Mining Equipment BEST OF GERMANY and Technology 2018

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

In cooperation with VDMA

Mining TAKRAF Dry Stack Tailings

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TAKRAF GmbH Torgauer Straße 336 04347 Leipzig, Germany Tenova, a Techint Group company, is a worldwide partner for [email protected] innovative, reliable and sustainable solutions in the mining and www.takraf.com metals industries. www.tenova.com Foreword:

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

Glückauf!

Dr. Michael Schulte Strathaus President VDMA Mining

Table of Contents:

A Special Supplement to: Your Contacts in the Mining Equipment Association ...... 2 Engineering & Mining Journal (E&MJ) and Coal Age VDMA Mining Prepares for the Future ...... 4 Produced by: Mining Media International Inc. Looking to the Future Continuously ...... 6 11655 Central Parkway, Suite 306 Jacksonville, FL, 32224, USA Tel: +1-904-721-2925 Smart Underground Mining ...... 12 Fax: +1-904-721-2930 www.mining-media.com Technology Improves Open-pit Mining ...... 18 Copyright 2018 Mining Media Int’l, Inc.

Sponsor: Moving More Material More Effectively ...... 26 German Engineering Federation Verband Deutscher Maschinen und Intelligent Processing...... 30 Anlagenbau (VDMA) e.V. Lyoner Str. 18, D-60528 Frankfurt/Main Equipment and Technology...... 32 Tel: +49-6966-031262 Fax: +49-6966-032262 www.vdma.org Vendor Matrix and Buyers Guide ...... 38

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

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

2018 • VDMA MINING SUPPLEMENT VDMA 1 Your Contacts in the Mining Equipment Association

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

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

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

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

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

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

VDMA 2 VDMA MINING SUPPLEMENT • 2018 — Let’s write the future. With gearless conveyor drives for medium power conveyors

Up to now, gearless conveyor drives were only economic for high powered overland conveyors (3 to 7 MW per motor). ABB has now developed a solution which makes the advantages of the gearless technology also feasible for a broader range of conveyor systems in the medium power segment (0.6 to 3 MW per motor).

The new gearless conveyor drive (GCD) with a permanent magnet (PM) motor reduces failure rates by 50% and improves energy efficiency. Different mounting variants enable application-optimized use for both, new or retrofitted conveyor drives. For more information, please visit us at www.abb.com/mining VDMA Mining Prepares for the Future Smart mining concepts lead the way toward safer, more-efficient operations

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

VDMA 4 VDMA MINING SUPPLEMENT • 2018 According to Schulte Strathaus, the decrease in domestic busi- ness to EUR 110 million is a byproduct of the general uncertainty in the German raw material sector, which includes the closing of the last two hard coal mines. Brown coal (lignite) mines are also facing an uncertain future. Policymakers are demanding a quick withdrawal from coal-based electricity and that places a burden on the power generation sector. “Germany energy policy is fragmented, unpredictable and, from an energy-economy perspective, not always comprehensible,” Schulte Strathaus said. “Although there is no ready substitute at hand, the energy supply safeguarded by brown coal is being undermined.” German experts have long warned about the incalculable risks for network stability and power supply, so the sector hopes to maintain its domestic turnover in 2018 and 2019. For the medium and long term, however, the overall downward trend for mining in Germany is expected to continue. European countries account for much of the VDMA Mining ex- ports. In 2017, approximately 28% of exports went to European countries, which is 7% more than the year before. In particular, conveyor technology, safety systems and accessories were popular exports. Tunneling is also an important mining-related industry for Europe. Tunneling turnover is expected to remain the same or even grow in 2018. The mines throughout the Americas are investing in operations again. The U.S. alone accounted for about 15% of VDMA Mining exports in 2017. This represented an increase of 5% compared to the previous year. Mining technology carrying the “made in Germany” label remains SOME THINK popular in the Near East and the Far East as well. Both regions are now focusing on creating large high-performance mining installa- LONG-DISTANCE tions, while closing small, unsafe and inefficient mines. This higher level of mechanization requires new equipment and better technology. TRANSPORT IS Smart Mining INFRASTRUCTURE- When asked, most people would likely associate the digital revolu- tion for industry with aerospace or manufacturing, not necessarily INTENSIVE. with underground mining. Surprisingly, this edition of Best of Ger- man reveals that underground mining is one of the hot bed areas WE THINK that could benefit most from it, and several groups are making that a reality, especially when it comes to longwall mining. DIFFERENT. Many surface and underground mining systems already had some level of autonomy. The next stage under development involves communication and cross-linking of machines and systems with Transporting materials from remote locations has each other throughout the entire operation. Mining in a connect- traditionally required signifi cant infrastructure invest- ed environment means using new technologies for connecting and ments in road or rail links, vehicles, personnel and fuel. communicating with sensors, machines, systems and people. BEUMER off ers an economical, effi cient and environmental Autonomy and digitalization may be the two terms that are alternative – long-distance overland conveying. This gives used to describe the future of mining. Digitalization tools can be you a dedicated, around-the-clock transport link at the integrated into all aspects of mining, from exploration to engineer- fraction of the cost of infrastructure development. The ing and design simulation to advanced process controls. The min- reduced noise and air pollution minimises environmental ing industry will see a paradigm shift as strategic and real-time impact and improves personnel safety. Add to that a high planning and scheduling are aligned, while remote mining oper- degree of design fl exi bility and customisation and you can ations are controlled by decision-support systems based on key see why overland conveying makes a big diff erence to performance indicators. operational effi ciency and environmental protection. Use of these techniques means that operators can step away For more information, visit www.beumergroup.com from active control tasks in a hazardous environment and concen- trate on monitoring and control functions from the safety and com- fort of a control room. All of this should lower the mine’s cost per ton and give the mining company the flexibility to respond to changes in geology as well as demand. The proud members of VDMA are ready to assist mine operators as they develop and install these “smart” mining systems.

2018 • VDMA MINING SUPPLEMENT VDMA 5 Looking to the Future Continuously From fostering fairness to exporting German craftsmanship, VDMA Mining and its members celebrate 125 years of achievement

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

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

VDMA 6 VDMA MINING SUPPLEMENT • 2018 wall business in the USA. Today, they have mining and industrial partners around the world. The Hauhinco production facilities in Sprockhövel look much different today than they did 110 years ago. At peak times, 300 em- ployees were building Pickaxes and rock drills to support not only the local miners extracting coal in the Ruhr Valley, but also to mines in neighboring countries. Today, the company’s engineers and factory workers have the same level of commitment to quality manufactur- ing, but they have more sophisticated tools and they supply equip- ment and solutions worldwide. The German coal mines may be closing, Hoffmann explained, but the suppliers in Germany are still developing leading mining The Eickhoff shearer loader remains a vital, progressive aspect of longwall mining. technology. Following the mining industry’s needs, Hauhinco has evolved from a component supplier to an engineering company over maintained their commitment to the mining business, retaining the last 110 years. specialists at a time when others were downsizing. Eickhoff manufactures machinery and gearing technology de- Of Cranes and Mining Equipment signed to withstand extreme conditions. Those offerings range from Hans Liebherr founded his company in 1949, Hans Liebherr equipment used in deep underground mines to wind turbines 100 Maschinenfabrik (engineering works), in Kirchdorf, Germany, to meters above the Earth’s surface. supply tower cranes to ports. By the end of the 1950s, Liebherr had From the beginning, the engineers at Eickhoff were pioneers introduced companies in Ireland, South Africa and Austria to expand in the field of mechanical engineering. The foundry established by the organization beyond its own borders. The company began explor- Carl Eickhoff in 1864 has become a high-tech company, located in ing production sites for crawler excavators and eventually settled the heart of the Ruhr Valley and at two additional production sites on Colmar, France. This central location in Europe was ideal for ma- in Germany. chine transportation. Eickhoff has adapted with time. Many in the mining industry After the cornerstone was laid in July 1961, the Colmar site recognize Eickhoff’s line of equipment, which is used for cutting soft developed rapidly. As the industries for excavators expanded, rock such as coal and potash. The company’s wealth of experience the design and technology of the machines were enhanced, and has been very helpful in other markets, too. Long ago, it recognized the French factory became a prominent manufacturer of techno- developments, which not only included the growing need for energy logically advanced crawler excavators. This progressive spe- and raw materials, but also the trend toward urbanization and the cialization lead to new business areas, one of which was min- demand for renewable energy. ing-class excavators. Eickhoff Bergbautechnik GmbH produces shearer loaders and In 1970, Liebherr took root on the North American continent. continuous miners for underground mining, Schalker Eisenhütte Service as well as the proximity to local customers were import- Maschinenfabrik GmbH manufactures locomotives for ore and coal ant to Hans Liebherr, and subsequently, Liebherr-America Inc. was mining, and meanwhile also state-of-the-art hybrid locomotives for founded in Newport News, Virginia. The company supplied the Amer- urban underground service and maintenance applications. Eick- ican market with hydraulic excavators, crawlers and wheel loaders hoff Antriebstechnik GmbH has entered an important market with and also represents the company’s other interests. During this pe- the manufacture of gearboxes for wind turbines. Eickhoff Gießerei GmbH and Eickhoff Maschinenfabrik GmbH develop new materials and processes for all areas of the company, such as improving stan- dards for metallurgy.

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

2018 • VDMA MINING SUPPLEMENT VDMA 7 riod, new companies were founded in Guaratinguetá, Brazil, and Burlington, Ontario, Canada. In Europe, the company responded to rising demand by introducing new production sites in Austria and Switzerland. During the 1990s, excavator manufacturers began to pair up with haul truck makers. Liebherr Mining Equipment acquired Wise- da, a haul truck maker in Kansas, in 1995. The company renamed its electric drive KL-2450 haul truck as the Liebherr T 262 haul truck. Eventually, haul truck production moved to Newport News, where it’s headquartered today. The market for Liebherr hydraulic excavators continued to grow. In 2011, Liebherr Mining Equipment established a new production and development center for mining excavators at the Colmar loca- tion. The new facility specialized in the development and production of large hydraulic excavators for surface mining, as well as the as- sociated service. Cat Global Mining Europe’s factory was established on the banks of the Lippe The Liebherr mining excavators have some of the highest dig- River in Lünen in 1826. ging forces in their class. To harness those digging forces, the ma- chine must have the most robust and fatigue resistant design. In (LHDs and trucks). The aim is to apply technologies that will achieve addition to high levels of productivity, these diggers can be found in high-performance, safe and continuous hard-rock mining. some of the most remote, extreme conditions, such as high-altitude Over the years, the Lünen facility has accomplished many arctic or arid, high-temperature desert settings. achievements. They are credited with inventing plowing technology For nearly 70 years, the Liebherr Group has grown steadily. for longwall mining in the early 1940s. They produce the world’s Long-term investments, organic growth and strategic enhance- first AFC for longwall mines in Poland and Germany. In 1971, the ments to equipment production have proven to be significant fac- world’s first lemniscate shield was introduced here. In the 1990s, tors for success. Today, Liebherr embraces future challenges, yet the company introduced controlled soft-start systems for longwall remains faithful to its trusted principles as a family-run business. mining, another technology breakthrough. Today as longwall oper- ators focus their attention on automation, the Cat Global Mining Power Transmission Europe is providing the equipment and tools to make those systems Voith traces its roots back to 1867, where it was founded in Heiden- work as well. heim, Germany. The company began supplying heavy equipment to the paper industry. In 1870, it began producing water turbines and From Hardware to Data has been involved in many major hydroelectric projects ever since. For more than 50 years, Becker Mining Systems AG has been a Gearbox construction began in 1929, based on the hydrodynamic preferred infrastructure supplier for mine operators from around power transmission, which was invented by Hermann Föttinger. the world. The company was founded by Walter Becker in 1964 Voith then developed its first fluid couplings. A fluid coupling factory in southwest Germany to repair and service hydraulic machinery was established in Crailsheim, Germany, in 1956, and it is still the for the surrounding coal mines. He soon recognized the poten- headquarters for fluid couplings today. Last year, Voith founded a tial for properly engineered equipment. The immediate success digital solutions group to accelerate the digital revolution. of high-quality Becker products made an expansion of the young company into other German areas and France possible. With the Longwall Longevity foreseeable conclusion of the German underground mining mar- The foundation was laid for today’s Cat-owned facility back in 1826 ket, however, Franz Becker began to develop export markets for the on the banks of the Lippe River in Lünen, Germany. Originally, the family business in 1983. With a mixture of new subsidiaries and plant started as iron works, and it quickly moved on to a foundry acquisitions, the Becker Mining Systems Group is now represented and machine works before finally becoming a specialized mining in every major mining region around the world and provides on- equipment manufacturer in the early 1900s when mechanized min- site sales and services. ing was become increasing popular in the area. The company’s product range has evolved and today it pro- Today, the Lünen plant is a world-class manufacturing facility vides solutions in the five areas of energy distribution, automation, specializing in underground mining equipment for a global market. communication, infrastructure and haulage/transportation. Becker It exports equipment to all major mining markets for both hard and Mining Systems’ 1,500 employees have a common goal of constant- soft rock operations. ly improving products and adopting the leadership in innovation. Formally known as Caterpillar Global Mining Europe GmbH, the Becker’s electrical products were always considered to be at the 120,000-m2 Lünen facility employs 1,000 people, who build longwall technological forefront of their fields. mining equipment for miners around the world. The product line With the Internet of Things moving more and more into focus includes hydraulic roof supports (shields), shearer loaders, plow of industrial products and the characterization of the German term systems, armored face conveyors (AFCs) and the associated drive Industrie 4.0 and the related term in mining, Mining 4.0, the Becker system technology. Mining Systems Group leads the market once again with connect- More recently, the group has been developing new products ed products for underground production. The company’s integrated for underground hard rock mining. The company believes this mine wide software solution MineView is available to the markets continuous rock-cutting and haulage equipment will complement and will be updated with further features. When complete, it will the company’s existing portfolio of hard rock underground vehicles be able to process any incoming data from a mine operation and

VDMA 8 VDMA MINING SUPPLEMENT • 2018 Pioneers of the PAST – Masters of the FUTURE

FIRST grinding roller redundancy concept

FIRST company to sell 400 vertical rollers mills for cement grinding FIRST compact plant design

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

VDMA 10 VDMA MINING SUPPLEMENT • 2018

Smart Underground Mining Traditional equipment suppliers gravitate toward system engineers

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

VDMA 12 VDMA MINING SUPPLEMENT • 2018 conditions, Mavroudis explained. “Despite the dynamic and extreme For full autonomous mining, the system will have to control the mining conditions found underground, these optimized systems are longwall face between the gate entries as far as asynchronous cuts adapting independently to their operating environment, and per- (the shearer grades the floor correctly), and identify the coal-rock forming their own regulation and control functions.” interface and marker bands. The systems would have to know its Another optional system developed by Eickhoff allows miners to boundaries and how steer the longwall. “We not only want it to plan observe all of this in real time with the Eickhoff Face camera system cuts, but we also want it to control the face mechanically and pro- (EiFaceControl). The system’s data exchange and analysis enables vir- tect the equipment from damage,” Becker said. tual longwall visualization, which gives the operator the ability to focus “We have to look at the entire longwall system as a numeric ma- on monitoring and control functions from a secure room on the surface. chine,” Becker said. “We need to know exactly where our extraction At the same time, they can access historical data within seconds. “All tools are located in relationship to the face. That data can be gained of this enlarges the sphere of knowledge in the control room, which in by sensors placed on the shearer that communicate with sensors on turn allows the cutting sequences to be planned, implemented, and the roof supports.” Ideally, the system would consider the angle to executed in a proactive and more precise manner,” Mavroudis said. the conveyor for the advancing system while protecting the lemnis- The nerve center for the control process is the state-based Eicon- cate and preventing the shearer from cutting into the canopy or the trolSB automatic system. This is effectively the core element of the flippers on the shields. shearer loader, as it separates the cutting process, methodically into Marco is designing an inertial navigation system, which would be different and independent steps. The preconfigured process can be attached to the shearer. It would use RFID to talk to the PM32 on the altered and extended by the user at any time so that it can be adapted shields. The data from the sensor could be downloaded either through to meet external requirements. The machine reacts independently and the trailing cable or wirelessly. The PM32 controls the hydraulics on in a manner that is tailored to the changing conditions. The remote each shield and the data could be retrieved. Cameras with ethernet operator can correct parameters and alter the process accordingly. connection could also be used to support decision-making. “The shearer follows a defined profile, cut by cut, until it receives a “To make the system work autonomously, the shearer needs to correction,” Mavroudis said. “The shearer is operated completely un- be integrated into the process,” Becker said. “Cut planning and manned with a 99% use of ranging arm and haulage automation.” feedback from the shearer makes it possible for the system to find Initial results show a more even mining operation and better a relative position to avoid collisions. Currently, the Eickhoff system longwall conditions for the manless face in Australia. These new de- would be the best option for data exchange. Once we can exchange velopments in longwall mining will transfer people from monotonous, and see the operating data, we can use the sensors and the cut physically demanding and hazardous workplaces to other fields of profiles to transfer and get the feedback accordingly.” activity. A main challenge is preparing and integrating the people He emphasized the use of cameras. “That is what customers are into the new processes. In most cases, it’s the longwall operators demanding,” Becker said. “We have been looking at ways to improve and that are asking for and advancing this technology. But an important incorporate more video into longwalls. Our first step was the so-called hot prerequisite for the success of such advanced automation projects is spot strategy, where the operator doesn’t need to click through dozens of based upon the transformation in how the mines change their culture camera screens to see what is happening where. Rather, we control the around managing a longwall. Mine operators and industry suppliers process in such a way that the screens will be shown that are relevant to will have to undergo a fundamental change in vision and in strategic the process at that point in time. The other screens are hidden.” focus if the substantial changes needed are to be achieved. Manual cutting processes often lead to mistakes and they need to be optimized. Especially unexperienced shearer operators only react Machine Communications is Key to to the current situation, which can cause oscillations. This effect is Autonomous Longwall Mining exacerbated by information loss due to shift exchange. Correcting this Longwall controls have developed progressively with continuous requires time and at least three to five shearer cuts. Becker proposes improvements in safety and reliability, increasing performance at intelligent cut planning as a solution with the marco’s Horizon Control the same time, explained Mark Becker, mining engineer with marco system. “There is always resistance to change, but it’s more important systems. “The industry is currently converting from electrohydraulic that the operator understands what’s happening within our system,” controls that automatically move banks of roof supports to a digital Becker said. “We want to offer the operator the opportunity to visualize process that will automate mining,” Becker said. “The next step will the cut sequence, the seam height, the seam thickness, the deviation, be the intelligent use of data to optimize the entire process.” the general inclination and most importantly, the goal,” Becker said. Drawing the bow to the principles of Industry 4.0, Becker add- So how does intelligent cut planning work? The system gathers ed: “At Marco, we apply the principles, which Industry 4.0 is mainly all the data and calculates the horizon. Using the data on the shield based on, in the following way: using a solid backbone, we meet the technological requirements of cross-linking, which allows us to consolidate all data in our control and visualisation system, called integrated face control (IFC). IFC enables a wide area of technical assistance and peripheral decisions, such as direct horizon input and intelligent cut planning.” He outlined some milestones for the longwall industry to consider. Based on fully automated shield control, the milestones for autono- mous mining, would be face basis and position capture in 3-D, direct horizon input and shearer integration. “Many longwalls have already achieved fully automated shield controls,” Becker said. “Then next step is to control the system in 3-D by controlling the horizon by direct Manual operation versus planned automation for an optimized consideration cut inputting and planning the cuts intelligently.” of geological and operational issues.

2018 • VDMA MINING SUPPLEMENT VDMA 13 height from the PM32 and the position of the AFC, it calculates the will also be the first Koepe necessary cut sequence and transfers it to the shearer control sys- system used at a hoisting tem. The graphic visualization of the face is not only shown in the height of 2-km.” control room on the surface and the headgate computer, but also on Both systems were every PM shield control unit. Becker pointed out that, due to cus- designed, engineered and tomer requirements, no connection to the surface is required, as the manufactured by SIEMAG entire process is done on the underground IFC-computer. TECBERG. Both will be In the future, corrections will be made automatically based on the equipped with SB1 decel- roof and the boundary layer. “In Russia, we have a face that is perform- eration-controlled brakes ing a boundary analysis with the sensors on the shields, so we can rec- and the company’s own ognize any boundary violations,” Becker said. “That data is fed into the types of slide bearings IFC, where adjustments are calculated and transferred to the shearer.” and brake elements. Looking toward the future, Becker discussed an inertial navigation The four-rope Koepe system. “Independent of the longwall manufacturer, we want to be able hoist of Ø 6.5m will be to exchange cut data with the shearer,” Becker said. “We have an in- used for service. In ad- ertial sensor attached to the frame of the shearer. It is connected to a dition to the hoist, the PM32 and just like every PM shield, it has an RFID antenna. To determine system will have two sets machine geometry, we will place additional inclination sensors on the of Ø 6.5-m deflection ranging arms. With our cameras in every fifth or 10th shield, the system sheaves, a large cage will identify the marker band and make a cut correction automatically.” and counterweight with For an autonomous longwall to plan cuts intelligently, the in- rope attachments, head tegration of the shearer is essential. The industry already has the and tail ropes, supplied prerequisites. With further developments, such as the inertial navi- together with a four-point The Blair hoist uses load compensating sheaves to avoid long-term damage. gation system, autonomous longwall mining will soon be within the lifting system to install industry’s grasp. the heavy-load components. It has a 20-ton payload and maximum operating load of 360 tons (T1 + T2). Engineering Russia’s Deepest The double-drum Blair production hoist of Ø 5.75 m has two Shaft-hoisting System ropes per drum, rope-load compensating sheaves, the related steel Norilsk Nickel plans to pursue ore at deeper levels, and the company work with guiding beams and two 30-ton skips. SIEMAG TECBERG de- recently approached SIEMAG TECBERG to provide what is believed to signed a complete loading system at the shaft bottom as well as the be Russia’s deepest shaft-hoisting system. Over the years, the com- discharge system on the surface, supplied together with the required pany has provided hoisting equipment for many Norilsk Nickel instal- belt conveyors. SIEMAG TECBERG also designed the head-rope attach- lations, but this one, the SKS1 project, is different. In addition to being ments and selected head ropes for carrying the skips and payload. more than 2-km deep, SIEMAG TECBERG will be supplying a complete “We are now in the supply phase,” Krenzer said. “This hoisting shaft-hoisting system with a defined yearly ore output for the Siberian shaft is currently scheduled to go into operation during the fourth nickel miners, rather than simply supplying individual components. quarter of 2019.” They are also providing rope-handling equipment, The SKS1 project will add around 500 m depth to other exist- such as a 200-ton, four-rope clamping and lifting device (2,000- ing hoisting installations in Russia. It will use two types of hoist- kN), a 1,800-kN friction winch with a component weight greater ing arrangements, a Koepe system for service applications and a than 150 tons, along with rope reelers, messenger winches, related double-drum Blair system for the production. “For this project, we horizontal and vertical deflection sheaves, and special tools. are supplying a complete system with the best hoisting technology, In addition to its hoisting system construction experience, designed based on long years of experience,” said Michael Krenzer, SIEMAG TECBERG is also familiar with the local Russian machine senior project manager, hoisting technology, SIEMAG TECBERG. “This building guidelines. “An important part of the equipment supply was to be certified to fulfill the local requirements for explosion pro- tection to work underground,” Krenzer said. The double-drum Blair production hoist is powered by an 8.6-megwatt motor. The weight of the drum shaft alone is 90 tons. The 30-ton skips will travel at 14 m/s to hoist approximately 1.5 million tons of ore per year to the surface, based on 12 operating hours per day and 330 days per year. “The double-drum Blair hoist uses rope-load compensating sheave technology, and this is only the second time we have supplied this complex technology,” Krenzer said. “The hoist has two ropes at- tached to each drum. For different reasons (e.g., rope elongation), the rope load varies. Basically, each sheave is supported by a hy- draulic cylinder that is hydraulically connected with the cylinder of the corresponding second sheave, which enables load compensation for each other. The use of this system avoids long-term damage of The double-drum Blair production hoist of Ø 5.75 m has two ropes per drum, the hoisting ropes. If for whatever reason a rope coiling failure oc- rope-load compensating sheaves, the related steel work with guiding beams curs, for example, this system would detect it immediately and the and two 30-ton skips. hoist can be brought to a safe stop.”

VDMA 14 VDMA MINING SUPPLEMENT • 2018 What sets SIEMAG TECBERG apart for others is its detailed engi- LIFE CAN neering and design work, and its ability to fabricate large systems. Over the last 10 years, the engineering team has used modern fi- nite element analysis systems to improve existing designs and to BE SO SIMPLE produce new drum technologies. The company has its own types of specially designed slide bearings, types of brake elements and ap- proved electrohydraulic braking systems with deceleration controls. Output “We are only one of a very few companies in the world with the abil- ity to deliver such types of large hoisting sytsmems,” Krenzer said. “And, the 90-ton main shaft for the Norilsk Nickel double-drum Blair hoist is the largest hoist shaft we have ever supplied.” From a mining engineering perspective, Norilsk Nickels’s SKS1 project will be a major shaft-hoisting achievement. Designing a Koepe system that will hoist 2 km in a single lift is a feat unto itself. In addition to the 90-ton main shaft, SIEMAG TECBERG will also ship about 3,000 tons of equipment to the mine site and they will charter a vessel to transport the two shaft-hoisting kits with service auxiliaries form Germany to Russia. “This is a very big, exciting project for us with a lot of firsts,” Input Krenzer said. “For many years, Norilsk Nickel has relied on our equip- ment, but now they have asked us to supply complete service and production hoisting systems with a defined yearly output.” Throughout its history, which began in a blacksmith shop in 1871, SIEMAG TECBERG has always focused on quality craftsman- ship and has never shied away from major projects. Today that tra- dition continues as the company broadens its scope from a compo- nent supplier to a systems provider.

Water-based Hydraulic Solutions The Hauhinco name is synonymous with water-hydraulic systems for longwall mining, and they have evolved with mining markets. In 1981, they established a subsidiary close to Pittsburgh to service a growing longwall business in the USA. Today, they have mining and industrial partners around the world. “Wherever there is a long- EICKHOFF SL SHEARER SERIES wall market, you will find Hauhinco,” said Holger Hoffmann, general manager. “We are the leading supplier for high-pressure water hy- draulic applications and we are developing new solutions here in Highest reliability combined with state of Germany.” the art automation features make work at coal The Hauhinco production facilities in Sprockhövel look much faces the most productive and safest ever. different today than they did 110 years ago. At peak times, 300 employees were building Pickaxes and rock drills to support not Eickhoff SL Shearer series represent the only the local miners extracting coal in the Ruhr Valley, but also to apex of longwall shearer technology. mines in neighboring countries. Today, the company’s engineers and Even in diffi cult applications and harshest factory workers have the same level of commitment to quality man- mining conditions, the most powerful ufacturing, but they have more sophisticated tools and they supply and reliable solutions are attained equipment and solutions worldwide. “We have made a significant through Eickhoff. investment in our manufacturing and testing machinery during the last three years,” said Christopher Durst, strategic marketing man- We continually demonstrate why ager, Hauhinco. “Tolerances today are tight and to meet production longwall operators rely on us. standards, we need to use the most modern equipment.” Training, quality control, and research and development are three areas where the company is committed to excellence, Hoffmann explained. Hauhinco not only has an apprentice program to train its own employees, but they also have a training center for their custom- ers. They have a shield sitting on the factory floor next to a classroom where instructors can teach both theory and offer hands-on training. Hauhinco is certified according to DIN EN ISO 9001-2015. “Each Experience has no substitute · Eickhoff since 1864 system is tested and receives a certificate before it leaves this fac- tory,” Hoffmann said. “We want to make sure everything works as WWW.EICKHOFF-INTERNATIONAL.COM: planned. The last thing we want is for a mine in Australia to take a AUSTRALIA · BELORUSSIA · CHINA · GERMANY · POLAND · pump or a valve underground only to find it does not work.” RUSSIA · SOUTH AFRICA · USA

2018 • VDMA MINING SUPPLEMENT VDMA 15 When asked how often pumps are rejected once they reach the tivity of 1,990 micro-Siemens (μS) to 1,000 l/h of clean water with test bench, Hoffmann said, “Rejected? Never. The quality is moni- 19.5 μS. The system can be adapted to water characteristics and tored throughout the entire production process. If there is problem, the required volumes of water. it is rejected earlier in the chain. Once it reaches this test bench, it’s The main 6,000-l tank holds 5,000 l of water-HFA-emulsion and an ISO-certified product.” 1,000 l of HFA concentrate. An automatic emulsion-mixing system “Ruhrkohle AG has Hauhinco pumps that have run for more enriches the water with concentrate. Analog measurement devices than 30 years without a problem,” Hoffmann said. “We come from in the HFA and concentrate compartment show the filling level. A the underground mining sector and deliver products to the indus- transmitted light refractometer with a biprism monitors the emul- trial sector, while most of our competitors come from the industrial sion. “All of our pumps and components are running with HFA [97% sector and now also supply to underground mines.” water and 3% emulsion] or clear water,” Hoffmann said. “Clear wa- Hauhinco offers seven models for the mining business that ter is of course used for dust suppression.” range from the EHP-3K 75 to the EHP-5K 400, which would be five The high-pressure station is also equipped with two hydraulic plungers, 400 kilowatts, 725 m3/min and 500 bar pressure. “The accumulators that reduce pressure spikes and shocks. Two auto- EHP-5K 400 is currently our largest pump and it is becoming very matic high pressure double back-flush filters clean the mixture popular with the longwall mines,” Durst said. “We have installed again before it leaves the high-pressure station for the roof sup- them in Russia, China and the USA.” ports in the longwall. The pressure requirements in underground longwall mining Mines in different parts of the world use different pump station have changed. “The new Russian longwalls need the power,” Hoff- designs. Hauhinco for example supplies high-pressure pump sta- mann said. “Some Russian longwalls have as many as four or five tions and water spray stations mounted on crawler tracks through- 5K 400s for a single face.” out mines in Australia. Onboard the crawler track mounted pump The company is modifying existing pumps and also developing station is a dual-shaft motor system with pumps on either end of entirely new plunger pumps and systems. “We have also improved the motor. A variety of pumps with different flow and pressure ap- the condition monitoring system,” Hoffmann said. “Normally, we plications can be suited to this system. measure temperature, pressure and energy consumption. Now we This system was developed to ensure all equipment is located can also measure vibration, which allows users to see problems de- in the one high-pressure area and therefore simplify transport lo- veloping.” Hauhinco has supplied more than 1,000 systems world- gistics when only moving one piece of equipment in the mine. On wide and it keeps $6 million in parts for pumps and valves in stock. the run, maintenance with minimal downtime can also be achieved They have air freight area ready to ship pumps, valves and spare with this design. “With the dual-shaft arrangement, one pump can parts anywhere at moment’s notice. be quickly disengaged without any hot works or additional labor re- Six years ago, Hauhinco started to develop water treatment quired to achieve this, then the other pump application can still systems for underground mining. With this system, the company be left in operation. General maintenance can be carried out or the reacted to the concerns of mines and OEMs on the possible effects pump can planned to be removed if required, therefore continuing bad water quality can have on the entire longwall equipment. “We operation reducing downtime and production. are working with water as a hydraulic medium and it’s important to This design is very compact and mobile, but the mine also must have a clean medium,” Durst said. “Longwalls are a high capital ex- have a minimum 2.2-m seam height to accommodate the dual shaft pense and coal companies want to make sure that they operate for a design on crawler tracks. long time. Water is the blood of the system and it must be clean.” The dual shaft application can be incorporated into a monorail A hydrocyclone filters solids from the water before it enters a mounted station or a transportable base sled design. However, gen- three-step filtration process with a fineness-of-filtration of 100 erally we can accommodate all types of configurations. microns (μm), 50 μm and 25 μm, and an automatic backwash. A 50-μm bag filter clarifies the returning water-HFA-emulsion from Improving Longwall Productivity and Safety the longwall face. The water treatment system filters the impurities. While the use of automation grows, Caterpillar Global Mining Europe Hauhinco asks the mine for a water quality analysis and they cus- GmbH, continues to develop new longwall system components that tom design a treatment system to filter the water. “Miners are much lend themselves to automation, such as its High Torque Drive system. more in tune with water quality,” Hoffmann said. “Customers on the The armoured face conveyor (AFC) drive system improves longwall industrial side often take water quality for granted.” The standard performance by replacing traditional components with more efficient system converts 2,000 liters per hour (l/h) of water with a conduc- ones. Such evolving and new technologies, according to Cat, promise to drive longwall production higher and cost per ton lower while reduc- ing exposure of miners to health and safety hazards. Recent production results recorded during automation implemen- tation on a high-production Australian longwall illustrate the positive roll that automation can play. In brief, weekly production grew from 61,592 metric tons (mt) to 118,094 mt as automation grew from 0% to 98%. Production grew more than 90% as the use of automation increased, as indicated by shearer ranging arm override commands. Cat said it has found similar results at two other Australian longwall mines owned and operated by different mining companies. In the first case, the average time taken per shearer pass dropped from 56 minutes to 44 minutes as automation was imple- Hauhinco’s water treatment system produces 1,000 l/h clean and salt-free water. The conductivity of the water is approximately 20 μS after the treatment mented. The reduced travel time increased the average number of process and nearly salt-free. passes per week from 68 to 91.

VDMA 16 VDMA MINING SUPPLEMENT • 2018 WE PROUDLY INTRODUCE OUR NEWEST PRODUCT In addition to soft starts and stops, Cat’s High Torque Drive system reduces AFC wear.

In addition to increases in productivity, automation increased equipment availability and reduced in-panel parts usage, specifi- cally replacement of conveyor flights, shear pins and conveyor con- nectors, also known as dog bones. Over three panels, longwall sys- tem availability increased from 91% to 96.5%. The data collected, however, does not distinguish between mechanical availability and mine attributable delays, such as repair time and parts availability. The use of variable frequency drive (VFD) technology in long- wall applications is a recent trend that has already made a pos- itive impact on many installations. Using VFD technology and an innovative low-speed, high-torque motor, Caterpillar is working to step up longwall face conveyor performance even more. The permanent magnet synchronous motor (PMSM) combined with the VFD promises multiple benefits, such as higher productivity and reduced total cost of ownership through low maintenance and high mechanical availability. The drive system also features an extensive automation pack- age, programmable for the application. It can be adapted to special applications or geological situations (roof falls, geological faults, etc.). Because the torque motor delivers max torque at any speed, the automation system can adjust speed to optimize production, reduce electricity consumption, and minimize wear on components such as sprockets and flight bars. EICKHOFF SL SHEARER SERIES The automation system is combined with enhanced condition monitoring to make sure that the machinery is protected and can Highest reliability combined with state of run at maximum output. All of the necessary data is linked to a database to support predictive and condition-based maintenance. the art automation features make work at coal The High Torque Drive system is built around the low-speed mo- faces the most productive and safest ever. tor, which delivers the same high torque at all speeds. The convert- er-controlled torque motor operates at speeds between 0 and 300 Eickhoff SL Shearer series represent the rpm versus 1,500 rpm for induction motors. Lower speed reduces apex of longwall shearer technology. inertia acting on the output shaft by a factor of eight and enables Even in difficult applications and harshest the system to react quickly, which translates to little or no damage to mining conditions, the most powerful the gearbox and conveyor chain in the event of a conveyor blockage. and reliable solutions are attained In addition to soft start and stop, the High Torque Drive delivers through Eickhoff. very fast acceleration. The variable conveyor chain speed can be efficiently adapted to the production conditions — resulting in less We continually demonstrate why wear on the conveyor. The system also is about 5% more efficient longwall operators rely on us. than conventional drives. The improved system efficiency means lower energy consumption and reduced cooling requirements. The new drive system consists of two main components — a variable frequency converter and the motor-gearbox combination. As compared to previous systems, a medium-voltage converter-con- trolled torque motor replaces the AC induction motor. The control principle of the drive is direct torque control — the most advanced AC-drive control technology available. High torque even at low Experience has no substitute · Eickhoff since 1864 speeds enables using only one gear stage, which results in smaller dimensions while retaining the same torque capabilities as systems WWW.EICKHOFF-INTERNATIONAL.COM: that are as much as 20% larger. The low speed of the motor also AUSTRALIA · BELORUSSIA · CHINA · GERMANY · POLAND · reduces wear and extends service intervals. RUSSIA · SOUTH AFRICA · USA

2018 • VDMA MINING SUPPLEMENT VDMA 17 Technology Improves Open-pit Mining Using new intelligent tools, miners pursue automation with haulage and maintenance as well as selective mining

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

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

VDMA 18 VDMA MINING SUPPLEMENT • 2018 A copper mine in Panama recently purchased several Liebherr T 284 haul trucks. copper mine in Panama purchased three. The company also placed its The Liebherr group has relied on its extensive market knowledge first T 284 in Canada as well. In additional to a full line of trucks and and experience of the mining industry to manufacture V-type en- excavators, Liebherr also makes and supplies ancillary equipment gines tailored for these kind of applications. The engines have been that supports the mining business, such as dozers and diesel engines. engineered to face the most challenging mining environments, such At a field demonstration at the Erzberg iron ore mine in Leo- as dust, heat, humidity, vibrations and extreme cold conditions. All ben, Austria, during October, Liebherr showcased its T 236 mining Liebherr diesel engines are also based on solid and secure designs truck. This 100-metric-ton (mt) haul truck, which is powered by a with constant quality assurance and process monitoring to ensure diesel-electric drive system, is the first in this class to incorporate the highest quality standards, parts reliability, and on-site safety. an oil-immersed braking system with four-fcorner retarding capa- With productivity and efficiency as key factors for excavators, bilities, providing reliable braking technology. Liebherr engines can reach outstanding performances and deliver The T 236 takes advantage of Liebherr’s electric-drive sys- required horsepower at the most demanding moments. This results tem innovations with the introduction of the vertically integrated Li- in a reduction of everyday costs per ton while optimizing the fuel tronic Plus Generation 2 AC-drive system. Referring to it as the next consumption of the machines. The Liebherr engines also benefit from evolution in electric-drive system design, Liebherr said the drive sys- best-in-class cylinder power densities, increasing cycle times for the tem introduces advanced, active front-end technology. Making efficient excavators, and delivering greater productivity outcomes. Further- use of electrical energy during retarding events, the drive system con- more, the engines comply with the most stringent emissions regula- trols engine speed with almost no fuel consumption. A variable-speed tions thanks to innovative exhaust gas aftertreatment solutions. hydraulic system reduces parasitic losses to provide maximum power, Liebherr offers dedicated parts supply and technical service while lowering fuel consumption when power is not required. support to its customers in order to reduce operating costs and With its high take-off torque and continuous power to ground maximize machines uptimes. Liebherr diesel engines are designed capability, Liebherr said the T 236 is less sensitive to grade and for quick and easy servicing, extending maintenance intervals. Lieb- payload variations. herr is finally combining its in-house engines with Liebherr mining Liebherr also rolled out a new crawler tractor at the Erzberg excavators to achieve on-site availability and low total cost of own- mine. The 50-mt PR 766 crawler tractor was designed for power, ership, the company said. low emissions, efficiency, driver comfort and durability. The dozer features a hydrostatic drive, ECO function, a 310-kW engine, and an A Paradigm Shift for Maintenance ergonomic cab. Seeing the promise that digitalization holds, RWE Technology A LiDAT fleet management system, which comes standard, International GmbH continuously improved its maintenance pro- provides comprehensive machine data via state-of-the-art com- gram by eliminating paper and developing an app. Soon it plans munication technology, Liebherr reported. This improves efficiency to add component tracking with real-time updates similar to the by enabling optimized operational planning and reliable remote service consumers receive today from DHL or Amazon. monitoring. Data is updated several times a day and can be called RWE generates power for Germany burning brown coal that is up at any time using a web browser. An automatic alarm can be mined from large open-pit operations that use a combination of 20 set for important information, for example, if the machine leaves a bucketwheel excavators (BWEs) and 19 spreaders and more than predefined zone or if a critical operating situation arises. 250 km of conveyors. The massive mining equipment and coal Liebherr’s components division designs and manufactures min- transportation network require regular maintenance. ing engines from 565 kW up to 2,013 kW for the Liebherr hydraulic About eight years ago, RWE began to look at a holistic approach excavators. The R 9100 B and R 9150 B are using the D9512, a V12 to maintenance that has now evolved into mobile solutions with engine assembled in Bulle, Switzerland, and the R 9400 is currently apps. In 2010, the company introduced a maintenance management testing the brand new D9812 from Colmar, France. system based on key performance indicators (KPIs). A year later, they

2018 • VDMA MINING SUPPLEMENT VDMA 19 were defining various mobile requirements, especially for mainte- RWE is now developing a Material Ready App for logistics, nance management. In 2015, RWE rolled out the Asset Care app, which will digitally track the material management process. “We and today they are refining it by incorporating IT/SAP technology do not want to reduce jobs, we want to empower the worker to be that will optimize purchasing, storage and delivery of spare parts. more productive,” Eberlein said. Looking toward the future, Eber- Recalling the paperwork and the issues with logistics and down- lein envisions an integrated system, consisting of maintenance and time, Mark Eberlein, technical support, RWE Power’s Maintenance materials that knows what the company has in stock and what it and Engineering Center, described the company approach to digita- needs to transport to the site. Similar to Amazon, when ordering a lization. “We couldn’t fit all of our equipment with sensors overnight component, it would suggest other parts that are usually ordered to because it would simply cost too much money,” Eberlein said. “So, complete a certain job. It would track materials on lorries and, like we approached the equipment through the people and then back to DHL, give the users updates as far as arrival time. the system. They were taking photos of the parts and sending it to other people using private email or WhatsApp, which is a great use Integrating Surface Miner Technology of technology, but all of the information is lost.” The company began The New Acland coal mine in Queensland, Australia, recently incor- to develop an app for the maintenance technicians that does the porated a Wirtgen 4200 Surface Miner (SM) into an existing mining same thing and keeps the information inside the company. fleet. While it was a major departure for a group that ordinarily re- The RWE system offers tailored solutions according to needs and sists change, the mine realized many benefits as far as health and priorities of the equipment and maintenance. It has reduced main- safety, environmental performance, productivity, particle size distri- tenance periods through real-time capture of systems data. It has bution, loss and dilution, and unit costs were realized. Working with reduced equipment downtime through predictive equipment data one of the leading German schools for mining engineering, RWTH and maintenance. It has a high level of KPI transparency as far as Aachen University, and Wirtgen GmbH in Germany, New Acland im- costs, performance and safety on an equipment level. “It’s also easy plemented a new mining method. to use and intuitive with a simplified user interface,” Eberlein said. Located 35 km northwest of Toowoomba, the New Acland mine, “Technicians always have precisely the right tool for the job at hand. which is part of the New Hope Group, has been operating since 2002 Maintenance and repair information is monitored continuously and and today produces about 5 million metric tons per year (mt/y) of backed up.” The system connects the KPIs to Big Data systems and it thermal coal. will eventually offer real-time updates as well as tracking systems. Because of its close proximity to adjacent neighbors, the mine To make a system like this work, upper management and the operates within strict environmental limitations. Noise and dust employees must both understand the value proposition. Over time, emissions are especially relevant and lower environmental impacts barriers were identified and managed. “People want access to data are desired. The coal is washed on site and then railed to the Port of and information, but they won’t use the system if it doesn’t function Brisbane for export. properly,” Eberlein said. The geologic formation consists of multiple coal seams ranging Today, RWE’s Asset Care App (www.rweti.com) connects its peo- in thickness from 0.3 m up to 3 m, interrupted by partings of the ple with the company’s system, and the company’s efforts in this same thickness. In total, the number of different bands exceeds 40, area were recognized with an innovation award from Handelsblatt resulting in high importance of selective mining practices. Consid- IT for digital products, projects and business models. ering these geological conditions, the Wirtgen 4200 SM offered a Jointly developed by RWE and Apple IBM, the Asset Care App potential solution to reduce the amount of operating equipment and is used by maintenance engineers, technicians and craftsmen. deliver greater control and accuracy to the mining process. It has been deployed to RWE field forces using iPads to improve The 4200 SM began mining at New Acland in June 2014 and maintenance efficiency. When the app is launched, the user sees has been selectively mining coal and partings. Operator training their personal tasks and settings. An intuitive function, Around Me, commenced in overburden. The decision to test the surface miner shows them jobs that need to take place near their location. “They was based on multiple expectations such as increased production can review maintenance plans,” Eberlein said. “All backup docu- rates, reduced mining costs, better coal recovery delivered through mentation is available online, even some of the old paper records. less loss and dilution, improved Run-of-Mine (ROM) coal quality, They can also find short instructions for maintenance tasks and simplification of the mining process, and reduced environmental view work order details.” The app uses photos and has red-lining emissions. To validate those expectations, a structured trial was capabilities as well as speech recognition. conducted from June to September 2014, evaluating machine per- formance against defined key performance indicators (KPI). With about 500 machines sold worldwide, Wirtgen GmbH, located in Windhagen, Germany, is the market and technology leader for sur- face miners. The direct-loading Surface Miner cuts, crushes and loads the material in one step and thereby replaces multiple conventional mining steps. Depending on job requirements, the Surface Miner can also side-cast the cut material or even cut-to-ground. The cut-to- ground option requires a different machine setup, i.e., different drum housing, no conveyor system. With the Surface Miner models 2200 SM/2200 SM 3.8, 2500 SM and 4200 SM, Wirtgen provides three per- formance classes, which can be configurated exactly to project needs. The strongest Wirtgen miner is powered by a 1,623-hp power plant and it weighs about 200 mt. The cutting drum, located in the RWE’s Material Ready App will eventually track the material management center of the machine between front and rear tracks, is equipped process digitally. with cutting tools, i.e., picks that grind the material. Cutting tool

VDMA 20 VDMA MINING SUPPLEMENT • 2018 Experience the Progress.

Liebherr’s Innovative Mining Solutions

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

Liebherr-Mining Equipment SAS 49 rue Frédéric Hartmann - CS 50038 68025 Colmar Cedex Phone: +33 369 49 20 00 E-mail : [email protected] www.facebook.com/LiebherrMining www.liebherr.com holders are mounted onto the drum in a job-specific layout. Number The Surface Miner cuts lanes alongside each other. At the end of picks, pick spacing, and pick design are a few of the parameters of each cutting lane, it cuts its own ramp and turns around 180° that are designed to the conditions on the mine site and desired to start the next lane. The cutting lane length is a major parameter project deliveries, e.g., particle size distribution or cutting rates. influencing productivity. With increasing cutting lane lengths, the In the development of the cutting drum for the New Acland proj- fraction of operating time spent turning around decreases while ect, the engineers had to design the Surface Miner to cut both coal actual cutting time increases. To enable an efficient surface mining and rock partings. On the direct-loading machine, the tool holders operation, it is recommended to operate the 4200 SM in blocks of are mounted in a helix layout to pull the material toward the mid- more than 300 m. New Acland’s conventional mining method oper- dle of the drum. The cutting depth can be adjusted to follow the ated in 150-m x 150-m blocks. So multiple traditional mining blocks coal-rock interface, down to 830 mm. A scraper is located behind were added together to create a mining area of up to 600 m, allow- the cutting drum and from there the material is transported onto a ing the Surface Miner to operate efficiently. primary conveyor, which transfers the material onto the discharge An in-depth trial program, designed around the KPIs, formed an conveyor that slews 180° with an adjustable height. It can load haul essential part of the implementation process. They were categorized truck easily and efficiently while minimizing dust emissions. as performance; health, safety and environment (HSE); financial The conventional mining system consisted of dozers and a and downstream impact. Most of the KPIs refer to the continuous wheel loader for loading rock and coal into the 130-mt to 190-mt mining system employed. The KPI for fines generation was defined haul trucks. This dozer-assisted, truck-and-shovel operation has as “fine coal generation less than 2 mm not to exceed limitation of been well developed over the years at New Acland. The dozer oper- dozer/loader system.” ators have extensive experience and achieve good loss and dilution Operators with no previous experience were trained to operate figures. New Acland, however, wanted to improve recovery and fur- the 4200 SM. A ramp up was applied to some KPIs to account for thered reduce coal loss and dilution. that training. During a period of four months, performance of both A change in the mining process can be risky and uncertain so mining systems was measured and compared against each other. New Acland opted for a four-month trial. For the successful imple- The assessment revealed that about 70% less machines would mentation of new technology, it is important to take a whole-of- be required for the Surface Mining system compared to the conven- process view, which requires cooperation between the divisions. tional ripping, stacking and loading system. The 4200 SM has less KPIs of the Surface Miner trial were not only limited to productivity impact on the environment, less equipment resulted in less emis- and mechanical availability, but also addressed impacts across the sion of noise, vibration and dust. The fuel usage per volume mined whole process chain. An example is the particle size distribution material was around 65% lower with than the traditional method. (PSD), particularly fines generation. The operators experienced a number of ergonomic benefits as well. During the commissioning of the surface miner, New Acland and Wirtgen jointly conducted an extensive comparison of the gradation Optimized Methods for Moving Ore of the specified coal. To this end, Wirtgen supplied a tracked MS 19 After successfully installing two gearless conveyor projects in Peru triple-deck screening plant from Kleemann to analyze the grain sizes (Antapaccay and Las Bambas), Siemens completed the world’s big- of the 5-mm to 150-mm fractions and a laboratory screening plant to gest installation of a direct conveyor drive system. In this modern- analyze the grain sizes of the fractions between 0.5 mm and 5 mm. A ization project, the belt conveyor replaced the railway system that total of 100 individual 30-ton samples were analyzed. The samples for was previously used to transport ore from the mine to the processing the conventional mining equipment and the 4200 SM were taken from plant. The conveyor consisted of three individual sections equipped identical mining fields, which were divided into two for this purpose. with a total of five integrated drive systems. For the largest of the The Wirtgen Surface Miner was tailored to mine-site specifica- belt sections, Siemens supplied two gearless drive systems with an tions and arrived at the mine site in May 2014 and was commis- output of 6,000 kilowatts each. sioned within two weeks of arrival. The implementation of the new Siemens is also supplying a new conveyor system with gearless mining system required some adjustments to the traditional block and conventional drives to thyssenkrupp Industrial Solutions for the mining system. Oyo Tolgoi underground copper mine in Mongolia. The new system

New Acland participated in a four-month trial that compared the use of a Wirtgen Surface Miner against its traditional mining techniques and realized several benefits with the new system.

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950,$ expands the existing open-pit mine and is expected to bring 95,000 data logging system — is connected to all components of the convey- metric tons per day (mt/d) of copper ore to the surface. The conveyor ing system, including mechanical and electrical parts. The mass of system has to overcome differences in elevation of almost 1,400 m. produced data is then integrated with data from other sources, such Production is expected to commence in 2020. as field service reports. Through advanced analytics, experts can pre- Despite these advances, there is still more potential to be dict impending failures and take action in time. An added advantage tapped with conveyors. ContiTech, thyssenkrupp and Siemens is that they can also uncover opportunities for performance improve- have founded a research and development consortium to devel- ments, as well as energy and cost savings. For remote-asset health op and market the Chevron-MegaPipe conveyor. The new conveyor management services, Siemens can go online from a competence cen- design is set to help reduce conventional heavy-duty truck traffic ter and provide instruction to help mine personnel fix a problem. and the resulting high operating costs in open-pit mines. High- A further tool for smooth operation is uniform IT structures. strength, ribbed steel cable Chevron-MegaPipes with a nominal Vale, one of the world’s biggest mining companies, is implementing strength of up to 9,500 N/mm and an outer diameter of up to 900 a single manufacturing execution system to replace 17 production mm facilitate cost-effective conveyance of ore and overburden management systems used at its operations in Brazil. Siemens was with lump sizes up to 350 mm over mine slopes with angles of selected to develop and commission a manufacturing execution sys- inclination of 30° to approximately 45°. The solution has already tem (MES), which goes under the name Vale Production Manage- proven its feasibility in a 350 m deep open-pit mine with a mass ment-Mining (GPV-M). It guarantees comprehensive transparency flow of 5,000 mt per hour (mt/h). along the entire value chain and at all facilities, from the mines to On the island state of Papua New Guinea, Ok Tedi Mining Ltd. the railway and port facilities. Nowadays, GPV-M is one of the foun- (OTML) runs a copper and gold mine. Like many mines in Papua New dations of Vale’s digital strategy, which aims to establish a platform Guinea, the drive train infrastructure on the grinding mills there is that will allow Vale to reach new heights of productivity through the in excess of 30 years old, and OTML was aware of the potential prob- combination of new technologies and processes. Results are already lems with the aging equipment. The company’s people also knew apparent. To date, more than 20 million mt of iron ore have already that, to ensure long-term profitability, a move to industry standard been shipped using the newly commissioned GPV-M. Plus, the IT variable-speed control of the SAG mills was required. costs for MES technologies will be reduced up to $19 million by 2020. Siemens was selected to equip the two SAG mills at Ok Tedi with Digitalization also makes autonomous operation of stock- new drive train infrastructure. The project will commence in 2018. yard machines — such as stackers and reclaimers — possible. Also part of the delivery scope: a cloud-based condition-monitoring Advanced material handling systems like these are paramount in system combined with remote access as well as contracts for main- helping mines reduce operational costs with the added benefit of tenance and analytics. increased safety. Digitalization of stockyards allows mining compa- Another area of bulk material handling gaining attention is pre- nies to track quantities and quality. It provides real-time material ventive maintenance. Here the goal is to minimize unexpected shut- inventory. Storage levels can be simulated and products with pre- downs caused by system failures. A continuous recording system — or cise qualities can be blended.

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

VDMA 24 VDMA MINING SUPPLEMENT • 2018 A WIRTGEN GROUP COMPANY

Blasting? No! Safety? Yes! www.wirtgen.com/mining

2500 SM: Surface Mining combines safe mining operations with modern cost-effectiveness: the 2500 SM replaces the entire equipment otherwise needed for blasting, drilling and pre-crushing. It cuts costs, delivers mined raw materials of higher quality, and ensures more efficient exploitation of the deposits. Take advantage of innovative solutions from the technology leader.

www.wirtgen.com

WIRTGEN GmbH · Reinhard-Wirtgen-Str. 2 . D-53578 Windhagen . T: +49 26 45 / 131 0 Moving More Material, More Effectively The use of intelligent, variable-speed systems help miners reduce transportation costs

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

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

VDMA 26 VDMA MINING SUPPLEMENT • 2018 to be changed, but also the installed drive power. The most cost-ef- fective solution was to install new drivetrains along the long conveyor (SB500). The installed power is now 2x 1.2 megawatts (MW) at the head and 1 x 1.2 MW at the tail of the conveyor. The existing Voith drives for the SB500 were used to double the number of drivetrains on the shorter 2-km SB200 conveyor. After 20 years, the drives only needed routine maintenance checks in order to connect with the new controller. The new configuration of the SB200 drive system consists of 4- x 600-kW installed power at the head equipped with new gearboxes. In addition to the new drivetrains, the overall performance of the drives was improved. Before the retrofit, the startup procedure of the long conveyor with 12.8 km took more than 10 minutes. The difficul- ties with control technology and conveyor dynamics in the past were resolved with the Voith TurboBelt Drive Control. The conveyor now starts up fully loaded with about 2,100 tons of aggregate, within half of the previous startup time, and the torque transmission con- trol achieves an extremely smooth and steady acceleration. Voith recently installed a TurboBelt DriveControl system at SsangYong Donghae plant in South Korea. Providing the Power Fleuchaus said. “The system knows why the conveyor was shut down ABB, as well as the VDMA, has a long history in the mining industry. and the operating conditions when it was shut down. Startup would Located in a traditional German mining area, with the Center of Excel- be influenced by the load and, if it’s a multimotor arrangement, the lence in Cottbus, ABB has decades of expertise in electrification and motors and drives might require a staggered start and the control automation for open-pit mining and bulk material handling applica- system would decide which motor would start first.” tions along the entire mining chain from pit to port. The many years of The TurboBelt 500 TPXL, which has been developed especially for experience was always coupled with innovative solutions that incorpo- new belt conveyors, is a smarter solution and has a smaller footprint rated the newest technology trends, such as digital mining solutions for the same level of power transmission. It operates at a higher based on ABB Ability, its open industrial internet technology platform. efficiency and has a simple method for controlling the fluid inside the ABB also has long-term successful partnerships with worldwide coupling. “By changing the fluid level of the fill control coupling, we leading mining equipment suppliers, such as Komatsu for electric rope alter the starting behavior of the coupling,” Fleuchaus said. “If you shovels and TAKRAF Tenova for high-power gearless conveyor drives. have an emergency stop with a belt that is potentially 10% to 15% ABB Germany has engineered a product platform for low-voltage AC overloaded, you have to ensure safe restarts.” Drives for extreme mining conditions and has made more than 100 de- As far as logic, two lines run between TurboBelt DriveControl to the liveries during the past 12 years. The product life cycle of this successful main PLC. In the past, an open source architecture was designed by PLC AC Drive system will now go into classic phase to ensure the availability manufacturers, that may not have understood the principles of fluid of spare parts from ABB Drives Service for another 12 years. Reliability couplings. “The function of the coupling and its behavior is a topic of and performance convinced Komatsu to deploy the next generation of its own,” Fleuchaus explained. “So we created our own controller based ABB low-voltage drives, which provide more power in the same footprint. on the features necessary to start and operate the system for reliable A FEM structure analysis of the cabinet system and IGBT live time analy- operation,” Fleuchaus said. “With PID controllers and sensors, we can sis will ensure the proven quality level for high capacity shovels. focus on the coupling’s behavior as far as torque and speed. We can Together with TAKRAF Tenova, ABB is partnering in the devel- calculate the power absorbed from the motor based on coupling slip. opment of gearless conveyor solutions. A recent example is the “We focus on the driven side of the conveyor and analyze the torque execution of the world largest conveyor system at the Chuquica- transmitted to the belt at what speed,” Fleuchaus said. “We know ex- matacopper mine in Chile, which will connect the newly developed actly when the system was stopped and the last level of motor power underground operation directly with the concentrator. consumption. Now, we can perform an optimized restart because our controller has saved the last value, which forms the basis of the restart conditions. It knows the difference between an emergency or overloaded shutdown and it automatically selects the proper restart scenario.” Voith recently installed a TurboBelt DriveControl system at SsangYong Cement’s Donghae plant in South Korea. By implementing the Voith system, the quarry managed to overcome local material han- dling challenges to increase its production of limestone significantly. SsangYong had used Voith’s equipment for more than 20 years and consulted the company for this retrofit project. With a goal of dou- bling the tonnage from the main quarry to the cement plant, essential technical changes became necessary. The conveying route was cov- ered by two belt conveyors with the longer one, a 12.8-km one-flight conveyor, belonging to the five longest single conveyors worldwide. After an initial analysis of the conveyor system, the belt speed was doubled from 3 meters per second (m/s) to 6 m/s to increase the con- veying tonnage. To allow for that increase, the gear ratio not only had ABB has a new gearless solution for medium-powered conveyor drives.

2018 • VDMA MINING SUPPLEMENT VDMA 27 While recent projects were mainly driven by gearbox limitations Condition Monitoring for high-power drives (3.7 MW per motor), ABB recently developed a Bosch Rexroth was working with connectivity long before concepts solution for the medium-power range (1.3 MW per motor) to make like Industry 4.0 became popular. The company’s first pilot solution this technology economically feasible for a broader range of conveyor was installed around 15 years ago by a large iron ore miner. At that systems, including on mobile equipment. A core element is a perma- time, operating data was relayed to the Hägglunds team over the nent magnet motor specifically designed for mining applications. GSM network, not more than a couple of times per day. Working with local mine operator LEAG, ABB is now implementing a “Back then we simply called it remote monitoring,” said Uno pilot project of this solution that is showing very encouraging results in Sundelin, manager, mining and materials handling for Hägglunds operation. The new gearless solution was installed on a high-capacity Products. “The equipment recorded important indicator values, and (15,000 mt/h) discharge conveyor of a bucket-chain excavator in paral- thresholds were set for pressure, temperature and so on. By having lel with the existing geared drive. The operational data demonstrate the good routines for monitoring those values, we could prevent damage advantages of the gearless solution with less components like: from happening if something outside the set parameters occurred • Higher reliability (50% lower failure rate) and less maintenance; with the drive. It was basic, but it worked and was well appreciated • Higher efficiency with lower energy consumption (according ISO by the customer. It established the principle.” 50001) and lower noise emission; and Bosch Rexroth’s solution today, known as Hägglunds Condition • Extended lifecycle (expected motor lifetime of 25 years is 10 years Monitoring premium, CMp, is a quantum leap from that first system, longer than with a traditional gearbox). with more sensors, real-time reporting and an analytic algorithm The new solution can be applied for both greenfield and brown- that has far greater diagnostic power. It can be found in Hägglunds’ field systems, and significantly decreases the cost threshold for drive systems worldwide, including at that first iron ore mine, where gearless conveyor technology. it safeguards, for example, the availability of a large belt conveyor. After the successful implementation of the stockyard manage- “Belt conveyors are typical positions where you want to have ment system (SYMS) at Vale’s iron ore distribution hub in Malaysia, condition monitoring,” Sundelin said. “If a conveyor stops, the ABB has extended the functional scope for the material tracking and whole production often stops. They’re autonomous systems, and if quality management in integrated lignite mine and power plant sys- you have no parallel path, you want to see in good time if something tems. These systems in Europe are often characterized by the combi- is outside the norm, so that you can take any actions needed to keep nation of different mines feeding a nearby thermal power generation the conveyor running.” plant without additional coal processing. The quality of the mined The Hägglunds CMp system provides advanced notice with the lignite is highly variable in terms of calorific value, ash, sulfur con- help of ODiN, Bosch Rexroth’s proprietary analysis solution. Using tent, and influenced by non-ideal coal seam courses. To secure an readings from sensors installed throughout the drive system, ODiN efficient combustion process, it is necessary to homogenize the coal creates a machine health index that provides an accurate picture of feed by selective mining and blending processes on stockyards. the system’s condition. ABB is now executing an online coal quality management sys- It is the health index — not the individual sensor signals — tem project that tracks the quantity and quality of the excavated that makes the difference for mining customers. The usefulness of coal directly on the conveyor lines by the use of belt scales and the data collected through Hägglunds CMp becomes apparent when online analyzers. The system compares the parameter from the pro- Bosch Rexroth experts interpret it and determine what service ac- duction planning system, which is based on the geological model tions might be needed to keep the system running. of the coal deposit with the real measured values. It then creates “Anyone can deliver sensor data, but data says nothing to the a feedback loop to the production system. The new parameters for miners,” said Mattias Ljungdahl, application manager, Hägglunds the excavating and blending process, which are calculated online, Inside Intelligence. “With ODiN we have a constantly learning al- are transmitted directly back to the mine’s control system and the gorithm that takes the sensor data and compares how things look stockyard. So the system then enables continuous quality control of normally with how they look right now. When our experts see a di- the coal feed with an optimal mix of blending directly on the convey- vergence from that health index, they determine what is happening or lines, or if necessary, by the use of stockyard blending in parallel. and what needs to be done. It’s that combination of health index and expert analysis that makes our solution work for the customer.” A further difference, according to Wolfram Ulrich, vice president sales and service, Hägglunds Products, is the integration of Häg- glunds CMp with Bosch Rexroth’s total service offering. What cus- tomers buy, he said, is not just knowledge, but also the ability to act. “The connectivity Bosch Rexroth offers is paired with fast, pro- fessional reaction by technicians with deep knowledge,” Ulrich said. “Monitoring is everywhere today, but our ability to interpret, conclude and take corrective actions is one of a kind.” “Simply delivering a high-performance mining machine is not enough for today’s global customers,” Ulrich said. “Suppliers need to know how their customers want to operate their machines, and how to secure the information that will let them do it most effective- ly. What Bosch Rexroth offers through drive connectivity in its full extent is a proven way for OEMs to take the next step for optimized designed machines and the end users to minimize maintenance costs, optimizing the availability plus running the processes as ef- Bosch Rexroth’s Hägglunds drive provides the power to clear the truck dump. ficient as truly possible.”

VDMA 28 VDMA MINING SUPPLEMENT • 2018 Intelligent Driving of Belt Conveyor Systems. The New TurboBelt 500 TPXL

This new fluid coupling combines the Your Benefits: proven reliability of hydrodynamic power • Intelligent speed & torque control transmission with digital control tech­ • Self­diagnosis & remote services nology. The integrated controller assures • Easy plant control integration optimized coupling and conveyor perfor­ • Up to 98.5% efficiency mance in every operating mode. The • Unrivaled Total Cost of Ownership intelligent logic protects all conveyor components, providing a longer lifetime of utilization.

[email protected] www.voith.com/intelligent-mining Intelligent Processing The proliferation of technology leads to automated processes and new grinding techniques

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

VDMA 30 VDMA MINING SUPPLEMENT • 2018 sequences for filter cake washing are preconfigured for optimum the logbook functionality and automatic email notifier for the most washing results. critical process alarms. Metris Internet of Things (IoT) products focus on smart sensors, Big Data analytics and augmented reality. These technologies are Dry Ore Grinding applied and adapted individually to meet the requirements of each Santral Mining has decided to use a Loesche dry vertical roller mill to individual customer — exploiting the capabilities of systems al- grind gold ore in Turkey. The project is attracting a lot of attention world- ready installed and measurably enhancing plant performance. wide because the gold content of the raw ore is relatively low, and there- In combination with additional upgrade packages, the Me- fore, the profitability of the finish grinding and subsequent flotation is of tris addIQ control system maximizes performance regardless of particular importance. In grinding and flotation tests, it was proven that whether it is applied to ANDRITZ filter presses or other makes. The Loesche grinding technology not only works in a more energy-efficient packages available for filter presses include addIQ Dynamic, addIQ and wear-resistant way than the conventional wet ball milling, but it also Prime and addIQ Flex. makes a significantly higher yield of the dryly ground product possible. All four addIQ packages can be equipped with addIQ Footprint, The energy demand for vertical roller mills depends on the pressure a long-term data trending tool whose features include a dashboard, and, in particular, the speed when grinding hard rock. Loesche is also trends, a logbook, updates and reports, mobile access, and QR Iden- developing vertical roller mills with drive-power capabilities of up to 18 tification. What’s more, with addIQ Connectivity, one can monitor the MW for use in mining applications. Wet grinding systems (SAG and ball health status of their machine 24/7 from anywhere in the world. mills) have drive systems with power capabilities of up to 25 MW. The These add-ons allow users to store trend data for 24 months Loesche mill requires substantially less power for comparable grinding and present the most important KPIs for process values on the capacities of up to 2,000 mt/h. The cost benefits of using large grinding dashboard, all with a certified data connection and backup in plants with vertical roller mills will encourage the more widespread use of the data cloud. Operators can also generate and email automatic this technology, which is a relatively new concept for the mining industry. reports with process values and corresponding trend curves. The The largest Loesche mills to date have drive-power capabilities mobile app provides direct access to live data and machine-relat- up to 10 MW. The mills have redundant systems to avoid machine ed documentation, while peace of mind is guaranteed thanks to failures and to be able to ensure high levels of availability.

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

2018 • VDMA MINING SUPPLEMENT VDMA 31 A New Generation of Extreme Oils Sands Crushers

Tenova TAKRAF has recently developed a symbiotic niche in the oil sands industry by giving both new and existing production trains the supercharged boost they need to sustain profitability in a low oil price environment. While boosting production, TAKRAF has also achieved a recovery increase in the downstream extraction process. Critically, this combined success has been proven during the perfor- mance-limiting artic winter months. During 2013, TAKRAF was engaged by one of the principle oil sands producers to solve the winter time stalling of their existing double roll crushers (DRC). The direct effect of the halt, as well as their inability to restart, resulted in significant cumulative annual restrictions on winter production. In 2014, TAKRAF began retrofitting all their primary crushing plants with the New Generation TAKRAF TRC 25.34 double roll crusher. The New Generation DRC increased drivetrain inertia (200%), use- able kinetic energy (185%) and available motor torque (168%). This resulted in peak crushing demand dropping from nearly 600% full load torque (FLT) to a level near 350% FLT. A specially designed motor with a The TAKRAF New Generation DRC increased drivetrain inertia over 200%, Breakdown Torque (BDT) greater than 430% FLT was then implemented useable kinetic energy 185% and available motor torque 168%. This resulted in peak crushing demand dropping from nearly 600% Full Load Torque (FLT) to deliver the full 350% FLT through a larger capacity fluid coupling. to a level near 350% FLT. These changes represented a paradigm shift in the basic crush- ing principles used for a primary crusher in oil sands. Previously, the plant, the upgrade to the powerful New Generation TAKRAF TRC technology primarily relied on expending its limited kinetic energy 25.34 DRC has proven to be an economically effective means to during every major crushing event; however, if the kinetic energy increase production through elimination of stalls and reduced was completely expelled before the feed material was processed, the maintenance downtime, as well as increased recovery through crusher would stall. Subsequent restart attempts were insufficient achieving a high crushing ratio, even in the most extreme winter and often consumed the available heat capacity of the fluid cou- conditions. This type of primary crusher upgrade typically requires pling, further suspending the production recovery. The New Genera- a shutdown period of 22 to 30 days. Economically, the payback tion DRC possesses the ability to process the most difficult materials period is less than two winter seasons. without primarily relying on consuming any kinetic energy. The iner- tial storage buffer translates directly to production guarantee. Transporting and Charging Explosives This philosophy was then applied to the entire primary crushing With the increasing number of panel-caving operations, where ore is plant, two trains of which were put into production in 2016. The robust mined by conventional drill-and-blast operations, transporting ex- TAKRAF drive units and an abundance of surplus kinetic energy are plosives to the loading locations and scheduling blasts are two very already proven to process sustained tonnage rates exceeding 14,000 important underground mining issues. Many mines rely on a mixture metric tons per hour (mt/h), while maintaining an impressive 400- x of ammonium nitrate and fuel oil (ANFO). Production drill holes can 400-mm maximum product size — even when the feed approaches a be as long as 25 m with a diameter up to 3 inches, which means 10:1 crushing ratio. At the same time, the TRC 25.37 is able to develop the typical round requires approximately 3,000 kg of ANFO. By lim- an 11% increase in the surface area of the product, significantly as- iting the hole-charging time and reducing the transportation costs, sisting the oil recovery process. In the redesign of the primary crush- mines could achieve a higher level of productivity at a lower cost. ing plant, none of the components were ignored in the new generation Paus has developed an ANFO-charging concept that combines plant. In addition to functionality and reliability, maintainability and a the transportation and charging of ANFO in one machine to extend reduction of downtime were key areas of focus. The net result, according to TAKRAF, is the most effortlessly maintainable, cleanest and pow- erful primary crushing plant, which now fulfills both the immediate and future needs for mining oil sands. The TRC 25.37 is designed for a sustained 17,000-mt/h throughput capacity in all oil sands materials during the most frigid conditions. The two units, which commenced production in 2016, are derated to the contracted 14,000-mt/h capac- ity, but can be fully realized with a simple change to the ratio of the apron feeder. For those mines not immediately requiring the implementation of a complete new crushing The Universa 50 from Paus can be equipped with a full ANFO charging platform.

VDMA 32 VDMA MINING SUPPLEMENT • 2018 charging capacity for one full pattern. The system is based on the Universa 50-2 with a Deutz TCD 2012 diesel engine, Posi Stop axles and a hydrodynamic drive line from Dana Spicer. The Universa 50 is equipped with an ANFO storage platform with a maximum capacity of up to 120 ANFO bags (22 kg each), a 500-l ANFO vessel, rotary vane compressor and a telescopic platform in the rear part of the machine to cover the full drilling pattern with a fixed-carrier positioning. The carrier with boom/basket at the rear is also the ideal platform for all kinds of emulsion units. An experienced driver can accomplish this changing procedure within a maximum of 5-10 minutes. In addition, the Uni 50 can be equipped with a working platform, which permits working heights above 7 m to cover 40-m2 faces. All machines implement extended safety features. This concept enables the increase of charging time of every unit and the use of the 500-l vessel keeps the machine dimensions as compact as possible. With its famous hydraulic quick changing system, the Uni 50 can quickly switch cassettes to a scissor platform, cement mixer Economies of scale: KAMAT has developed the first quintuplex (five-cylinder) and sprayer, tire handler, diesel generator, loading platform, etc. pumps with a rating of 530 or 800 kW on the basis of the thoroughly redesigned triplex pumps. High-pressure Pumps for Large Volume Flows The (water-based) hydraulic systems in various high-pressure The advantages for the longwall operator result from “econo- plunger pump applications, especially longwall roof supports, are mies of scale.” A large pump is working far more cost-effectively getting larger and larger. As a result, longwall operators are using than two or three smaller ones, and clearly needs less space — an multiple, large triplex pumps given that the volume flow of these important argument in most modernization projects. pumps is limited by design and the high pressures involved. And, A lot of detailed design work was, however, required to transfer the cylinder size is limited by cavitation, which implies that it makes the basic concept of the triplex design to the quintuplex pump. The sense to produce triplex pumps with ratings of “only” about 400 kW. crankshaft, for example, is supported by multiple bearings, and the KAMAT has now taken the next step and developed, on the ba- crossheads are oil-spray lubricated rather than splash lubricated so sis of the thoroughly redesigned triplex pumps, the first quintuplex that sufficient lubrication of the center crossheads is ensured as well. (five-cylinder) pumps with a rating of 530 or 800 kW and the capabil- KAMAT, nevertheless, managed to keep spare parts stocking ity to reliably deliver distinctly larger volume flows than triplex pumps. economical through the use of many parts that are common to the

Strength of steel and passion of men to protect equipment´s most important asset.

ERLAU TYRE PROTECTION CHAINS – NEVER WITHOUT!

www.erlau.com Erlau AG | Erlau 16, 73431 Aalen, Germany | Tel +49 7361 595-0

2018 • VDMA MINING SUPPLEMENT VDMA 33 triplex pumps. The housing was developed and optimized by KAMAT RWE Assett CaCare. in close collaboration with the IFAS Institute at the Ruhr University Bochum who also simulated the thermal load of the pumps and carried out the respective optimizations. Anticipating maintenance needs is essential The quintuplex pumps furthermore offer the same advantages to keeping heavy equipment up and running, as the redesigned triplex pumps. They operate at extremely low- yet many technicians are hamstringed by noise and low-vibration levels and are capable of working at full ineffi cient, manual processes. By combining operating pressure over a speed range of 10% to 100% in con- critical data with diagnostics capabilities, junction with speed-controlled drives. Thus, they can ideally be this real-time app helps increase productivity, adapted to the respective volume flow requirements. The flow rate reduce equipment downtime and lower the is not controlled through unloading valves in on/off technique but overall cost of maintenance. RWE supports you through an electronically controlled speed regulation of the pump. in your digital transformation towards a more As a result, wear is significantly reduced since the pump, the pipes effi cient and optimized maintenance process. and the valves are subjected to far less load. The first 530-kW quintuplex pump was quickly followed by an 800-kW model. The two versions are already produced in the series, T +49 201 12-28742 and the operators benefit from significant cost savings in terms of E [email protected] energy consumption and maintenance and service bills: Three 800- I www.rweti.com kW pumps — one each as a master, slave and standby unit, which is the common constellation — are able to generate even very large volume flows at pressures up to 3,500 bar at highly economical rates. In 2017, KAMAT added a quintuplex pump with a rating of 1,200 kW to the portfolio.

Mine Duty Air Hoists JD Neuhaus air hoists have been designed specifically for mining and other underground applications including their M series air hoists. They operate off a 4-bar pressure and can be supplied in lift capacities of 1, 2, 3 and 6 metric tons (mt). Twin chain pulls are provided for alternate working and all hoists feature a top hook mounting to accommodate oblique or horizontal pulling of loads. These products can be equipped with two optional control systems for single- or two-handed operation. The DS system, which is designed for the two-handed operation, has compressed air connected to the hand-control valve. A built-in pressure regulator prevents hoist overload in the event of inadmis-

Powering. Reliable. Future.

JD Neuhaus Profi 37 TI hoist successfully handles a 1,000-meter-long pipeline string weighing 30 metric tons, being positioned within a mining shaft.

VDMA 34 VDMA MINING SUPPLEMENT • 2018 sibly high air pressure. An oiler, situated directly at the hoist motor, Communications for Mine Rescue Equipment is operated from the controller housing to ensure the oil flow auto- Rescue operations have been and are still one of the most challeng- matically ceases when the hoist stops. The operating air immedi- ing jobs in the mining industry. During training, rescue teams of ately initiates the motor when the hand lever is activated. This lever five to six members are confronted with demanding situations that is spring-loaded and returns automatically to zero position when push them to their limits, both physically and mentally. Some of the released. This forced release also serves as an emergency stop. possible scenarios they face include bad visibility, presence of toxic The optional PS control is for single-handed use with emergency and/or explosive gases, fire and smoke, rock fall and injured miners. stop fitted as standard. It operates indirectly with a compressed air Exceptional training, which for many includes competitions at state supply connected to the control valve of the motor. The control pistons and national levels, prepare them well — to quickly assess the risks of the motor are actuated by the hand control push buttons, which au- and to know how to deal with them. tomatically return to zero position. In the control valve of the motor, a The need for a clear exchange of information is imperative in pressure regulator protects the hoist from inadmissibly high pressure, these critical circumstances, and verbal communication is usually the while the integrated oiler provides the necessary lubrication. preferred option. A rescue team needs to be able to talk to the fresh The Profi TI series hoists are also suitable for underground work- air base, the surface, to miners and to each other. Today, traditional ing and operate off air pressures of 4 or 6 bar, with hydraulically op- technology such as mining telephones is still widely used. Mine rescue erated units also available. Lift capacities from 250 kg up to 100 mt teams carry their own cables for communication. They do this for good are available with traverse trolleys for overhead monorail operation reason—it works. Unfortunately, there are certain also available for lift ratings up to 20-mt maximum capacity. limitations that could result in miscommunication, A Profi TI hoist with 37-mt lifting capacity was recently used for misunderstanding and wrong decision making. the safe and successful handling of an assembled 1,000-m string Modern communication technology has been of pipeline. This involved the connection of individual pipeline sec- available for years and is a common tool for every- tions, each 8 m long, to create a completed string weighing 30 mt, one. This same technology is used in underground which had to be positioned within a shaft. mines for a completely different challenge, however. These compact hoists offer excellent weight/load ratios, with the Here, the conditions are extreme. The rescuers face Profi 37 TI having an all-up weight of 880 kg (with a standard 10-m harsh environmental conditions, such as humidity, chain length) while providing an impressive 37.5-mt lifting capacity. water ingress, danger of collapse, risk of explosion, The elimination of any electrical power supply for drive mechanisms fire as well as excessively handled equipment. Mod- or ancillary equipment eliminates the potential for ignition risk, while ern communication needs to support the task of a increased spark-protection features ensure the highest ATEX ratings mines rescue team, not distract from it. for hazardous area operation. Hydraulically operated hoists can also be The Dräger FPS-COM 5000 is a communi- The FPS-COM 5000 communication system has provided where a compressed air supply may not be readily available. cation device that is designed to fill that gap. It been integrated into the Dräger full-face mask.

In 110 years of company history we have shaped the German and International Mining Industry with Quality and Reliability. With these values and our experience we will continue to be a reputable supplier to underground mines around the world – today and in the future.

Central Pump Station in the RAG Mine Auguste Victoria Hauhinco – The Expert in Water Hydraulic Solutions Hauhinco Maschinenfabrik, G. Hausherr, Jochums GmbH & Co. KG Beisenbruchstraße 10 | 45549 Sprockhövel | Germany 110 years [email protected] | www.hauhinco.de of excellence

2018 • VDMA MINING SUPPLEMENT VDMA 35 I

attaches to the widely used Dräger FPS 7000 RP full-face mask easily. In addition, it includes a voice amplifier that is voice activated, so it is hands free, allowing for more mobility. Every unit has an interface that connects to a radio with a cable or via Bluetooth. Connections to the most frequently used radios underground are available. All the rescuer needs to do is simply press the push-to-talk button to activate the voice communication through the radio. If a mine is already equipped with communication infrastructure and radio, the Dräger FPS-COM 5000 can be easily integrated and is ready to use for applications underground as well as above ground. In keeping with the Smart Mining vision, the FPS-COM 5000 fits as an integrated part of the communications’ sys- tem within the team and fresh air base, which is crucial in order to concentrate on the job at hand. Some mines also require cable-supported communications for its rescue teams to be able to work independently from the infrastructure When a frequency converter is used, the HMQ can pump at very different of the mine. Therefore, a version for such an application is in prepa- flow rates. ration. It would work independently from any other possible station- ary-installed system. This means that operating the Dräger FPS-COM two directions, the delivery pistons activate, by means of two cylinders, 5000 would be the same as any cable-supported communication sys- the four product diaphragms in the radial direction with respect to the tem. It would include the voice amplifier, but instead of using a radio pistons. The power transmission is ensured by the hydraulic fluid. The cable, it would connect the team to the fresh air base independently. (equal) linear deflection of the diaphragms is ensured by a mechanical First introduced at the 2016 International Mines Rescue Com- diaphragm position control. The product valves are opened accordingly petition in Canada, the Dräger FPS-COM 5000 was tested by a total to the suction stroke or the discharge stroke of the diaphragm. At each of 27 teams. The communication system was tested and tried under product side, there is one suction valve and one discharge valve. For a realistic underground rescue scenarios and received impressive, low pulsation operation, ABEL provides a special pulsation dampener, positive feedback. It was also commended as a viable and positive which is also equipped with an automatic regulation system. solution with real benefit for the future of mines rescue. The HMQ is powered electrically and, when a frequency converter is used, it is well suited for pumping at very different flow rates (gen- Variable Speed Diaphragm Pump erally at 10%-100% of the specified flow rate). Intermediate gear- The hydraulic membrane Quadruplex (HMQ) diaphragm pump is a boxes or belt/pulley systems, in case of a lower power transmission, quadruple-acting piston membrane pump. When they move in either of are used as a gear reduction between drive motor and HMQ gear.

UNIVERSA 50

Equipment Options Efficient dewatering technologies - scissor platform for mining and minerals applications - cement mixer / sprayer - diesel generator/ service support - ANFO System

ANFO System  2 tanks for optional filling (granulate/emulsion)

- Anfo storage platform for max. 120 Anfo bags - 500 l Anfo vessel As a separation special- presses, disc filters (hyper- - rotary vane compressor ist of many decades, baric and vacuum), and - telescopic platform ANDRITZ offers the most much more. comprehensive portfolio, covering sidebar and over- What’s your biggest head filter presses, cen- separation challenge? www. paus.de trifuges, heavy-duty belt ANDRITZ SEPARATION GmbH Hermann Paus Maschinenfabrik GmbH Edmund-Rumpler-Strasse 6 A 51149 Cologne, Germany Siemensstr. 1-9, 48488 Emsbüren Tel.: +49 (2203) 5752 0 [email protected] Germany andritz.com/separation

VDMA 36 VDMA MINING SUPPLEMENT • 2018 25th International Trade Fair for Coal Mining Technology, Preparation and Materials Handling NEDRA ROSSII 4th International Trade Fair for Exploitation, Processing and Refining of Metals and Industrial Minerals SAFETY & HEALTH 9th International Trade Fair for Occupational Health and Safety in the Mining Industry

www.ugol-mining.com Novokuznetsk, Russia 5 – 8 JUNE 2018

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Phone +49 (0) 2 11/45 60-77 05 _ Fax +49 (0) 2 11/45 60-85 29 [email protected] www.messe-duesseldorf.de

www.expomin.cl

XV WORLD EXHIBITION AND CONGRESS FOR LATIN AMERICAN MINING www.expomin.cl

APRIL 23 – 27, 2018 Santiago - Chile

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Phone +49 (0) 2 11/45 60-77 05 _ Fax +49 (0) 2 11/45 60-85 29 [email protected] www.messe-duesseldorf.de VDMA 38 GERMAN VENDORMATRIX

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware ABB • • • • • • • • • • • • • • • • • • • • ABEL • • • • • AEM • • • • • • • • • Air Liquide • • ALIMAK HEK • • • allmineral • • • • • ANDRITZ KMPT • • • • • • • Andritz Separation • • • Andritz Ritz • • • • apc analytics • •

VDMA MININGSUPPLEMENT AUMUND • AViTEQ • • • • BARTEC • • • • • • • • • • • • • • Bauer Maschinen • • • • • • • • • • • Becker Mining Systems • • • • • • • • • • • • • • • • • • • Bell Equipment • BEUMER • • • • • • • • • • • • • BHS-Sonthofen • • Bochumer Eisenhütte • • Bosch Rexroth • • • • • • • • • • • BRÄUTIGAM • • • • • Caterpillar Global Mining • • • • • • • • CFT • • • • • • CIV PRÄZISIONSTECHNIK • • • • Coal Control • • 2018 DEUTZ • • • DMT • • • • • Döpke • • • • 2018 • GERMAN VENDORMATRIX VDMA MININGSUPPLEMENT

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware Doppstadt Calbe • • • • • • • • Dräger Safety • • • • • • • • • • • • • • • • • • • • DÜCHTING • • • • Durum • • • • EEP • • • • • • • • • • • Eickhoff • • Eirich • • • EnviroChemie • • • • • ESI ITI • • • FAM • • • • • • • • • • • • • • Fagus GreCon • • • FELUWA Pumpen • • • Filtration Group (formerly MAHLE) • • • • • • FLSmidth Wadgassen • • • • • • • • • FLSmidth Wiesbaden • • • • • • GEA Westfalia Separator • • • • • Getriebebau Nord • GHH • • • • • • • GOTHE • • • • • • GTA • • • • • HADEF HEINRICH DE FRIES • Hammelmann • • • Hauhinco • • • • • • Haver NIAGARA • • • • • • HAWE HYDRAULIK • • • Hazemag & EPR • • • • • • • • • • • • • • • H.C. Starck Tungsten • H+E Logistik • • • • • • VDMA 39 VDMA 40 GERMAN VENDORMATRIX

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware hema • • Herrenknecht • • • • • • HYDAC • • • • • • • • • • • • Ingeteam • • • • • • • • • • • JÖST • • • • KAMAT • • • • • • • Kleemann • • Komatsu • • • • • KÖPPERN • • Krummenauer • • • •

VDMA MININGSUPPLEMENT KSB • • • • Liebherr • • • LOESCHE • • • • • • • marco • • • • MATO • • • • • • MBE Coal & Minerals • • • • • • • • • • MTU Friedrichshafen • • • • • • • • J.D. Neuhaus • • • • • • Nilos • • • • • • • • • oddesse • • • • • Paus • • • • • • PFISTER WAAGEN • • • • • PFREUNDT • • • • • • • • • • • • PLARAD • • PRAKLA • • • • • • • 2018 Preinfalk • • • • • • • • • • • • • • • • Pumpentechnik Erkrath • Putzmeister • • • • • • • • 2018 • GERMAN VENDORMATRIX VDMA MININGSUPPLEMENT

Shaft sinking Deep wellRoadway drillingRoof equipmentdriving/Heading support/ShaftExtractionExtraction &(longwall) roadwaysVentilation (vein, roomStowing & air-conditioning & pillarExtraction mining)Extraction in openSpecial pits in open (continuous) equipmentDewatering pits (truck/shovel)Blasting for (underground open Conveyingequipment pits &Shaft open& haulage winding pit)Winches underground equipment Trackless& hoistsPreparation undergroundCrushers plants vehiclesSizing & mills equipmentSorting equipmentDewatering,Briquetting proportioning,Dedusting, & granulationDewatering mixing water eq.equipmenttreatmentCoke plant ovenContinuous plant equipmentFeeding conveyor &Stockpile withdrawal & componentsDriving equipment equipment aggregatesControl equipmentPower supplyCommunication,Pneumatic navigationCompressors & hydraulicAccessories, toolsMine wear safetyServices parts Consulting/EngineeringSoftware RWE Technology International • • • • • • • • SAMSON • Sandvik Crushing Technology • SCHADE • Schaeffler Technologies • • • • Schäfer Pumpen • • • Schalker Eisenhütte • • Schopf • • Schulte Strathaus • • SEKA • SIEMAG Tecberg • • • • • • • • • • • Siemens • • • • • • • • • • • • • • • • • SMT Scharf • • • • • • • • • STEINERT • Stromag GmbH • • • • • • • • • • • • • • • • • • • • • • • • • • TAKRAF • • • • • • • • • • • • • • Thomas Magnete • • thyssenkrupp Industrial Solutions • • • • • • • • • • • • • • • TLT-Turbo • TML Technik • • • • • • Tüschen & Zimmermann • • URACA • • • • • VAUDID • • • • • • • • • • • VELCO • • VOITH TURBO • • • • • • • • • • • VULKAN • • • WILO SE • • • • • • • WIRTGEN • • • • • • VDMA 41 ABB Automation GmbH ANDRITZ Ritz GmbH Geschäftsbereich Open Pit Mining Güglingstr. 50 Bauer Maschinen GmbH Hänchener Str. 14 73529 Schwäbisch Gmünd BAUER-Str. 1 03050 Cottbus Web: www.andritz.com 86529 Schrobenhausen Web: www.abb.com/mining Web: www.bauer.de

ABEL GmbH Becker Mining Systems AG Abel-Twiete 1 Andritz Separation GmbH Walter-Becker-Straße 1 21514 Büchen Edmund-Rumpler-Str. 6A 66299 Friedrichsthal Web: www.abel.de 51149 Köln Web: www.andritz.com/separation Web: www.becker-mining.com

apc analytics GmbH AEM - Anhaltische Daimlerstrasse 17 Bell Equipment (Deutschland) GmbH Elektromotorenwerk Dessau GmbH 61449 Steinbach / Ts. Oberste Elpersweide 4 Daheimstr. 18 Web: www.apc-analytics.com 36304 Alsfeld 06842 Dessau-Rosslau Web: www.bellequipment.com Web: www.aemdessau.de

BEUMER Group GmbH & Co KG Alimak Hek GmbH AUMUND Fördertechnik GmbH Oelder Str. 40 Frauenbrunner Str. 25 Saalhoffer Str. 17 59269 Beckum 75031 Eppingen 47495 Rheinberg Web: www.beumergroup.com Web: www.alimakhek.de Web: www.aumund.com

AViTEQ Vibrationstechnik GmbH allmineral Aufbereitungstechnik Im Gotthelf 16 BHS-Sonthofen GmbH GmbH & Co KG 65795 Hattersheim An der Eisenschmelze 47 Baumstr. 45 Web: www.aviteq.de 87527 Sonthofen 47198 Duisburg Web: www.bhs-sonthofen.com Web: www.allmineral.com

BARTEC Sicherheits- Schaltanlagen GmbH BOCHUMER EISENHÜTTE ANDRITZ KMPT GmbH HEINTZMANN GMBH & CO KG Industriestrasse 1-3 Holzener Str. 35 - 37 Klosterstr. 46 85256 Vierkirchen 58708 Menden 44787 Bochum Web: www.andritz.com Web: www.bartec-mining.com Web: www.be-heico.de

VDMA 42 VDMA MINING SUPPLEMENT • 2018 Coal Control DÜCHTING PUMPEN Gesellschaft für Automation mbH Maschinenfabrik GmbH & Co KG Bosch Rexroth AG Reisholzstr. 15 Wilhelm-Düchting-Str. 22 Maria-Theresien-Str. 23 40721 Hilden 58453 Witten 97816 Lohr am Main Web: www.coal-control.com Web: www.duechting.com Web: www.boschrexroth.com

DURUM Verschleißschutz GmbH Carl-Friedrich-Benz-Str. 7 47877 Willich DEUTZ AG Web: www.durmat.com BRÄUTIGAM Gear & Mining Tech Ottostr. 1 GmbH & Co KG 51149 Köln Am Schürmannshütt 8 - 18 Web: www.deutz.com 47441 Moers Web: www.braeutigam-group.com

DMT GmbH & Co KG EEP Elektro-Elektronik Pranjic GmbH CATERPILLAR Global Mining Am Technologiepark 1 Am Luftschacht 21 Europe GmbH 45307 Essen 45886 Gelsenkirchen Industriestr. 1 Web: www.dmt-group.com Web: www.eep.de 44534 Lünen Web: www.cat.com/mining

Eickhoff Bergbautechnik GmbH CATERPILLAR Global Mining Am Eickhoffpark 1 HMS GmbH Maschinenfabrik Heinrich Döpke 44789 Bochum Karl-Funke-Str. 36 GmbH Web: www.eickhoff-international.com 44149 Dortmund Stellmacherstr. 10 Web: www.mining.cat.com 26506 Norden Web: www.doepke-gmbh.de

Maschinenfabrik Gustav Eirich CFT GmbH GmbH & Co KG Compact Filter Technic Doppstadt Calbe GmbH Walldürner Str. 50 Beisenstr. 39 - 41 Barbyer Chaussee 3 74736 Hardheim 45964 Gladbeck 39240 Calbe (Saale) Web: www.eirich.com Web: www.cft-gmbh.de Web: www.doppstadt.de

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

2018 • VDMA MINING SUPPLEMENT VDMA 43 ESI ITI GmbH Schweriner Str. 1 GEA Westfalia Separator Group H + E Logistik GmbH 01067 Dresden Werner-Habig-Str. 1 Josef-Baumann-Str. 18 Web: www.itisim.com 59302 Oelde 44805 Bochum Web: www.westfalia-separator.com Web: www.helogistik.de

FAM Förderanlagen Magdeburg und Baumaschinen GmbH Sudenburger Wuhne 47 H. C. Starck Tungsten GmbH Landsberger Str. 98 39112 Magdeburg Getriebebau Nord GmbH & Co KG 80339 München Web: www.fam.de Getriebebau-Nord-Str. 1 Web: www.hcstarck.com 22941 Bargteheide Web: www.nord.com

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

Hammelmann GmbH Carl-Zeiss-Straße 6-8 Gothe & Co GmbH 59302 Oelde Filtration Group GmbH El.-Ap. Elektro-Apparate Web: www.hammelmann.com (Formerly MAHLE Industrial Filtration) Kruppstr. 196 Schleifbachweg 45 45472 Mülheim an der Ruhr 74613 Öhringen Web: www.gothe.de Web: www.filtrationgroup.com

Hauhinco Maschinenfabrik Fagus GreCon Greten GmbH & Co KG GmbH & Co KG Hannoversche Straße 58 Beisenbruchstr. 10 FLSmidth Wadgassen GmbH 31061 Alfeld 45549 Sprockhövel Karl-Koch-Str. 1 Web: www.grecon.com 66787 Wadgassen Web: www.hauhinco.de Web: www.flsmidth.com

FLSmidth Wiesbaden GmbH GTA Maschinensysteme GmbH HAVER NIAGARA GmbH Am Klingenweg 4a Loikumer Rott 23 Robert-Bosch-Str. 6 65396 Walluf 46499 Hamminkeln 48153 Münster Web: www.flsmidth.com Web: www.gta.eu Web: www.haverniagara.com

VDMA 44 VDMA MINING SUPPLEMENT • 2018 Krummenauer GmbH & Co KG Ingeteam GmbH Wellesweilerstr. 95 Grand Bateau - Zollhof 6 66538 Neunkirchen HAWE Hydraulik SE Web: www.krummenauer.de Streitfeldstr. 25 40221 Düsseldorf 81673 München Web: www.ingeteam.com Web: www.hawe.de

JÖST GmbH + Co KG KSB Aktiengesellschaft Gewerbestr. 28 - 32 Pumpen & Anwendungen 48249 Dülmen Feststofftransport Web: www.joest.com Johann-Klein-Str. 9 67227 Frankenthal HAZEMAG Mining Web: www.ksb.com Brokweg 75 48249 Dülmen Web: www.mining.hazemag-group.com

KAMAT GmbH & Co KG Salinger Feld 10 KVT Kurlbaum AG 58454 Witten Sachsenring 4-6 Web: www.kamat.de 27711 Osterholz-Scharmbeck Web: www.kvt-group.de hema electronic GmbH Röntgenstraße 31 Kleemann GmbH Manfred-Wörner-Straße 160 Liebherr-Mining Equipment SAS 73431 Aalen 49 rue Frédéric Hartmann Web: www.hema.de 73037 Göppingen Web: www.kleemann.info 68025 Colmar, France Web: www.liebherr.com

Komatsu Germany GmbH Forststr. 29 LOESCHE GmbH Herrenknecht Mining 40597 Düsseldorf Web: www.komatsu-mining.de Hansaallee 243 Schlehenweg 2 40549 Düsseldorf 77963 Schwanau Web: www.loesche.com Web: www.herrenknecht.com

Maschinenfabrik KÖPPERN GmbH & Co KG HYDAC INTERNATIONAL GmbH Königsteiner Str. 2 Industriegebiet 45529 Hattingen 66280 Sulzbach/Saar Web: www.koeppern.com Web: www.hydac.com marco Systemanalyse und Entwicklung GmbH Hans-Böckler-Str. 2 85221 Dachau Web: www.marco.de

2018 • VDMA MINING SUPPLEMENT VDMA 45 MATO GmbH & Co KG PRAKLA Bohrtechnik GmbH Benzstr. 16 - 24 oddesse Pumpen- und Moorbeerenweg 3 63165 Mühlheim Motorenfabrik GmbH 31228 Peine Web: www.mato.de Am Pappelwald 12 Web: www.prakla.de 39387 Oschersleben Web: www.oddesse.de

WOLFGANG PREINFALK GMBH Im Oberen Werk 4 Hermann Paus Maschinenfabrik GmbH 66386 St. Ingbert MBE Coal & Minerals Siemensstr. 1 - 9 Web: www.preinfalk.de Technology GmbH 48488 Emsbüren Gottfried-Hagen-Str. 20 Web: www.paus.de 51105 Köln Web: www.mbe-cmt.com Pumpentechnik Erkrath GmbH + Co KG Max-Planck-Str. 28 40699 Erkrath MESUTRONIC Gerätebau GmbH PFISTER WAAGEN BILANCIAI GMBH Web: www.pumpentechnik-erkrath.de Hackenfeld 13 Linker Kreuthweg 9 94259 Kirchberg 86444 Affing-Mühlhausen Web: www.mesutronic.de Web: www.pfisterwaagen.de

PFREUNDT GmbH Putzmeister Solid Pumps GmbH Robert-Bosch-Str. 5 Max-Eyth.Str. 10 MTU Friedrichshafen GmbH 46354 Südlohn 72631 Aichtal Maybachplatz 1 Web: www.pfreundt.de Web: www.pmsolid.com 88045 Friedrichshafen Web: www.mtu-online.com PLAKOMA GmbH Bahnhofstr. 101 66809 Nalbach-Körprich Web: www.plakoma.de J. D. NEUHAUS GmbH & Co KG Windenstr. 2 - 4 SAMSON AG 58455 Witten MESS- UND REGELTECHNIK Web: www.jdngroup.com PLARAD Maschinenfabrik Wagner Weismüllerstr. 3 GmbH & Co KG 60314 Frankfurt Birrenbachshöhe 17 www.samson.de 53804 Much Web: www.plarad.de Nilos GmbH & Co KG Reisholzstr. 15 40721 Hilden Web: www.nilos.com

VDMA 46 VDMA MINING SUPPLEMENT • 2018 Schopf Maschinenbau GmbH Parkstr. 19 - 21 STEINERT Elektromagnetbau GmbH Sandvik Mining & Construction 73760 Ostfildern Widdersdorfer Str. 329 - 331 Crushing Technology GmbH Web: www.schopf-mining.com 50933 Köln Friedrich-Ebert-Str. 75 Web: www.steinert.de 51429 Bergisch Gladbach Web: www.sandvik.com

F. E. Schulte Strathaus GmbH & Co KG Fördertechnik - Dichtungssysteme Stromag GmbH Runtestr. 42 Hansastr. 120 59457 Werl 59425 Unna SCHADE Lagertechnik GmbH Web: www.fess-group.de Web: www.stromag.com Bruchstraße 1 45883 Gelsenkirchen Web: www.schade-lagertechnik.com

TAKRAF GmbH Torgauer Str. 336 SEKA Schutzbelüftung GmbH 04347 Leipzig Schäfer Pumpen & Hydraulik GmbH Im Höger 4 a Web: www.takraf.com Kaiserswerther Str. 74 76829 Landau 40878 Ratingen Web: www.schutzbelueftung.de Web: www.schaefer-ph.com

Thomas Magnete GmbH San Fernando 35 Schaeffler Technologies AG & Co KG 57562 Herdorf Georg-Schäfer-Straße 30 SIEMAG TECBERG GmbH Web: www.thomas.magnete.com 97421 Schweinfurt Kalteiche-Ring 28-32 Web: www.schaeffler.de/ 35708 Haiger rohstoffgewinnung_verarbeitung Web: www.siemag-tecberg.com

Schalker Eisenhütte Maschinenfabrik GmbH Siemens AG thyssenkrupp Industrial Solutions AG Am Eickhoffpark 1 Process Industries and Drives Division thyssenkrupp Allee 1 44789 Bochum Schuhstr. 60 45143 Essen Web: www.schalke.eu 91052 Erlangen Web: www.thyssenkrupp-industrial- Web: www.siemens.com/mining solutions.com

Schenck Process Europe GmbH Pallaswiesenstraße 100 SMT Scharf GmbH 64293 Darmstadt Römerstr. 104 Web: www.schenckprocess.com 59075 Hamm Web: www.smtscharf.com TLT-Turbo GmbH Gleiwitzstr. 7 66482 Zweibrücken Web: www.tlt-turbo.com

2018 • VDMA MINING SUPPLEMENT VDMA 47 VULKAN Kupplungs- und Getriebebau Bernhard Hackforth GmbH & Co KG TML Technik GmbH Heerstr. 66 Daimlerstr. 14 - 16 44634 Herne 40789 Monheim VAUTID GmbH Web: www.vulkan.com Web: www.tml-technik.com Brunnwiesenstr. 5 73760 Ostfildern Web: www.vautid.com

WILO SE Nortkirchenstr. 100 Tüschen & Zimmermann 44263 Dortmund GmbH & Co KG VELCO Gesellschaft für Förder- Web: www.wilo.com Winterberger Str. 82 Spritz- und Siloanlagen mbH 57368 Lennestadt Haberstr. 40 Web: www.tueschen-zimmermann.de 42551 Velbert Web: www.velco.de WIRTGEN GmbH Reinhard-Wirtgen-Str. 2 53578 Windhagen URACA GmbH & Co KG Web: www.wirtgen.de Sirchinger Str. 15 Voith Turbo GmbH & Co KG 72574 Bad Urach Voithstr. 1 Web: www.uraca.de 74564 Crailsheim Web: www.voith.com

ADVERTISING INDEX

ABB Automation GmbH...... VDMA 3 Liebherr Holding GmbH ...... VDMA 21

Andritz Separation GmbH...... VDMA 36 Loesche GmbH...... VDMA 9

Beumer Group GmbH & Co KG...... VDMA 5 Messe Düsseldorf GmbH...... VDMA 37

Eickhoff Bergbautechnik GmbH...... VDMA 15, VDMA 17 RWE Power International RE GmbH ...... VDMA 34

Erlau AG...... VDMA 33 SIEMAG TECBERG GmbH ...... VDMA 11

Expomin 2018 ...... VDMA 37 Siemens Industry International ...... VDMA 23

TAKRAF GmbH ...... VDMA IFC, VDMA IBC Hauhinco Maschinenfabrik G. Hausherr, Jochums GmbH & Co KG ...... VDMA 35 UGOL ROSSII & Mining 2018 ...... VDMA 37

Hermann Paus Maschinenfabrik GmbH...... VDMA 36 Voith Turbo GmbH & Co KG...... VDMA 29

Kamat Pumpen GmbH & Co KG ...... VDMA BC Wirtgen GmbH...... VDMA 25

VDMA 48 VDMA MINING SUPPLEMENT • 2018 VDMA SUPPLEMENT PROFILE

PAID ADVERTISEMENT

TAKRAF dry stack tailings management systems

Water is life. The world’s water is increasingly The DELKOR sedimentation method using high dry stack tailings can be rehabilitated and blend being degraded in quality and a new approach compaction thickeners produces one of the with the natural environment. to the manner in which we plan, manage and highest concentrations of solids in the industry. TAKRAF’s depth and breadth of dry stack use water is needed. The issue of sustainable The DELKOR thickening process increases wa- tailings equipment includes: overland convey- water management is thus becoming increas- ter recovery reducing the requirement for fresh ors, mobile overland trippers, mobile stacking ingly important to global mining operations, water and overall environmental impact. conveyors, and mobile trippers/spreaders. especially in areas where water conservation is critical, and the employment of dry stack tailings management systems is a tangible approach to sustainable water management. Dry stack facilities offer a number of ad- vantages to other surface tailings storage op- tions – some of these include: • Reduced water requirements, principally achieved by recycling process water and near elimination of water losses through seepage and/or evaporation • Groundwater contamination through seepage is virtually eliminated • Significant safety improvement with the risk of catastrophic failure and tailings runout being eliminated. Dry stack facilities are also suitable Filtration The DELKOR proprietary Fluid Actuated Screw to areas of high seismic activity and areas Technology (F.A.S.T.TM) filter press is designed where there is limited construction material to to replace a traditional high pressure system develop a conventional retention impoundment with a fully automatic filter press without a hy- • Smaller tailings footprint and can be used in draulic system. The system is designed for “aggressive environments” (e.g. undulating flexible operation and easy maintenance by and steep terrain) employing a cushioned screw. Approximately • Significantly better regulator and public 85% of the moisture can be removed during the perceptions filtration process enabling concurrent water re- • Easier to close and rehabilitate. covery and a reduced requirement for fresh wa- ter. After the filtration process, the tailings can Our competence in dry stack tailings then be transported by conveyor. management systems TAKRAF with their roots dating back to 1725, together with the integrated DELKOR brand of products, boasts significant competence in dry stack tailings systems: • Decades of experience in engineering and building of conveyor and stacker systems • Strong expertise in high yield stress underflow with DELKOR high compaction thickener products • Developed global network for local technical support and site services • Experienced tailings deposition planning team. Mobile conveyor stacking bridge Dry stack tailings equipment: systems and spreaders • DELKOR thickeners TAKRAF’s mobile conveyor stacking bridge • DELKOR F.A.S.T.TM filter presses which boast systems provide an efficient, reliable and easy the following technical highlights: to operate bulk material handling solution for o Up to 21 m3 per batch transporting and storing filtered tailings. This o Cushioned screw technology for higher method maximizes throughput to maintain plant feed pressures, greater filter plate utiliza- uptime. By stacking compacted tailings, land tion and longevity requirements are reduced and the risk of cat- • Overland and shiftable conveyors astrophic dam failures is eliminated. Conven- • Mobile trippers tional tailings storage methods incur costs post- • Mobile conveyor stacking bridges which boast mine closeout due to maintenance; however, the following technical highlights: o Length span of 500 m o Transport up to 12,000 tph o Discharge boom outreach of up to 20 m • Single or double-boom spreader.

Sedimentation thickeners DELKOR takes its knowledge and experience of over 30 years providing thickeners for the mining industry and applies it to the extreme mechanical and process requirements needed when dealing with high yield stress underflows. LESS IS MORE

Where others need more pumps, we simply use bigger ones. Our 5-plunger-pumps provide power - up to 800 kW. When using a variable speed drive, the range of adjustment is between 10 % to 100 %. Your advantages: less pumps, less service, longer lifetime and higher availability, energy savings. Plus: only one of the pumps in the system needs to be run by a variable speed drive.

THIS REDUCES YOUR CAPITAL INVESTMENT.

Smooth operation at bigger flows

Product data Parameters 1185 l/min (max) at 350 bar Fluid Viscosity < 2000 mPas 763 l/min (typ) at 360 bar Input power 800 kW (max) up to 641 l/min at 430 bar (max) Operating Pressure 3 500 bar (max) without boosterpressure

HIGH PRESSURE PLUNGER PUMPS AND SYSTEMS

KAMAT GmbH & Co. KG . Salinger Feld 10 . 58454 Witten . Germany Phone: +49 2302 8903-0 . Fax: +49 2302 801917 . Mail: [email protected] . www.KAMAT.de