s already strong interna- most experienced shaft-sinking contractors, having undertaken more tional reputation. Now, as part of Caterpillar, Bucyrus Europe remains a than 500 shafts. As well as sinking new shafts, the company provides committed member company of the VDMA, with its production facilities rehabilitation services for old mine accesses, together with raiseboring, founded in their traditional heartland. ground-freezing and mine-closure services. An example of its raiseboring For underground coal and soft-rock mining, Caterpillar offers the full skill comes from a ventilation shaft at Deutche Steinkohle’s West mine, range of longwall equipment—roof supports, armoured face conveyors, where it achieved an accuracy of 300 mm over a 600 m pilot hole length, shearers and plows—together with room-and-pillar mining equipment, the company reports. including continuous miners and haulers. For underground hard-rock min- Underground transport systems are SMT Scharf’s speciality, with the ing, Cat equipment now encompasses loaders, trucks and drills. Hamm-based company offering suspended monorail systems, floor- Since completing its Bucyrus acquisition, Caterpillar has been focus- mounted rail systems, chair-lift transport for man-riding, roadheaders ing strongly on its underground coal equipment range, and in October 2011 and conveyors. Orders reported by the company during 2011 included a 7 was a first-time exhibitor at the China Coal & Mining Expo in Beijing—the largest underground mining exhibition in the world. Designed under the ‘Wherever there’s mining’ theme, Caterpillar’s stand featured as its center- piece its recently rebranded EL3000 shearer, which was developed for medium-to-high coal seams in the 2.5-5.5 m (98-217 in.) range. With 2,295 kW (3,078 hp) of installed power, the EL3000 is designed for pro- duction rates of up to 5,000 metric tons per hour (mt/h). Industry-leading automation can be configured to meet individual control needs, Caterpillar says, from basic monitoring and protection to advanced automation and data transmission. In addition, an automation package allows improved utilization of manpower in a safe environment, with increased yields from any given seam section, faster haulage speeds, improved face manage- ment, and increased equipment life. Cat’s coal sector equipment that is produced at its Lünen factory includes the company’s longwall face-support, armored face conveyor and plow ranges, as well as its haulage conveyors and CST (Controlled Start Transmission) drive units. Built to meet individual site require- ments, face supports are available to cover seam heights of 800 mm to 7.5 m (22-295 in.), and are capable of providing support loads of up to 1,750 mt (1,930 ton). Support units are also made in various widths from 1.5 to 2.05 m, with special units for systems such as longwall caving also available. Caterpillar participated in the China Coal & Mining Expo for the first time km- For seams less than 1,800 mm (71 in.) thick, Caterpillar offers plow in 2011, where the company displayed its EL3000 shearer.
22 VDMA MINING SUPPLEMENT • 2012 VDMA_pg22-25_Underground 11/16/12 11:20 AM Page 23
systems that can produce up to 3,500 mt/h. With 2x800 kW installed, 900 combines the compact dimensions of the SL 750 with the power of the these are the most powerful plow systems available, the company says, larger SL 1000, and although it is of similar size to the SL 750, it weighs capable of out-performing shearers, with features such as horizon con- in at around 25 mt heavier—a consequence of its higher machine body trol and overload protection that make this a future-orientated solution stiffness and rigidity, Eickhoff says. Installed power of 2.35 MW means VDMA for hard-coal mining. that the SL 900 can produce in seams from 2.1 to 5.5 m high. With what it claims is the world’s most powerful shearer loader, Sophisticated Shearers, and Much More Eickhoff commissioned the first SL 1000 at a Shenhua mine in China in Part of the Eickhoff group, Bochum-based Eickhoff Bergbautechnik 2007. The machine is designed to achieve peak performance in seams GmbH develops, builds and supplies high-performance machinery to the more than 7.1 m thick, although it can be modified to work at seam heights underground mining industry. The company’s product line ranges from down to 3 m. shearer loaders for longwall mining, via continuous miners for heading Turning to continuous miners, Eickhoff offers two versions of its CM 2, and room-and-pillar mining, to roadheaders for mining and tunnelling. All one with hydraulic drive for better traction in wet or muddy conditions, and of its development activities on these machines are focused on achieving the other with electric traction drive. Both provide low ground pressure and the optimum benefit for the customer, the company says, with maximum high tramming speeds, the company says. A 1.2 m-diameter cutting drum availability and reliability, ease of maintenance and long service life being is fitted as standard, with 360 kW of installed power. features of its products. The highest possible installed powers assure high Speaking to Best of Germany, the company’s CEO, Dr. Paul productivity at low machine-specific mining cost, Eickhoff adds. Rheinländer, said Eickhoff’s continuous miner fleet recently increased by Eickhoff’s shearer range encompasses four models: the SL 300, SL another four machines, with orders received from China, Russia and 750, SL 900 and SL 1000. When the SL 300 was introduced in 1994, the Belarus. “Although they have only been on the market for a short time, company points out, it was equipped with two 220 kW cutter motors and these machines are already getting a good reputation,” he said. two 35 kW DC haulage motors. Today, an SL 300 comes with two 480 kW cutter motors and two 90 kW AC haulage motors, giving increased cutting Safety First with the New Paus Scaler and travel capabilities while producing up to 600,000 mt/month at opera- “The market needs companies like us to come up with solutions to indi- tions in Australia and the U.S. vidual conditions,” Franz-Josef Paus, managing director of Hermann Paus The SL 750, introduced in 2006, built on the success of the SL 300 and Maschinenfabrik GmbH told Best of Germany. “We love engineering, and former SL 500 machines, being only slightly larger than the SL 300 but we try to offer machines that are as specialized as possible. Within each of with significantly higher cutting power. The shearer is designed for seam our ranges, there are good opportunities for customization.” heights of 1.8-4.5 m, with 1.9 MW of installed power. Paus went on to note that the mechanization of scaling, and protec- While this machine grew from its smaller relations in the range, the SL tion against rockfalls in general, is growing in importance in the mining
MEN INVENTED THE RUBBER TYRES THAT MOVE THE EARTH. ERLAU INVENTED PROTECTION CHAINS TO PREVENT TYRE FAILURES.
2012 • VDMA MINING SUPPLEMENT 23 VDMA_pg22-25_Underground 11/16/12 11:21 AM Page 24
and tunnelling sectors world-wide. As a result, he said, the company has world’s leading manufacturers in the field of high-pressure water tech- analyzed the issue in detail and hopes to contribute to the improvement of nology. Its extensive product range is sold through an international dis- roof and impact safety by the use of its redeveloped scaler. “The keyword tributor network and experienced specialists in more than 40 countries. VDMA here is ‘safety first!,’” he said. Based in Witten, the company now offers a product range that cov- According to Paus, scaling equipment in use at the moment is often ers high-pressure pumps, pump systems and accessories for pumping too large or too inflexible, and is hard to move quickly from one site to various kinds of fluids, and suitable for working pressures up to 3,500 another, especially where mines have small cross-sections. Operators also bar. Besides supplying its products to users such as industrial cleaning quickly lose their ‘feel’ for the rock with longer reaches or comparatively contractors and to heavy industry, Kamat claims to be the world’s lead- heavy hydraulic hammers. ing manufacturer of pumps developed specifically for longwalling and Having been in production for more than 15 years, the company’s dust suppression in the mining industry, with both a standard range of scaler has now been completely redesigned, with a number of new features pumps and tailor-made products and systems designed to meet cus- and functions—and a change of name, from TSL 852 to Scaler 853 S8. tomers’ special needs. With articulated steering and a compact design, a radius of just 2.8 m is Kamat reports its pumps are compact and robust, have a long ser- all that is needed to make a 90° turn. The telescopic boom can extend to a vice life and are simple to maintain. Designed and manufactured to pro- reach of 8 m and, with a pivot angle of ±45°, a heading width of up to 9 vide smooth, trouble-free operation under a continuous duty cycle, its m can be covered from one set-up. Paus uses NPK hammers as standard high-pressure plunger pumps provide a reliable solution to the provision since, as Paus pointed out, “we know that they will work pointing upward.” of hydraulic power on longwall installations. Maximum safety during scaling is assured by the operator sitting up Its product range covers high-pressure plunger and piston pumps, to 8 m from the scaling point, depending on the pivot angle and the actu- as well as complete pressure systems, for a power input range up to al length of the telescopic boom. Deflectors on the boom prevent broken 1,100 kW, and includes accessories for all kinds of applications. Single rock from sliding onto the cabin and, during scaling, the operator has a pumps offer flow rates of up to 2,400 liter/minute at 95 bar, handling clear view of the cutting point because of the way that the boom and fresh water, demineralized water, emulsions, light oils and other similar hammer pivot. fluids, while pressure capabilities range up to 3,500 bar at 58 The new machine has a ROPS/FOPS cab with large windows and a liter/minute. Special pumps are available for mining and for reverse- glass roof that give the operator a good view of what is happening dur- osmosis salt-water desalination plants. ing scaling; additional protection comes from a grill over the front and In October 2011, Kamat introduced a new family of pumps suitable for roof glazing. The turret is now significantly lower on the new model than power inputs of 100-160 kW. Offering low-vibration, low-noise operation, before, without any loss of reach, giving significantly better forward vis- these pumps are optimized for use with VSD-driven motors and with diesel ibility, Paus said. engines, the company says, allowing variable speeds in the range 10%- The scaler can be equipped with an optional ‘IntelliScale’ machine- 100% of their nominal speed. In addition, there is a high level of parts control system—a Canbus-based network of the key mechanical compo- commonality between the new pumps and the existing K10000, K13000 nents with the hammer, enabling various parameters like the engine and K16000 ranges. Kamat is following this in early 2012 with the intro- speed and hammer frequency to be coordinated automatically. Defined duction of its 3G pump series, used with 350-400 kW drives. operating statuses can also be called up, thereby preventing the possi- In the international market, to date Kamat has sold more than 75 bility of accidental or incorrect operation: the functions are blocked since, pumps into Australian mines. It reports that the Australian company, as the company points out, hazardous situations underground are often Longwall Hydraulics, is installing a pump system that includes its new the result of operator error. gearbox K35000-3G pumps. The system, being supplied to one of the BHP A unique safety feature is the vehicle’s reverse fleeing mode. In the Billiton Mitsubishi Alliance (BMA) mines, consists of three pump sets, event of imminent danger, such as falling rock, the operator presses a but- with each set housing a K35055-3G (439 liter/minute at 350 bar) and a ton on the control joystick, the hammer and boom are stopped and retract- K9030M (84 liter/minute at 415 bar) pump, driven by a Morley 400 kW ed, and the machine moves backward automatically. emulsion cooler motor. The pump station itself is a crawler-driven plat- form, 8.5 m long by 3.5 m wide and 2.6 m tall, with an 14,000 liter emul- High-pressure Longwall Pumps sion tank and a boosted suction system. The company also notes that this Established in 1974 as the European subsidiary of a large American contract represents a great success as BMA had previously been using pump manufacturer, today Kamat-Pumpen GmbH & Co. KG is one of the pumps from another supplier.
Eickhoff offers two versions of its CM 2 continuous miner. It recently received The IntelliScale control system, which links machine functions on Paus’ orders for a further four machines. 853 S8 scaler to give additional safety features.
24 VDMA MINING SUPPLEMENT • 2012 3680 3680 VDMA_pg22-25_Underground 11/16/1211:21AMPage25 solutions, please visit www.draeger.com. pleasevisit solutions, To equipmentand learnmoreaboutDrägersafety programs customer’s to needs. meetindividual support Over 100 years ofexperience matters! 100years Over well as offering a selection of professional service and ofprofessional aselection service well asoffering equipmentas manufactures ofsafety abroad spectrum for Life” guidingphilosophy, asits and Drägerdesigns to miners’ healthandsafety. “Technologycommitted With technology, andmedical in thefieldsofsafety hasbeen founding its in1889,Dräger,Since aninternational leader On yourside, at yoursite - Service programs andtrainingcourses - Service equipmentfor- Safety missions minerescue andsystems technologies to- Different enhance - Measurementandwarning againstdangerous protection againstdustandparticles - Respiratory inmines: safety and workplace to health Dräger’s holisticoffer enhance self escape and rescue capabilities andrescue self escape gas concentrations VDMA_pg26-29_Coal_Mineral 11/16/12 11:22 AM Page 26
Coal and Mineral Processing:
VDMA Getting Out the Most, Safely and Economically
Covering construction materials, industrial minerals, fuels and ores, Listwjashnaja washery, which is only 20 km from Kirowa. German companies provide the technology to upgrade, concentrate and recover valuable commodities, not only from newly mined raw Loesche’s Fine-grinding Mill Technology materials but through recycling as well. Today, mineral-processing Founded in 1906, Loesche GmbH specializes in the design, manufac- technology supplied from Germany can be found world-wide, with ture and installation of grinding equipment for the cement, mining and German innovation at the forefront of new concepts and developments. industrial minerals industries. The company designs vertical roller Not surprisingly, the growth of Germany’s coal industry in the 18th mills, and can deliver grinding, preparation and drying systems that and 19th centuries provided an early stimulus for the development of range in size and complexity from individual units to complete turn-key processing systems on a much larger scale than had been seen before. plants. Its product range also includes feeders and classifiers, togeth- However, it is also important to remember that central Europe has an er with hot-gas production units. As well as its main facility in even longer history of ore mining, with mineral-separation and metal- Düsseldorf, Loesche has associated companies in Spain, the U.S., the smelting processes forming an essential part of this. And, resourced UK, Russia, South Africa, India and China, as well as representatives from massive resources of bedded deposits like rock salt and potash, and agents worldwide. as well as coal, Germany’s chemicals companies were among the world For processing ferrous and non-ferrous ores, and base and pre- leaders in the development of the reagents that today are essential in cious metals, the company can supply grinding mills with capacities of the mineral recovery process. up to 2,000 mt/h, capable of reducing minus-150 mm feed to 20 In this chapter of Best of Germany 2012, we look at a cross-section µm(p80). For industrial minerals, its dry-grinding plants can be used on of the German companies that are currently offering mineral treatment materials such as barite, bentonite, chalk, dolomite, gypsum, graphite, and processing expertise worldwide. The depth of this expertise is sub- manganese ore, phosphate, titanium slag and titanium dioxide, among stantial, as each of the sections below clearly shows. Using state-of- others, while the technology is also applicable to grinding hard coal, the-art technology to help cut energy costs is one major focus from all petcoke and lignite for the cement, power, and iron and steel industries. of the companies involved here, as is enhanced safety in all aspects of In May 2011, Loesche was awarded a third order by Guangxi mineral-processing operations. Jinchuan Non-Ferrous Metals Co. Ltd. for a LM 31.3 copper matte mill. Destined for installation at Jinchuan’s copper plant at Fangchenggang Building Big Jigs City in China, this built on the experience gained with the successful Headquartered in Cologne, MBE Coal & Minerals Technology GmbH introduction of this technology at the company’s YangGu project in (MBE-CMT), is one of the world’s leading suppliers of plants and September 2009 and at its Tongling project in July 2010. Up to now, equipment for mineral and coal preparation. The former Humboldt Loesche says, it has been successful in winning all of the orders for Wedag Coal & Minerals Technology GmbH was acquired by the Indian copper matte grinding equipment for use with flash-smelting technol- company, McNally Bharat Engineering Ltd., in October 2009. ogy which, it adds, has been widely accepted by the Chinese copper MBE-CMT’s history goes back more than 150 years, with the com- industry. pany offering basic and detail engineering, components for complete Loesche’s first order for Jinchuan, consisting of an LM 31.3 copper plants and plant sections including modernization and capacity matte mill and a LOMA LF 25 hot gas generator, was commissioned at increase measures, as well as process control equipment. The scope of YangGu in Shangdong province at the beginning of 2011. The capacity services also includes feasibility studies, raw-material testing, financ- of the most recent mill unit to be ordered will be ing concepts, erection and commissioning, personnel training, and pre- 100 mt/h of finished product at 85% passing 200 mesh, giving an and after-sales service. annual capacity of 400,000 mt/y. The company notes that its main markets for coal and minerals Loesche reports that in the past few years it has sold three LM 31.3 projects are in Asia, Africa, South America and Russia. It has sub- units, one LM 31.2 and two LOMA LF 25s to handle this type of copper- sidiaries in China, India, Russia, South Africa, Brazil and Indonesia, as containing material. The first unit, installed in 1995 at Kennecott Utah well as agents in Vietnam, South Korea, Australia, Venezuela, Copper in the U.S. has given excellent performance, the company adds. Colombia, Chile, Peru and Mongolia. In October 2011, Loesche unveiled a new concept in coal grinding: During 2011, MBE-CMT was awarded a contract to supply the the world’s first containerized coal-grinding plant which, the company largest Batac jig that has ever been built. The client is the Russian coal says, is aimed at helping its customers reduce their operating costs by company, SUEk, and the machine will be installed in the Kirowa coal substituting coal instead of oil or gas in various thermal applications. preparation plant at Lenin Kuznetsk in the Kusbass coalfield of western Housed in standard-sized sea-freight containers, the plant is fully Siberia. automated and ready for operation MBE-CMT says the machine separates minus-100 mm raw coal Loesche explains that it has packed more than 100 years of expe- with a nominal feed rate of 800 mt/h into rejects, middlings and clean rience in coal grinding technology and plant engineering into a few coal. Built at the workshops of Cologne Engineering, part of the MBE seaworthy containers, representing a very compact and efficient coal- group, the jig will form the heart of the washing plant for power-station grinding plant. It has designed the new plant for grinding all types of coal. Commissioning is scheduled for spring 2012. coal, from dried lignite to anthracite with a grain feed size of 5-30 mm. MBE-CMT claims market leadership in the supply of high-capacity The grind will produce coal dust in the range of 5%-45%R 90µm, with jigs. It has supplied various 7 m-wide Batac jigs to coal-washing a potential output of 2-4 mt/h. plants around the world, with one of them delivered to the Capable of operating at temperatures between -30° and 40°C, the
26 VDMA MINING SUPPLEMENT • 2012 VDMA_pg26-29_Coal_Mineral 11/16/12 11:22 AM Page 27
plant offers a number of advantages, including its standardized with its services including the customized design, application and com- design, six-month delivery time, three-week commissioning period, missioning of ore-sorting, beneficiation and tramp-removal systems high flexibility on site, and the opportunity to write off its purchase cost that can increase product yields, improve concentrate qualities, reduce quickly from energy-cost savings by using coal rather than oil or gas. operating costs and boost process efficiencies. VDMA Steinert notes that it also invests heavily in product development Sandvik’s Crushing-technology Hub and testing, both in Australia and in Germany, where customers can Sandvik Mining & Construction Crushing Technology GmbH has sup- enjoy the confidence of having a fully appointed test facility for equip- plied a broad range of crushing solutions to the mining sector for near- ment performance analysis at its corporate head office. ly 60 years, with a widely spread customer base covering requirements The company’s range for the mining sector includes tramp-mate- that vary from copper and iron ore production in Australia and Africa to rial detection and removal systems to protect conveyors, crushers and coal-processing equipment in China and throughout Europe. high-pressure grinding rolls; heavy-media recovery and iron ore bene- The company says its CR810 Hybrid is unique in its product line, ficiation; upgrading upstream concentrator feedstock in mineral pro- combining the benefits of a classic double-roll crusher with sizer tech- cessing; wet and dry low-, medium- and high-intensity magnetic sep- nology to create a compact machine that achieves high throughput arators; induction, X-Ray, XRF, 3-D/laser, color and near infra-red ore- with relatively low power consumption. The aggressive teeth configu- sorting systems; electro and permanent suspension magnets; metal- ration of the CR810 Hybrid is capable of crushing lumps up to 2,100 detection systems; and magnetic drums and pulleys. mm with a reduction ratio ranging from 1:4 to 1:6, depending on the Steinert says its ‘Boomerang’ magnets are used to remove ferrous feed material. A standard CR810 Hybrid is capable of achieving a tramp metal from bulk materials, such as coal, at ship-loading facili- throughput of up to 10,000 mt/h, and is designed for use in crushing ties located at key export terminals on Australia’s eastern seaboard. ores, coal, salt and limestone, and in applications where the feed Coal is delivered by train from the mines to these terminals, where the material is wet and sticky. requirement for high-powered, deep and wide field magnets is Sandvik’s CR610 Centre Sizers are generally used in open-pit min- paramount for efficient and effective tramp-iron removal. The latest ing: other potential uses include primary crushing in underground min- Boomerang left its Melbourne factory in September 2011, bringing the ing, and secondary and tertiary crushing applications, the company number of these super-sized, powerful magnets installed in Australia to says. Inward-rotating rolls crush a variety of materials with hardness- six. Weighing in at 43 mt, these magnets are the largest of their kind in es of up to 120 MPa, including ores, coal, coke, potash and salt. The Australia, Steinert reports. machine is used for dry or sometimes moist material, and when used as a primary crusher can handle feed lumps of up to 1,500 mm. Schmidt, Kranz Takes allmineral Stake CR620 Side Sizers are primarily used for secondary and tertiary In November 2011, the Schmidt, Kranz group bought a 75% holding in crushing applications in both underground and surface mining. These allmineral Aufbereitungstechnik GmbH & Co. KG, the Duisburg-based machines can handle feed sizes of up to 300 mm, and are commonly supplier of mineral-processing plants to the coal, metals and extrac- used for crushing coal and lignite. Other materials up to a hardness of tive industries. “The Schmidt, Kranz group’s involvement is a further around 120 MPa can be crushed, Sandvik notes, including ores, gypsum and salt. The company says these machines are designed to handle feed material efficiently, and reduce product fines and dust production. Shields and guards are built into the machine to isolate moving parts from the operator. The focus of safety in the design is evident in the maintenance of the equipment; replaceable picks and seg- ments are designed for safe handling and installation, Sandvik points out. Finally, its CM420 Hammer Mills are used to crush boiler and coking coal, limestone, gypsum rock, salt and other minerals. They are designed exclusively for low- and medium-abrasive materials, have a high rotor speed (usually between 50 and 60 m/s) and have a throughput capacity up to 1,000 mt/h. The maximum feed size is 250 mm, and they achieve a crushing ratio of up to 1:25 (sometimes up to 1:50). Noise and vibration insulation options are also available.
Innovative Sorting Systems and Separators Steinert Elektromagnetbau GmbH, a family company from Cologne with a workforce of more than 200, has been delivering top techni- cal separation solutions for the primary and secondary raw materi- als sector for more than 120 years. The company says its interna- tional sales network provides close contact with its customers, with subsidiaries in the U.S., Australia, Brazil and Japan, and at Zittau in Germany, and a range of sales partnerships worldwide. Steinert claims to be one of the world’s leading companies in its field, with systems that include magnetic separators and sensor sorters such as the ISS induction-sorting system, the FSS color-sorting system and the XSS X-ray sorting system. Steinert Australia in particular specializes in delivering separa- tion technologies, not only for upgrading coal, but also for minerals and iron ore, and for contaminant removal. The company claims to offer an unrivalled, extensive product range for mining operations, Ready to roll – one of the SB 1525 R roll crushers that Hazemag supplied to Datang arrived on site in China in late 2011.
2012 • VDMA MINING SUPPLEMENT 27 VDMA_pg26-29_Coal_Mineral 11/16/12 11:23 AM Page 28
operation around the world, the company says, in both dry and wet min- eral processing. With subsidiaries in the U.S., South Africa, Poland and India, it is currently working in more than 30 countries. allmineral notes VDMA that, together with Schmidt, Kranz, it is now targeting India as a major market. Earlier in the year, allmineral announced it had won three indepen- dent contracts to supply its mineral processing products and equip- ment to Rio Tinto’s Low-grade iron ore pilot plant, which will be located at the Brockman 4 mine site in the Pilbara region of Western Australia. Being built by the engineering firm, Onyx Projects, this will play a strategic role in the optimization of beneficiation options for future Pilbara lower-grade deposits. allmineral will be providing an alljig with a design capacity of up to 80 mt/h of feed material. The alljig separates high-density iron ore from gangue material using stratification and separation processes. It is fitted with flexible design features that allow it to treat fines and lump material up to 32 mm, as well as treating wide-ranging particle- size ratios of up to 1:8, allmineral says. The company also secured an order for its unique three-product AFX 100 allflux classifier. This is designed to treat up to 2 mm iron ore par- ticles in two classification stages that upgrade the valuable mineral by A schematic of one of MBE-CMT’s Batac jigs. size and density, and also thicken and deslime in one step. The third allmineral product for the pilot plant, specifically developed for the expression of our consistent, internationally orientated market strate- beneficiation of haematite ores, is a model G 1000 gaustec wet high- gy,” said allmineral’s managing director, Dr. Heribert Breuer about the intensity magnetic separator (WHIMS). This separates iron ores, includ- new partnership. “The international market for ore and coal processing, ing paramagnetic and feebly magnetic minerals, up to a particle size of which is our core business, has grown considerably over recent years. 3 mm if required, but typically around 1 mm. High-gradient magnetic Now that an established company with a strong global presence like the fields are used, which can be independently adjusted for each rotor, Schmidt, Kranz group has joined us, we will be able to offer our clients allowing scavenger and cleaner process steps to occur in one single even more qualified expertise, and enter new markets.” Schmidt, machine. Kranz’s other interests in the mining equipment field include Hazemag “The equipment being supplied comprises of our proven technolo- & EPR, the sizer and underground machinery company, and GHH gies in haematite beneficiation, and we consider ourselves fortunate to Farhzeuge, which makes LHDs and other underground vehicles. be associated with the next generation of large-capacity downstream Founded in 1988, allmineral has developed processing and sepa- operations planned for the Pilbara,” Dr. Breuer said. “We are confident ration technologies for coal, ore, slag, gravel, crushed stone, sand and the upgrading processes for low-grade iron ore have the potential to various recycling materials. More than 600 allmineral plants are now in significantly add value to Rio Tinto’s existing and planned operations.”
According to Loesche, its new containerized coal-grinding plant can help save energy costs.
28 VDMA MINING SUPPLEMENT • 2012 VDMA_pg26-29_Coal_Mineral 11/16/12 11:23 AM Page 29
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Eirich intensive mixer type DW40 with an effective capacity of 12,000 liters. Eirich GmbH & Co KG Eirich supplies machines and turnkey plants • Agglomerating mixers for the disposal of Walldürner Straße 50 for the preparation of materials for the metal- sludges and dusts 74736 Hardheim lurgical industry and of metal production/ • Batching and weighing technology Germany working residues to be recycled or dumped. • Conveying technology and plant engineering Phone: +49 (0) 62 83 • 51-0 Field proven solutions are available for the • Control and process data technology Fax: +49 (0) 62 83 • 51-325 material preparation in the range of ores, CAQ/TQM/ISO 9000 E-Mail: [email protected] powder metallurgy, auxiliaries, and environ- • Maintenance and spare parts service Internet: www.eirich.com mental protection/recycling. With locations in worldwide Germany, France, Spain, the United States, Brazil, Japan, China, India, South Africa, as Mixer type DW31/7 - Capacity up to 700 t/h – well as agencies in over 60 other countries, Wear protection inside a mixer for iron ore (This we are always close to hand with our know- configuration can process how accumulated from countless projects more than 10 million tons without showing any worldwide. The production range covers an noticeable wear). extensive selection of highly reliable machines, components and complete sys- tems for continuous and batch operations. • Consulting and engineering for green- field and revamping projects • Application technology • Process optimization in our own test centers • Mixing and cooling technology for batch- wise and continuous operation • Intensive mixers with effective capacities from 1 to 12,000 liters VDMA_pg30-31_Safety & Prod 11/16/12 11:24 AM Page 30
Safety and Productivity Across the VDMA Board: Completing the Portfolio
Safety has always played an important role within mining operations. applications such as confined-space entry and post-blast inspection, the Globally “Safety First” has long been made a top priority by all of the key company says. players in the mining industry. Great endeavours have been made to reduce Measurements of diesel-engine exhaust can be carried out with the the number of fatalities and improve the lost-time and injury-frequency classic Dräger Tube or the MSI EM200-E, an electronic tester is specifically rates. To ensure the safety of employees and minimize downtime, the key designed to process flue gas. This measures carbon monoxide and nitrous industry players continuously strive for zero harm to people and the envi- fumes, as well as logging each test result for underground machines. ronment across their operations. In case of emergency, Dräger provides different technologies and sys- Originally introduced in Britain in 1887 to disadvantage imported tems to mine operators to enhance self-escape and rescue capabilities. goods, the term “Made in Germany” soon became associated with product With nominal durations of between 25 and 60 minutes, its chemical oxygen reliability and quality—a perception that continues to this day. German self-contained self-rescuers (SCSRs) can be incorporated into a self-rescue companies’ approach to built-in safety in their products comes in many system, while the company’s new Oxy 6000 SCSR offers a 10-year service forms, albeit with one over-riding goal: to minimize the risk of injury to peo- lifetime without additional testing and maintenance. ple and damage to equipment, while giving mining companies world-wide Dräger says its new ChargeAir system presents an enhanced concept a competitive edge in terms of life-cycle costs of doing business. for self-rescue and first-response capability of underground personnel. The Today, German technology is not just about the hardware that is visi- system provides cached self-contained breathing apparatus (SCBA) that ble when you walk through any mine or processing plant; behind the equip- allow for voice communication and the potential to react to, as well as to ment for digging, hauling, processing and smelting, there is a vast array of escape from hazardous situations. As workers exit the mine, they can systems that are all aimed at making the mining industry safer and more recharge their SCBAs at designated points without doffing the sets, there- productive. by ensuring that they always breathe uncontaminated air. In the event that a mine cannot be safely evacuated, Dräger refuge Mine Safety Technology: a Holistic Approach shelters, which provide their own breathable air and power source in a Founded in Lübeck in 1889, Dräger has been an international leader in the sealed positive-pressure chamber, further supplement the mine emergen- fields of safety and medical technology, committed to miners’ health and cy response plan. safety, for more than 100 years, “Technology for Life” continues to be its For mine-rescue teams, Dräger has its PSS BG4 Plus closed-circuit guiding philosophy, the company says, as it supplies a broad spectrum of breathing apparatus, which provides a four-hour working duration and the safety equipment that can be combined and used as an integrated safety option for hydration while wearing the set. The company also offers the first concept to protect, support and save lives. certified intrinsically safe thermal-imaging cameras, the UCF 7000 and For daily operational safety, Dräger notes its comfortable disposable 9000 which, it says, are invaluable tools for casualty search and situation- masks are commonly used in underground mines as everyday respiratory al assessment during rescue missions. protection, while its X-plore 1320 and 1720 series can also effectively fil- Last but not least, in response to the new ‘fitness for duty’ require- ter diesel particulate matter. ments in the mining industry, Dräger’s Alcotest 7510 and DrugTest 5000 Apart from airborne particulates, Dräger also offers a comprehensive systems represent an easy yet discreet and hygienic approach for non-inva- line of gas-detection products. The single-gas Pac series and the multi-gas sive workplace alcohol and drug testing. X-am series alert miners to dangerous gas concentrations, including toxic and explosive gases, vapors and oxygen deficiency. The X-am 5000 or X-am World Leader in Tire Protection 7000, which can measure both 0%-100% LEL and 0-100 vol% methane Originally developed some 70 years ago to protect the pneumatic tires of concentrations, can be used for regular cave monitoring and seal checks. the early hydraulic loaders working with sharp or abrasive rock, today RUD- In combination with an external pump for the X-am 2/5000 series or with Erlau claims a 65% share of the world market for tire-protection chains, the built-in pump for the X-am 7000, its monitors are also suited to other with designs to match the most demanding environments. Erlau’s light-weight but strong tire chains save energy, save tires, increase safety, cut maintenance down-time, aid productivity and signifi- cantly reduce the cost per loaded tonne, the company says. Sidewall piecing by slate or flint can reduce a tire to scrap in an instant, so for applications where this is a risk, the company offers its RING-RING system—a close-meshed chain that embraces the entire tire surface and deflects sharp-edged rocks for all-round protection. Where abrasive rocks are a problem, Erlau has developed the RING-LINK system that creates a barrier between a vehicle’s tires and the haul surface and can double and, sometimes, treble, tire life, the company adds. Working clayey seams or on icy haul roads can make loaders, trucks and graders hard to handle. Erlau notes that operators are fitting an open- ring chain such as its GARANT series to provide extra control or, where addi- tional grip is required, its Terraplus system would be an option, as it has studded links for extra ‘bite’. For underground, where any or all three of the these conditions may be encountered, the company produces the TORO X19—a lightweight, com- pact, all-embracing tire-protection chain that fits within the tight wheel arches of low-profile LHDs and trucks. Dräger’s closed-circuit breathing apparatus offers a four-hour working duration.
30 VDMA MINING SUPPLEMENT • 2012 VDMA_pg30-31_Safety & Prod 11/16/12 11:24 AM Page 31
Erlau points out that with high demand for mined products and no sidiaries in China, South Africa, the U.S., Poland, and Australia, and we foreseeable end to the shortage of earthmover tires, tire-protection chains also have representatives working for us in Russia and Chile.” can be an essential add-on. It is not by chance, the company says, that it The company claims to be the global market leader as a system has come to dominate the market for tire-protection chains, with a high provider for machinery and plant construction for shaft hoisting and heavy- VDMA level of quality control from the metallurgy used, through fitting, to life-of- duty hoisting technology, as well as for mine and tunnel cooling, and has product support. State-of-the-art production facilities ensure consistent noticed a clear trend toward increasingly large plant concepts in these weld integrity and lighter, stronger, energy-saving links. Before delivery, areas. Its successful cooperation with the Luan Mining Group in Shanxi each batch of chains is tested to destruction before being embossed with province, China, for example, is continuing with the supply of a two-com- an unique tracking code. partment skip-hoisting installation that Luan ordered for the main shaft at The introduction of a chain-monitoring system gives a new dimension its Licun mine. Using a four-rope ground-mounted winder with a diameter to its product support, Erlau adds, with each set of chains incorporating a of 5,000 mm, the system will hoist 30 mt capacity skips from a depth of 546 ‘Smart Link’ that records the set’s complete service history. A hand-held m at a speed of 12 m/s, and will handle about 5 million mt/y of coal. smart reader collects, updates and records data from several sets of chains; these data are then available for download and interpretation by maintenance staff. Erlau points out that its confidence in its tire-protection chains is such that it is providing the Smart Link free-of-charge, with Smart Links being shipped with every set of chains in the 22 mm range, and Erlau offering the smart reader at cost. Smart Link systems are already deployed in the U.S., South Africa, Europe and Australasia.
Servicing Bigger, Deeper and Safer Shafts “Our main area of expertise is the application of knowledge-based services in the fields of studies and planning, engineering, project management, product realization and technical service,” said Detlef Scheppe, executive vice president for shaft hoisting mining technology at Siemag Tecberg GmbH. “Technological leadership and customer orientation are the moti- vating factors behind our day-to-day work. Alongside our company head- quarters in Haiger (north of Frankfurt), we have established our own sub- Erlau tire-protection chains provide comprehensive protection in the toughest mining environments.
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Product Data Parameters max. 772 l/min at 370 bar Fluid viscosity: < 2,000 mPas typ. 523 l/min at 350 bar Input power: max. 550 kW typ. 385 l/min at 350 bar Operating pressure: max. 3,500 bar up to 641 l/min without booster pressure
Our pumps are installed in coal mines worldwide !
KAMAT pump stations with an input power of 130 kW – 350 kW per pump have been put into operation in the United States, Australia, China, Turkey, South Africa, Ukraine and Germany. Who´s next ?
=^\]EgZhhjgZEajc\ZgEjbehVcYHnhiZbh KAMAT Pumpen GmbH & Co.KG Salinger Feld 10 Application KAMAT mining pumps for roof supports (emulsion), dust suppression (water) etc. 58454 Witten, Germany Fluid Media Fresh water, demineralised water, emulsions, glycol/methanol, oils etc. Fon + 49 (0) 23 02 / 89 03 - 0 Fax + 49 (0) 23 02 / 80 19 17 Flow Rates From 58 l/min at 3,500 bar up to 2,363 l/min at 120 bar. www.kamat.de The KAMAT pump Compact, robust, easy to maintain, long lasting, low cost of ownership [email protected]
2012 • VDMA MINING SUPPLEMENT 31 VDMA_pg32-35_Drives 11/16/12 11:25 AM Page 32
Drives Technology: Placing Power VDMA Where it’s Needed
Often overlooked, but a critical component of most machines, a drive ing plant on a 1.37 m-wide belt travelling at 6.2 m/s. When the belt system involves converting raw energy into useful work—usually conveyer system has been commissioned in 2012, it will be capable of motion. Mining shovels and draglines need to turn and travel, convey- transporting some 5,260 mt/h of material. ors need to run, mills must rotate, crushers reciprocate. The one thing The Siemens drive system comprises two low-speed synchronous all of these have in common is a drive system, whether or not it uses motors—each with a total power of 3.8 MW—and the associated gears. Sinamics SL150 cycloconverters. In addition, Siemens is supplying the Drive technology is high technology, with tight tolerances needed to motor-cooling system, converter transformers and complete e-house for minimize noise, maximize efficiencies and optimize operating eco- the drive station. The closed-loop control, which is part of the delivery, nomics. Little wonder, then, that German companies are at the forefront improves load sharing between the two motors. here, with the country’s engineering and manufacturing traditions Gearless drives for conveyors can be a good alternative for power combining to produce state-of-the-art drive systems for every conceiv- requirements above 3 MW, Siemens says. The capex is similar to, or can able mining-sector application. be less than that for a conventional geared solution. Furthermore, gear- less conveyor drives offer high availability and robustness, as well as Gearless Conveyor Drives Offer lower operating costs, maintenance costs and noise. Major Benefits... Gearless drive technology is nothing new to the mining business, In many mining areas, ore grades are declining. New mines are being of course, and Siemens points out that mining companies have been developed in more remote areas, pits are getting deeper and under- installing gearless drives for mine hoists, excavators, draglines, pumps ground mines are becoming larger. This means that more and more and mill applications for many years. While the technology is similar, material must be transported over long distances, with materials han- the circumstances differ, however: similarly to mills, conveyors require dling posing new challenges. In order to achieve the increasing vol- a lot of torque during start-up, especially in uphill applications. umes and high demands for availability, conveying systems will need Siemens states that long conveyors with a high throughput and a to make use of the technologies that are made possible by today’s larg- large difference in elevation require a significant amount of power. er drive systems, says Siemens. When this exceeds 3 MW per pulley, gearless drives for the conveyor are For many years, Siemens has worked with ThyssenKrupp the right solution since drive configurations for large conveyors with Fördertechnik to help build some of the most impressive conveyor sys- gearboxes will reach their physical limits. tems in the mining industry, the company adds. One of the greatest There will be a lot of large overland conveyors being built in South success stories is the Los Pelambres downhill conveyor in Chile, the America in the next few years, and since mining companies will be highest-tension conveyor in the world, which transports looking to save energy and increase reliability, there will be big oppor- 10,000 mt/h of copper ore downhill over a distance of 12.7 km. tunities for gearless drive applications there, it adds. Continuing their successful teamwork, the two companies are now delivering a gearless drive system for the overland conveyor at Xstrata ...While Geared Drives Also Have Major Uses Copper’s new Antapaccay mine in Peru. The conveyor system will trans- After an independent history dating back to 1899, the specialist gear port ore over a distance of some 6.5 km from the mine to the process- and drives company Flender became part of the Siemens group in
Gearless drives offer significant advantages in high-capacity conveyor applications, according to Siemens.
32 VDMA MINING SUPPLEMENT • 2012 VDMA_pg32-35_Drives 11/16/12 11:25 AM Page 33
2005. Today, Flender acts as Siemens’ center of excellence for the pro- duction of geared drive technologies, including gearboxes, motors, couplings, starters, converters and controls. Flender’s product range covers helical, bevel-helical and bevel gear units, as well as plane- VDMA tary gear units in both standard and customized industry-specific configurations. Within the Siemens structure, Flender looks after the company’s mechanical drives, as part of the ‘drive technologies’ division of its industry sector. Flender’s product portfolio for gear units encompass- es two main categories: FZG-type standard gear units, and Planurex II standard planetary gear units. Flender produces 28 sizes of its FZG helical and bevel-helical units, with one to four stages and power ratings of up to 4.5 MW. Typical mining-sector applications include drives for belt conveyors, aerators and agitators. Meanwhile, it offers 27 sizes of its planetary gear units, capable of transmitting up to 13 MW and suitable for applications such as drives for bucket-wheels, slewing and travelling gears on rope shovels and draglines, and roller presses. Voith Turbo says its CPC 1600 is the most powerful mining coupling now When it comes to mill drives, Flender offers an alternative to available to AFC OEMs. Siemens’ gearless drives for large grinding mills, as well as supply- ing mechanical drives for vertical mills. individually in the control system. According to Flender, it can offer the right gear unit for every drive At the heart of the new development is the profile of the blade task, and its standard gear units are designed to be suitable for use wheels in the coupling. Voith says its fluid engineers have optimized in nearly all fields of mechanical power-transmission technology. this profile using computational fluid dynamics, such that the blade Most of the tasks can be solved by using gear units from its univer- wheels transmit double the power with the same diameter—1.1 MW sal standard range, the company says, providing a low-cost solution, at 900 rpm, 1.5 MW at 1,000 rpm and 1.9 MW at 1,200 rpm. Power while it can also quickly adapt these for application-specific uses. transmission is wear-free, as with all hydrodynamic couplings, the Customization represents a further step in the process. company points out. Examples of Flender’s drive units in mining applications include When combined with reliable mechanics, hydrodynamic power belt conveyors, where the company’s extensive experience enables it transmission provides extremely high system availability, Voith adds. to design gears, seals, cooling systems and anti-friction bearings, The TurboBelt itself offers availability of up to 99.8%, with very low and to select lubricants that are appropriate for the working environ- maintenance requirements—for example, the first overhaul is due in ment. For apron feeders, which require a lot of torque, Flender offers around 10 to 15 years. The company reports its latest technology has a very compact, high-efficiency shaft-mounted planetary gear unit. Its products for rope shovels and draglines cover customer-specific gear units for the hoist, swing and propel drives, with bucket and crawler drives for bucket-wheel excavators. Recent applications within the mining industry have included the supply of a 600 kW-rated planetary drive for an apron feeder for CNRL at its Horizon oil sands mine in Alberta, Canada, a 2.5 MW-rated bevel-helical drive for an overland conveyor for Southern Copper’s Tia Maria project in Peru, and a planetary gear unit supplied to Tenova Takraf for use as a travelling gear drive on a bucket-wheel excavator in Bulgaria. The company has also supplied planetary gear units to Bucyrus (now Caterpillar) for use as hoist and swing drives on its 495 electric rope shovels, as well as a 7 MW-rated helical gear unit to Polysius for use as a ball-mill drive at a project in Australia.
Fluid Couplings for Conveyors, on Surface and Underground With its headquarters in Crailsheim, Voith Turbo is a division of Voith GmbH. The company has more than 80 years of experience in design- ing fluid couplings, with its start-up components being used on belt and chain conveyors, bucket elevators, mills, crushers and other bulk materials-handling machines. Over 1200 high pressure pumps sold to various Voith Turbo recently introduced a new fluid coupling, the mines all over the world. Our experience of TurboBelt 780 TPXL, for the drives on long-distance open-pit mining more than 70 years, tailor made hydraulics, belt conveyors. The coupling has been specially designed for induc- best in class efficiencies, lowest lifecycle costs tion motors operating at speeds of 900-1,200 rpm, the company says, and constantly secured high quality lead to our and can transmit twice the power that previous couplings of the same competitiveness. size could achieve. The controlled start-up with a precisely-dosed introduction of torque is especially easy on the belt and on the entire www.duechting.com [email protected] drive-line, and start-up times of up to several minutes can be set
2012 • VDMA MINING SUPPLEMENT 33 VDMA_pg32-35_Drives 11/16/12 11:25 AM Page 34
VDMA
ABB supplied retrofit drive technology for this SchRs 1200 bucket-wheel excavator in Bulgaria.
already won over a Brazilian mine operator, which is using TurboBelt et-wheel excavators, stackers, belt conveyors and spreaders, while in couplings on belt conveyors that transport iron ore. the stockyard environment, it not only handles the needs of stackers Voith’s couplings are also widely used underground, with special and reclaimers, but also complete management systems and the applications including the drive units on armored face conveyors in design of centralized control rooms. coal mines. Here, Voith has developed what it says is the world’s most Looking at the company’s recent progress, Mühlbach explained the powerful mining coupling available to OEMs, with a transmission boom in mineral development projects that took place up to 2008 pro- capacity of 1.6 MW—the CPC 1600 (Chain Protection Coupling). vided ABB with a strong order-book that helped it weather the worst of This is a further development of the company’s 1.2MW CPC 1200, the global financial crisis in good shape. What is more, he said, it has of which more than 30 have already been installed in various coal built further on this foundation, such that it now has a much stronger mines over the past year. Designed to work reliably under extreme oper- project pipeline. “We use ABB’s international network to help generate ating conditions, the CPC units are robust and cope with rough sur- business here,” he said. roundings. They are fill-controlled and use water as an eco-friendly, With regard to developments within the mining sector, Mühlbach non-flammable operating fluid. said: “There is obviously a trend toward larger mines, especially in A coupling of this output class offers clear advantages to opera- copper. That is important for us, especially where mines are being tors: compared to a standard coupling of a similar size, the transmis- expanded. sion output of the CPC 1600 is 60% higher. In comparison with the CPC “There is also a trend toward the more widespread use of con- 1200, the increase in performance is around one-third. As a result of veyors, and more dragline projects where these are suitable, so we this improved capacity, up to 12 m-high coal faces can be cut to their expect both more greenfield and retrofit applications for our drive and full height. In short, Voith says, the CPC makes coal extraction even control technologies,” he said. more efficient, as none of the seam remains unexploited. Retrofitting is particularly important for draglines, as the head of The CPC 1600 was officially launched at the China Coal Exhibition ABB’s discontinuous mining business center, Boris Rathmann, point- in October 2011, since when couplings have been supplied to two of the ed out. “P&H, for example, has begun an initiative to go down the leading mining equipment suppliers in China. retrofit route for its existing machines, and this has obvious attrac- tions in terms of time- and cost-saving over buying a new one,” ABB: Drives for OEMs Rathmann said. Headquartered in Cottbus, in the heart of eastern Germany’s lignite ABB recently delivered drives for an in-pit crusher fitted with its mining region, ABB’s main technology center for materials handling mining-drive technology and this, Rathmann said, marks an interest- has an enviable record in export markets, with exports accounting for ing development for the company. “With the world trend toward in-pit around 80% of its business. However, as the center’s head, Peter crushing and conveying, we can now deliver systems that cover the Mühlbach told Best of Germany, much of the company’s business is complete haulage chain. The technology is already well-established in done with OEMs, with ABB’s control and drive technology fitted to the coal industry, and it’s now moving into hard-rock mining as well. equipment supplied by the likes of P&H, Tenova Takraf, ThyssenKrupp “There is also a steady increase in ship-borne trade in commodi- Fördertechnik, FAM, Sandvik and others. ties such as coal and iron ore, and that means more bulk-handling sys- ABB’s mining and minerals business unit operates in 27 countries tems at ports and stockyards,” he said. and includes four product groups, Mühlback said. These include the In another move, in mid-2011 ABB bought the Australia-based materials handling group in Cottbus, while others focus specifically on software company, Mincom with the aim, it said, of establishing itself grinding, mineral processing, underground mining and services. as a market leader in enterprise asset management software and ser- The Cottbus group’s area of expertise is in the electrification and vices. Mincom has mining-sector clients that include 17 of the top 20 automation of open-pit mining, conveying and stockpiling equipment. global players, ABB added, noting that Mincom has a strong presence This includes electric mining shovels, draglines, in-pit crushers, buck- in both Latin America and Asia.
34 VDMA MINING SUPPLEMENT • 2012 VDMA_pg32-35_Drives 11/16/12 11:25 AM Page 35
VDMA VDMA_pg36-43_Matrix 11/16/12 11:27 AM Page 36
GERMAN VENDOR MATRIX VDMAVDMA in open-pits (truck/shovel) Shaft sinking Deep well drilling equipment Roadway driving/Heading Roof support/Shaft & roadways Extraction (longwall) Extraction (vein, room & pillar) & air-conditioning Ventilation Stowing Extraction in open-pits (continuous) Extraction Special equipment for open-pits Dewatering (underground & open-pit) Blasting equipment Conveying & haulage underground Shaft winding equipment Winches & hoists underground vehicles Trackless Preparation plants Crushers & mills Sizing equipment Sorting equipment Dewatering, proportioning, mixing eq. Briquetting & granulation equipment Dedusting, water treatment Dewatering plant Coke oven plant equipment Continuous conveyor & components Feeding & withdrawal equipment Stockpile equipment Consulting Aggregates Control equipment Power supply Communication, navigation Pneumatic & hydraulic tools Compressors Components, spare parts Mine Safety ABB ••• ABEL •• Andritz Ritz •• Apollo •• ATG Solutions ••• Atlas Copco MCT ••• • • ••••• AUMUND ••• AViTEQ •• • • BARTEC ••• BAT •• • • • • •••• •• Bauer Maschinen ••• ••• • • • Becker Mining Systems •••••• •••• BEUMER • BHS-Sonthofen •• • Bochumer E. Heintzmann •• • BRÄUTIGAM ••• Caterpillar Global Mining ••••• •• •• • • • ••••• • CFT •• •• CMP •• CompAir • •• Cyrus ••• DAT •• •• • •• dh mining systems •••• DEUTZ ••• • •••••• DMT ••• Döpke •• •• Dräger Safety •• DÜCHTING • Durum • EEP •• Eickhoff ••• • • Eirich •• • • FAM •••• ••• •••• FLSmidth Wiesbaden •• FLSmidth Wadgassen •• • • •• ••• GEA Westfalia Separator • Getriebebau Nord •• GHH •• • • GOTHE • Habermann • Hammelmann •• • Hauhinco •• HAVER & BOECKER •• • • •• ••••• • HAWE Hydraulik •• ••• • •• Hazemag & EPR ••• • • • • ••• •• •• H+E Logistik •• HEINRICH DE FRIES •• • Herrenknecht •••• • • • •••••• • Hese •• ••• Hilti •• Howden • HYDAC •••••• ••• IAG •• •
36 VDMA MINING SUPPLEMENT • 2012 VDMA_pg36-43_Matrix 11/16/12 11:27 AM Page 37
GERMAN VENDOR MATRIX VDMA in open-pits (truck/shovel) Shaft sinking Deep well drilling equipment Roadway driving/Heading Roof support/Shaft & roadways Extraction (longwall) Extraction (vein, room & pillar) & air-conditioning Ventilation Stowing Extraction in open-pits (continuous) Extraction Special equipment for open-pits Dewatering (underground & open-pit) Blasting equipment Conveying & haulage underground Shaft winding equipment Winches & hoists underground vehicles Trackless Preparation plants Crushers & mills Sizing equipment Sorting equipment Dewatering, proportioning , mixing eq. Briquetting & granulation equipment Dedusting, water treatment Dewatering plant Coke oven plant equipment Continuous conveyor & components Feeding & withdrawal equipment Stockpile equipment Consulting Aggregates Control equipment Power supply Communication, navigation Pneumatic & hydraulic tools Compressors Components, spare parts Mine Safety JÖST ••• •• • KAMAT •• • • Komatsu • KÖPPERN •• Krummenauer ••• Liebherr • Loesche ••• •• LST GmbH •• •••• •• MARCO •• • •• • MATO • MBE Coal & Minerals ••••• • • MTU • J.D. Neuhaus •• •• • Nilos •••• ••••••••• NORDMEYER • oddesse Pumpen • Outotec •• • Paus •• • • • •• • PFISTER WAAGEN •• PFREUNDT ••• PRAKLA •• •• Pumpentechnik Erkrath • Putzmeister •• • • • Rensmann ••••• RWE Power • Sandvik Crushing Tech. ••• Sandvik Central Europe •••••• •••• • ••• •••••• SCHADE •• •• • Schalker •• Schopf •• Schulte Strathaus • SIEMAG Tecberg •• •• Siemens •• • • •• • • •• • STEINERT • Stromag • TAIMWESER ••• TAKRAF ••• • •••• THIELE •• ••• Thomas Magnete • ThyssenKrupp, Essen •• • • ThyssenKrupp, Enningerloh ••••• • ThyssenKrupp, St. Ingbert ••• • ThyssenKrupp, Uhde • TLT-Turbo • TML Technik ••• • • URACA •• • Vattenfall Europe Mining • Voith Turbo •• •• • • • Wagner •• WELLER • WILO SE •• Wirtgen ••
2012 • VDMA MINING SUPPLEMENT 37 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 38
45141 Essen Web: www.atlascopco.com
VDMAVDMA ABB Automation GmbH BEUMER Maschinenfabrik Geschäftsbereich Open Pit Mining GmbH & Co. KG Gaglower Str. 17–18 Oelder Str. 40 03048 Cottbus AUMUND-Fördererbau GmbH 59269 Beckum Web: www.abb.com/mining Saalhoffer Str. 17 Web: www.beumer.com 47495 Rheinberg Web: www.aumund.com
ABEL GmbH & Co. KG BHS-Sonthofen GmbH Abel-Twiete 1 AViTEQ Vibrationstechnik GmbH An der Eisenschmelze 47 21514 Büchen Im Gotthelf 16 87527 Sonthofen Web: www.abel.de 65795 Hattersheim Web: www.bhs-sonthofen.de Web: www.aviteq.de
ANDRITZ Ritz GmbH Güglingstr. 50 BARTEC Sicherheits- und BOCHUMER EISENHÜTTE 73529 Schwäbisch Gmünd Schaltanlagen GmbH HEINTZMANN GMBH & CO.KG Web: www.andritz.com Holzener Str. 35–37 Klosterstr. 46 58708 Menden 44787 Bochum Web: www.bartec-mining.com Web: www.be-heico.de Apollo Maschinenbau GmbH Grünauer Fenn 44 14712 Rathenow Web: www.apollo-maschinenbau.de BAT Bohr- und Anlagentechnik BRÄUTIGAM Gear & Mining Tech GmbH GmbH & Co. KG Borntalstr. 11 Am Schürmannshütt 8–18 Arthur Habermann GmbH & Co. KG 36460 Merkers 47441 Moers Goethestr. 12 Web: www.bat-maschinenbau.de Web: www.braeutigam-group.com 58453 Witten Web: www.habermann-gmbh.de
Caterpillar Global Mining Bauer Maschinen GmbH Bucyrus Europe GmbH BAUER-Str. 1 Industriestr. 1 86529 Schrobenhausen 44534 Lünen ATG Solutions GmbH Web: www.bauer.de Web: www.mining.cat.com Schäferstr. 5 99837 Berka Web: www.atgsolutions.de Becker Mining Systems AG Barbarastr. 3 Caterpillar Global Mining 66299 Friedrichsthal Bucyrus HEX GmbH Web: www.becker-mining.com Karl-Funke-Str. 36 Atlas Copco MCT GmbH D 44149 Dortmund Langemarckstr. 35 Web: www.mining.cat.com
38 VDMA MINING SUPPLEMENT • 2012 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 39
dh mining systems GmbH CFT GmbH Haustenbecke 1 VDMA El.-Ap. GOTHE & CO. GmbH Compact Filter Technic 44319 Dortmund Kruppstr. 196 Beisenstr. 39–41 Web: www.dhms.com 45472 Mülheim 45964 Gladbeck Web: www.gothe.de Web: www.cft-gmbh.de
DMT GmbH & Co. KG Am Technologiepark 1 F. E. Schulte Strathaus 45307 Essen GmbH & Co. KG Fördertechnik – CMP AG Web: www.dmt.de Dichtungssysteme Cement and Mining Processing AG Runtestr. 42 Alte Landebahn 15 59457 Werl 06846 Dessau-Rosslau Web: www.schulte-strathaus.de Web: www.cmpag.com Dräger Safety AG & Co. KGaA Revalstr. 1 23560 Lübeck Web: www.draeger.com FAM Förderanlagen Magdeburg CompAir Drucklufttechnik GmbH und Baumaschinen GmbH Zweigniederlassung der Gardner Sudenburger Wuhne 47 Denver Deutschland GmbH 39112 Magdeburg Argenthaler Str. 11 DÜCHTING PUMPEN Web: www.fam.de 55469 Simmern Maschinenfabrik GmbH & Co. KG Web: www.compair.de Wilhelm-Düchting-Str. 22 58453 Witten Web: www.duechting.com FLSmidth Wadgassen GmbH Karl-Koch-Str. 1 Cyrus GmbH Schwingtechnik 66787 Wadgassen Am Stadion 40 Web: www.flsmidth.com 45659 Recklinghausen DURUM Verschleiss-Schutz GmbH Web: www.cyrus-germany.com Linsellesstr. 125 47877 Willich Web: www.durmat.com
DAT Bergbautechnik GmbH FLSmidth Wiesbaden GmbH Am Schornacker 61 Am Klingenweg 4a 46485 Wesel 65396 Walluf Web: www.dat-bergbau.de EEP Elektro Elektronik Pranjic Web: www.flsmidth.com Am Luftschacht 21 45886 Gelsenkirchen Web: www.eep.de
Fritz Rensmann GmbH & Co. DEUTZ AG Maschinenfabrik Ottostr. 1 Eickhoff Bergbautechnik GmbH Bünnerhelfstr. 33 51149 Köln Hunscheidtstr. 176 44379 Dortmund Web: www.deutz.de 44789 Bochum Web: www.rensmann.com Web: www.eickhoff-bochum.de
2012 • VDMA MINING SUPPLEMENT 39 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 40
GEA Westfalia Separator Group HAWE Hydraulik SE HYDAC International GmbH VDMAVDMA Werner-Habig-Str. 1 Streitfeldstr. 25 Industriegebiet 59302 Oelde 81673 München 66280 Sulzbach Web: www.westfalia-separator.com Web: www.hawe.de Web: www.hydac.com
Getriebebau Nord GmbH & Co. KG Hazemag & EPR GmbH Rudolf-Diesel-Str. 1 Brokweg 75 IAG MAGNUM GmbH 22941 Bargteheide 48249 Dülmen Bessemerstr. 1 Web: www.nord.com Web: www.hazemag.de 49084 Osnabrück Web: www.iag-magnum.de
GHH Fahrzeuge GmbH HEINRICH DE FRIES GmbH Emscherstr. 53 Hebezeugfabrik 45891 Gelsenkirchen Gauss Str. 20 Web: www.ghh-fahrzeuge.de 40235 Düsseldorf J. D. NEUHAUS GmbH & Co. KG Web: www.hadef.de Windenstr. 2–4 58455 Witten Web: www.jdn.de H+E Logistik GmbH Josef-Baumann-Str. 18 Hermann Paus 44805 Bochum Maschinenfabrik GmbH Web: www.helogistik.de Siemensstr. 1–9 48488 Emsbüren JÖST GmbH + Co. KG Web: www.paus.de Gewerbestr. 28–32 48249 Dülmen Hammelmann Maschinenfabrik Web: www.joest.com GmbH Zum Sundern 13–21 59302 Oelde Herrenknecht AG Web: www.hammelmann.de Schlehenweg 2 77963 Schwanau KAMAT-PUMPEN GmbH & Co. KG Web: www.herrenknecht.de Salinger Feld 10 58454 Witten Hauhinco Maschinenfabrik Web: www.kamat.de G. Hausherr, Jochums GmbH & Co. KG Beisenbruchstr. 10 Hilti Deutschland AG 45549 Sprockhöve Hiltistr. 2 Web: www.hauhinco.com 86916 Kaufering Web: www.hilti.com Komatsu Mining Germany GmbH Buscherhofstr. 10 40599 Düsseldorf Web: www.komatsu-mining.de HAVER & BOECKER OHG Howden Ventilatoren GmbH Drahtweberei und Maschinenfabrik Stubentalstr. 44 Carl-Haver-Platz 3 89518 Heidenheim 59302 Oelde Web: www.howden.com Web: www.haverboecker.com
40 VDMA MINING SUPPLEMENT • 2012 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 41
Krummenauer GmbH & Co. KG LST GmbH Wellesweilerstr. 95 Maschinenfabrik Heinrich Gewerbestr. 17a VDMA 66538 Neunkirchen Döpke GmbH 82211 Herrsching Web: www.krummenauer.de Stellmacherstr. 10 Web: www.lst-group.com 26506 Norden Web: www.doepke-gmbh.de
Liebherr-Mining Equipment SAS 49 rue Frédéric Hartmann 68025 Colmar, Cedex marco Systemanalyse und Entwicklung GmbH Web: www.liebherr.com Maschinenfabrik Hese GmbH Hans-Böckler-Str. 2 Magdeburger Str. 16a 85221 Dachau 45881 Gelsenkirchen Web: www.marco.de Web: www.hese.de
LOESCHE GmbH Hansaallee 243 Maschinenfabrik Gustav 40549 Düsseldorf Maschinenfabrik KÖPPERN Eirich GmbH & Co. KG Web: www.loesche.com GmbH & Co. KG Walldürner Str. 50 Königsteiner Str. 2 74736 Hardheim 45529 Hattingen Web: www.eirich.com Web: www.koeppern.de
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Mining The gathering for the entire mining industry
More than 600 mining exhibitors from around the world
Approximately 100,000 trade visitors
Enjoy the benefi ts – Go online and register directly: www.bauma.de/tickets/en
2012 • VDMA MINING SUPPLEMENT 41 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 42
VDMAVDMA Maschinenfabrik Wagner oddesse Pumpen- und RWE Power International RE GmbH GmbH & Co. KG Motorenfabrik GmbH Stüttgenweg 2 Birrenbachshöhe Am Pappelwald 12 50935 Köln 53804 Much 39387 Oschersleben Web: www.rwepi.com Web: www.plarad.de Web: www.oddesse.de
Sandvik Mining and Construction Outotec (Filters) GmbH Crushing Technology GmbH MATO Maschinen- u. Eschweilerstr. 101–109 Kölner Str. 94 Metallwarenfabrik Curt Matthaei 52477 Alsdorf 51702 Bergneustadt GmbH & Co. KG Web: www.outotec.com Web: www.sandvik.com Benzstr. 16–24 63165 Mühlheim Web: www.mato.de PFISTER WAAGEN BILANCIAI GMBH Sandvik Mining & Construction Linker Kreuthweg 9 Europe GmbH 86444 Affing Hafenstr. 280 MBE Coal & Minerals Web: www.pfisterwaagen.de 45356 Essen Technology GmbH Web: www.sandvik.com Gottfried-Hagen-Str. 20 51105 Köln Web: www.mbe-cmt.com PFREUNDT GmbH Robert-Bosch-Str. 5 SCHADE Lagertechnik GmbH 46354 Südlohn Dorstener Str. 360 Web: www.pfreundt.de 44653 Herne Web: www.schade-lagertechnik.de MTU Friedrichshafen GmbH Maybachplatz 1 88045 Friedrichshafen PRAKLA Bohrtechnik GmbH Schalker Eisenhütte Web: www.mtu-online.com Moorbeerenweg 3 Maschinenfabrik GmbH 31228 Peine Magdeburger Str. 37 Web: www.prakla.de 45881 Gelsenkirchen Web: www.schalke.eu Nilos GmbH & Co. KG Reisholzstr. 15 40721 Hilden Pumpentechnik Erkrath Web: www.nilos.de GmbH + Co. KG Schopf Maschinenbau GmbH Max-Planck-Str. 28 Parkstr. 19–21 40699 Erkrath 73760 Ostfildern Web: www.pumpentechnik-erkrath.de Web: www.schopf-mining.com NORDMEYER GmbH & Co. KG Werner-Nordmeyer-Str. 3 31226 Peine Web: www.nordmeyer.com Putzmeister Solid Pumps GmbH SIEMAG TECBERG GmbH Max-Eyth.Str. 10 Kalteiche-Ring 28–32 72631 Aichtal 35708 Haiger Web: www.pmsolid.com Web: www.siemag-tecberg.com
42 VDMA MINING SUPPLEMENT • 2012 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 43
Siemens AG Werner-von-Siemens-Str. 43 TAIMWESER GmbH Thomas Magnete GmbH VDMA 91052 Erlangen Königstr. 45 San Fernando 35 Web: www.siemens.com/mining 32547 Bad Oeynhausen 57562 Herdorf Web: www.taimweser.com Web: www.thomas.magnete.com
STEINERT Elektromagnetbau GmbH Widdersdorfer Str. 329–331 TAKRAF GmbH 50933 Köln Torgauer Str. 336 ThyssenKrupp Fördertechnik Web: www.steinert.de 04347 Leipzig GmbH Web: www.takraf.com Business Unit Materials Handling Ernst-Heckel-Str. 1 66386 St Ingbert Stromag AG Web: www.tk-materialshandling.com Hansastr. 120 59425 Unna THIELE GmbH + Co. KG Web: www.stromag.com Werkstr. 3 58640 Iserlohn Web: www.thiele.de
Ore-, minerals- and coal beneficiation are our key markets since business decades. Processes with BATAC® and ROMJIG® jigging separators, magnetic separators like JONES® WHIMS and PERMOS® MIMS, flotation system PNEUFLOT® and PALLA® vibrating mill are widely used and worldwide well proven beneficiation technologies. It is daily quality control. Our team is looking forward to provide you with the best possible solutions and state of the art technology.
MBE COAL & MINERALS TECHNOLOGY GMBH www.mbe-cmt.de
2012 • VDMA MINING SUPPLEMENT 43 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 44
ThyssenKrupp Fördertechnik GmbH Aufbereitungstechnik Schleebergstr. 12 Vattenfall Europe Mining AG VDMA 59320 Ennigerloh Mining Consulting WILO SE Web: www.tk-processing.com Vom-Stein-Str. 39 Nortkirchenstr. 100 03050 Cottbus 44263 Dortmund Web: www.vattenfall.de Web: www.wib.com
ThyssenKrupp Fördertechnik GmbH ThyssenKrupp Allee 1 45143 Essen Voith Turbo GmbH & Co. KG Wirtgen GmbH Maschinenbau Web: www.tk-mining.com Voith-Str. 1 Reinhard-Wirtgen-Str. 2 74564 Crailsheim 53578 Windhagen Web: www.voithturbo.com Web: www.wirtgen.de
ThyssenKrupp Uhde GmbH Friedrich-Uhde-Str. 15 44141 Dortmund WELLER Pumpen GmbH Web: www.uhde.eu Westicker Str. 44–46 59174 Kamen Web: www.weller-pumpen.de
TLT-Turbo GmbH Gleiwitzstr. 7 66482 Zweibrücken Web: www.tlt.de
ADVERTISING INDEX TML Technik GmbH Beumer ...... VDMA 17 Daimlerstr. 14–16 Caterpillar...... IBC 40789 Monheim Coal Prep 2013...... VDMA 35 Web: www.tml-technik.com Derrick Corp ...... 7 Dräger...... VDMA 25 Duchting Pumpen...... VDMA 33 Erlau AG ...... VDMA 23 Gustav Eirich ...... VDMA 29 Hedweld ...... 5 Joy Global...... BC URACA PUMPENFABRIK Kamat Pumpen...... VDMA 31 GmbH + Co. KG Komatsu Mining Germany GmbH ...... VDMA 21 L-3 Communications ...... 8 Sirchinger Str. 15 Liebherr International GmbH ...... 3, VDMA 14 72574 Bad Urach MBE Coal & Minerals Technology ...... VDMA 43 Web: www.uraca.de Messe Muenchen GmbH Bauma 2013 ...... VDMA 41 US Tsubaki ...... 9 Weir Slurry Group...... IFC
44 VDMA MINING SUPPLEMENT • 2012 VDMA_pg36-43_Matrix 11/16/12 11:28 AM Page 45 46-48 CAIndia_Products_India_pg02-03 11/16/12 3:03 PM Page 46
Product News
Volvo CE Fleet Goes the Distance in India
An Indian mining and logistics company is Volvo wheel loaders,” said Operations projects and a committed effort to expand running three long-lasting Volvo Construction Manager Satish Kadian. “Because of their our capabilities to meet the demands of cus- Equipment (Volvo CE) wheel loaders that, longevity and reliability, we want to pur- tomers in the Indian marketplace,” said Dale combined, have logged an incredible chase more of these machines as we grad- Guidry, president and CEO, TMEIC 150,000 hours on the job. Sainik Mining ually retire the older ones. We’re working Corporation in North America. “This new and Allied Services, one of the largest con- with Volvo CE to have them buy back some location in Mumbai further solidifies that tract mining and logistics companies in north- of our older wheel loaders so that we can commitment and we look forward to the eastern India, is also a big Volvo CE cus- make room for new equipment.” opportunities that this growth will bring.” tomer, with more than 30 of Volvo’s heavy- Buying back older equipment helps reuse Under the management of Hemant Joshi, weight EC460 excavators and 11 wheel and recycle parts that are still in good condi- managing director of TMEIC Industrial loaders of various models working in the tion—enforcing Volvo CE’s core values and Systems India Pvt. Ltd., the office in Mumbai region. Many of these machines are on the its dedication to environmental care. It also will support sales and service for automation job 16 hours a day, seven days a week, in helps the customer generate more cash-flow systems for metals and material handling. Gevra—Asia’s largest open cast mine, locat- to invest in new machinery. But for now, the ed near Korba in the central Indian state of three veteran wheel loaders are still going Chhattisgarh—as well as on other projects. strong, and Satish said Sainik will continue Open since 1981, the busy Gevra mine using them in the mines as long as they’re Longwall Mining has, at one time, produced as much as equal to the task. Which at the rate they’re Equipment 100,000 tons of coal in a single day. going, could be a very long time. FAMUR presented a wide range of machines Sainik’s machines work 16 hours a day and equipment for the mining industry in seven days a week loading the coal into rail- India. During January 2012, the company way cars. Sainik’s fleet includes three Volvo TMEIC Opens took part in the International Mining, wheel loaders that have each clocked more Exploration, Mineral Processing Technology than 50,000 hours. The latest machine to New Sales Office & Machinery Exhibition, where it introduced cross 51,000 hours is an L120E that was innovative machinery for the demanding purchased in 2004, while another—an in Mumbai geo-mining conditions of Asia. To expand in L120D—has put in 54,000 hours. Those are Toshiba Mitsubishi-Electric Industrial Systems that market, the Group has set up FAMUR big milestones, particularly for the wheel Corporation (TMEIC) of Tokyo, Japan, has India Mining Solutions. loaders at work in the brutal tropical condi- opened a sales and service office in “India is the world’s third largest produc- tions of Chhattisgarh, where temperatures Mumbai, India, to further support customers er of coal and the fourth largest country in can sometimes reach a sweltering 48°C. in the region. The office is part of TMEIC terms of raw material resources. Coal is For its wheel loaders, Sainik holds ‘blue’ Industrial Systems India Pvt. Ltd. Co. in mined in about 600 mines and there are still customer service agreements with the deal- Hyderabad, a subsidiary of TMEIC that was some areas where the mineral resources er SVP Mining and Technology, and thus established in 2010. have not been evaluated. In addition, for sev- far, the wheel loaders have only had to “Since TMEIC first opened the Hyderabad eral years there is a visible trend of modern- have routine maintenance and overhauls branch in 2007, our presence has steadily ization of machinery and mining equipment. conducted. “We are very happy with our grown through the acquisition of significant Participation in the prestigious Fair Mining Expo 2012 was an excellent opportunity for direct presentation of FAMUR new products and to provide expert technical and user information to our potential customers,” said Ireneusz Tomecki, vice president, FAMUR SA. In view of the apparent interest of Indian contractors in machinery for mining and solu- tions offered by FAMUR, the company creat- ed FAMUR India Mining Solutions, based in India. Its establishment aims to step up FAMUR in that market, including increasing the frequency of participation in the mining exhibitions that provide direct contact with potential customers. FAMUR India Mining Solutions is managed by Julian Ryszkowski. At this year’s IME2, FAMUR presented innovative technological solutions providing not only an increase in coal extraction process efficiency and reduce the probability of failure, but also increasing the safety of miners. Visitors were able to see FAMUR’s mechanized longwall systems designed to work in difficult geological and mining con- ditions that allow the execution of even the This wheel loader isn’t ready for retirement.
46 COAL AGE INDIA 2012 46-48 CAIndia_Products_India_pg02-03 11/16/12 3:03 PM Page 47
Product News
As well as supplying equipment to the project, Trolex will provide methane moni- toring advice to ensure everything runs smoothly. Until now, most methane recovery moni- toring systems have been inaccurate due to the presence of other gases and compounds in the gas mixture which can fool conven- tional sensors into errors of up to 30% and sometimes even more. These kinds of errors can endanger lives, damage valuable equip- ment and machinery, which can lead to prob- lems with regulatory authorities. Sentrum uses proven technology to deliver bespoke, high accuracy solutions to suit specific requirements. Trolex is the only company in the world to manufacture and support a methane recov- ery monitoring system that functions across all industries, for all applications, putting them at the forefront of the Clean Coal mining is a major Development Mechanism, gas-to-energy and industry in China and safety monitoring movements. India, yet coal mine methane drainage is employed with relatively low yields of gas and puri- ty. Two gassy coal mines in China and a coal mine with recent coal mine methane experience in a coalfield in India have been selected as pilot sites for the project. The project is jointly car- ried out with the Royal School of Mines at most complicated orders for customers Imperial College, London. The aim of the proj- around the world. ect is to achieve significant improvements in Trolex’s Sentrum system has been specified for an EU-funded Additionally, FAMUR presented a wide methane drainage efficiency and purity to methane extraction project focusing on accelerating the devel- range of modern shearers and roadheaders demonstrate European know-how and devel- opment of energy technologies toward cost-effectiveness for a in different versions and with different equip- op the necessary technologies to achieve this more sustainable energy economy for Europe. ment, capable of mining mainly the galleries objective. and tunnels. Specialized versions of Sentrum systems use state-of-the-art soft- machines allow to cut rocks in quarries, old ware to deliver the most accurate and reli- concrete foundations, quartz sands, parched able methane recovery monitoring on the and burnt mine waste on the mines’ tailings market today. Methane is now a valuable piles. Fair participants were able to familiar- commodity. It is also an extremely potent and ize with FAMUR offer concerning a compre- dangerous greenhouse gas yet its capture hensive designing, construction and installa- and usage can have enormous environmen- tion works within the scope of construction of tal, economic and social benefits. the shaft towers, coal preparation plants and Trolex will also provide a mine upcast process lines. ventilation shaft airflow and methane con- centration monitoring system to assist with a ventilation air methane usage system research and feasibility assessment. A data communication system will also be installed Trolex Selected to log and transmit the data continuously to for Methane the UK for analysis. Funded under the 7th Framework Extraction Project Program, it aims to enhance the dynamism, Trolex’s Sentrum system has been specified for creativity and excellence of European an EU-funded methane extraction project focus- research at the frontier of knowledge in all ing on accelerating the development of energy scientific and technological fields, including Trolex’s Sentrum system uses state-of-the-art software to technologies toward cost-effectiveness for a engineering, socio-economic sciences and deliver the most accurate and reliable methane recovery more sustainable energy economy for Europe. the humanities. monitoring on the market today.
COAL AGE INDIA 2012 47 46-48 CAIndia_Products_India_pg02-03 11/16/12 3:03 PM Page 48
Product News
Mobile Wash Plant
A new mobile iron ore washing plant for new iron ore washing plant is located in introduced to downstream processes very Bhushan Power & Steel is delivering a sub- Sambalpur in the state of Orissa. In addition to soon after it has been washed. stantial increase in iron (Fe) through the effec- the M2500 mobile washing plant, there is an Following processing of the -5 mm iron tive removal of alumina and silica from the Aquacycle A600 thickener that allows for the ore fines through the dual pass washing sys- feed material. recycling of 90% of the water used as well as tem the waste water containing the -75 Introduction of the M2500 washing plant significantly reducing the space required for micron (200 mesh) material is the delivered from CDE Asia to the Bhushan Power & Steel settling ponds. to the adjacent Aquacycle thickener to allow facility in Orissa, India, has resulted in an The processing capacity of the plant in this for recycling of wash water to the M2500. increase in Fe from 58.24% to 63.2%, which instance is 200 tph of minus 40 mm material This serves a dual purpose in that it reduces delivers significant efficiency savings in down- and the washed products are -5 mm washed the volume of fresh water required to feed the stream processes. The increase in Fe has been fines in addition to 5-16 mm and +16 mm washing plant while also reducing the space achieved as a result of a 37% reduction in alu- washed ore. The washed ore is subsequently required to accommodate on site settling mina from 4.3% to 2.7% and a 32% reduction used as input to the blast furnace. ponds. in silica from 6.6% to 4.5%. It is the compact, modular nature of the Once the waste material is delivered to “The reduction in alumina and silica levels M2500 that made it appealing to Bhushan the Aquacycle thickener it is dosed with floc- and the resulting increase in Fe will lead to a Power & Steel as it integrates a feed system, culant in the deaeration chamber. This floc- reduction in coal consumption of around 5% screening, fines washing and stockpiling onto culant has been prepared in the FlocStation during the various steel production processes a single chassis. The minus 40 mm material is polyelectrolyte dosing plant that is housed in which represents a very significant efficiency first delivered to the integrated feed hopper an insulated 6 m cabin located beside the gain for Bhushan Power & Steel,” said Dr. before being sent to the Prograde screening Aquacycle. This flocculant assists the sludge Arabinda Bandyopadhay, CDE Asia. phase by a 14 m feed conveyor. settlement process by forcing the fine parti- This project represents the completion of a A washbox is located at the head of the cles to bind together and sink to the bottom major product development initiative by CDE feed conveyor to add sufficient water to the of the tank where the CDE QuadRake mech- to produce a mobile washing plant suitable for material to ensure efficient screening. anism ensures the sludge density is optimized application in the iron ore processing sector. Following this the material is discharged to the for discharge via the integrated slurry pump. “Following the initial success of the M2500 in double deck rinsing screen and the washed Meanwhile the recycled water overflows a sand and aggregate washing applications, +16 mm ore and 5-16 mm ore are subse- weir at the top of the Aquacycle thickener we embarked on a project to develop the quently stockpiled via the two integrated 9 m and is re-circulated around the washing M2500 to cope with the specific challenges of wing conveyors offering a stockpile capacity plant. iron ore processing,” said Manish Bhartia, of 150 m3. Given the success of the M2500 on this managing director, CDE Asia. The minus 5 mm material is sent from the project in terms of the delivery of a five per- “The success of the M2500 on this iron ore screen sump to the integrated fines washing centage point improvement in Fe as a result of washing project is evidence that the major plant and is initially delivered to the cus- the successful reduction in both alumina and product developments we have introduced tomized hydrocyclone set up. The cluster of silica, it is expected that there will be further over the last 12 months will lead to further hydrocyclones specified on this project have iron ore washing projects for CDE in the com- opportunities in iron ore applications not only been lined with XTril high wear resistance lin- ing months. in India but throughout the world,” said ers designed to cope with the harsh operating “The new washing plant has performed to Dermot Murphy, strategic projects manager, conditions of iron ore processing. The washed our total satisfaction and we will be opting for CDE Global. minus 5 mm fines are then stockpiled via the same configuration when opportunities The M2500 has now been applied suc- another integrated 9 m stockpile conveyor to arise at our other processing facilities,” said R cessfully on a wide variety of projects. The 12% moisture content that ensures it can be N Pattajoshi, director, Bhushan Power & Steel.
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