VDMA_2014 Cover 991_VDMA_2014 Cover 991 1/14/14 11:13 AM Page FC1 Mining Equipment and Technology BEST OF GERMANY 2014 A supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal Age China, Coal Age Russia, Coal Age India, Coal Age Indonesia, The ASIA Miner and Mining & Technology Australia In cooperation with VDMA VDMA_IFC 992_VDMA_IFC 992 1/8/14 10:02 AM Page IFC1 VDMA_pg01_VDMA_pg01 1/16/14 10:22 AM Page 1 Foreword: Welcome to the 2014 edition of Best of Germany, highlighting the expertise of companies that sup- Germanply equipment andMining services to theTechnology exploration, mining and Serves mineral-processing the Global industries worldwide, VDMA and are members of the German Engineering Federation (VDMA). Expertise in engineering is not eas- ily achieved; it requires dedication and a long-term vision. Many of these companies have histories that date back to the 19th century, and they understand the cyclic nature of commodity markets. The situation in the mining sector has changed in the last 18 months. Prices for most mined commodities have softened and mining companies have tabled ambitious future plans. Even though the level of investment for new projects has declined for the moment, miners will still produce sig- nificant amounts of gold, copper, iron ore, nickel, potash, coal, oil sands and more. The difference today is that they are looking to optimize processes to not only improve profit margins, but to also compensate for a lack of skilled labor and a growing regulatory burden. Through innovation and continued investment in research and development, German equipment and service providers are meeting the needs of today’s miners. This edition of Best of Germany focuses on work being done by VDMA mining branch member companies to increase efficiencies, optimize operating costs, and improve safety underground, on the surface and at the mill. We hope that you find value in this publication, wherever you are in the world. Glückauf! Dr. Paul Rheinländer President of the VDMA-Mining Equipment Association VDMA, the German Engineering Federation, Mining Equipment Association Lyoner Strasse 18 D-60528 Frankfurt Germany Table of Contents: A Special Supplement to Your Contacts in the Mining Equipment Association (MEA) ............................................................2 Engineering & Mining Journal (E&MJ) Produced by Mining Media International Miners Looking to Optimize Operations Can Rely on German Engineering Expertise ......................4 11555 Central Parkway, Suite 401 Jacksonville, FL 32224, USA Surface Mining: Increasing Productivity and Reliability ..................................................................6 Tel: +1-904-721-2925 Fax: +1-904-721-2930 Underground Mining: Longwalls Mine Safely at Low Cost Per Ton ................................................12 www.mining-media.com Copyright 2014 Mining Media Int’l Customized System Solutions for Bulk Materials ..........................................................................25 Mineral Processing: Magnetic Separators Reduce Energy Consumption for Iron Ore Recovery ......30 Sponsor: German Engineering Federation Innovations: Modern Storage and Reclamation..............................................................................38 Verband Deutscher Maschinen- und Anlagenbau (VDMA) e.V. Energy Efficient Pumps Help RWE Save Energy ............................................................................48 Lyoner Str. 18, D-60528 Frankfurt/Main Tel: +49-6966-031262 Safety: De-dusting Technology for Underground Mining ................................................................52 Fax: +49-6966-032262 www.vdma.org Vendor Matrix and Buyers Guide ....................................................................................................54 Articles in this publication were researched and written by Steve Fiscor, editor-in-chief of Engineering & Mining Journal (E&MJ) and Coal Age. For additional information about the articles or the manufacturers highlighted here, please contact Mining Media International ([email protected]). Published by Mining Media Int’l in cooperation with the VDMA EQUIPOEQUIPO | INGENIERÍAINGENIERÍA | TECNOLOGÍATECNOLOGÍA 2014 • VDMA MINING SUPPLEMENT VDMA 1 VDMA_pg02-03_VDMA_pg02-03 1/14/14 11:34 AM Page 2 Your Contacts in the VDMA Mining Equipment Association Joachim Schmid Klaus Stöckmann Managing Director Deputy Managing Director Phone: + 49 69 6603-1261 Economy and statistics, trade fairs, Fax: + 49 69 6603-2261 markets Asia and Australia Email: [email protected] Phone: + 49 69 6603-1270 Fax: + 49 69 6603-2270 Email: [email protected] Helmut Schgeiner Monika Bind Director Manager Markets Technology, standardization and research, CIS and Russia markets Europe, Africa, USA and Canada Phone: + 49 69 6603-1262 Phone: + 49 69 6603-1680 Fax: + 49 69 6603-2262 Fax: + 49 69 6603-2680 Email: [email protected] Email: [email protected] Alessandro Colucci Yvonne Golle Director Markets Assistance Latin America Phone: + 49 69 6603-1577 Phone: + 49 69 6603-1254 Fax: + 49 69 6603-2577 Fax: + 49 69 6603-2254 [email protected] Email: [email protected] Alexandra Landgraf Rajesh Nath Assistance Chief Representative Phone: + 49 69 6603-1577 VDMA Representative Office India Fax: + 49 69 6603-2577 Phone: + 91 33 2321-9522/7391 Email: [email protected] Fax: + 91 33 2321-7073 Email: [email protected] Stephanie Heydolph Thomas Junqueira Chief Representative Ayres Ulbrich VDMA Representative Office China Chief Representative Phone: + 86 10 87730212-808 VDMA Representative Office Brazil Fax: + 86 10 877302-09 Phone: + 55 11 430580-42/-43 Email: [email protected] Fax: +55 11 3078 4335 Email: [email protected] Volkmar Clauß Holger Wittich Chief Representative Chief Representative VDMA Representative Office Russia VDMA Representative Office Japan Phone: + 7 499 41803-71 Phone: + 81 3 3363-6632 Fax: + 7 499 41803-72 Fax: + 81 3 3363-7582 Email: [email protected] Email: [email protected] VDMA 2 VDMA MINING SUPPLEMENT • 2014 VDMA_pg02-03_VDMA_pg02-03 1/14/14 11:34 AM Page 3 VDMA_pg04-05_VDMA_pg04-05 1/16/14 2:02 PM Page 4 Miners Looking to Optimize VDMA Operations Can Rely on German Engineering Expertise Business plans among mine operators worldwide have changed. Cost control is benefiting small- and medium-sized compa- Instead of bringing as much capacity online as quickly as possi- nies in other ways, particularly for mine and plant construction ble, their attention has now turned to improving the bottom line. projects. “We see more mining companies refusing to purchase And, that might be a good thing for German mining equipment through ‘bundled contracts,’ where an engineering firm selects suppliers and service providers. This was one of the messages all of the equipment from a small group of providers,” Dr. Paul Rhinelander, president of the German Engineering Rhinelander said. “By opening these contracts to competitive Federation’s mining branch (VDMA), presented at a press confer- bids, the mining companies are essentially unbundling the pur- ence held during the branch’s annual meeting at the Zollverein chasing decisions for equipment, each of which could be worth mine in Essen during late November. many millions of euros. These smaller lots are more attractive for Similar to all equipment and service providers, the 130 or so medium-sized companies. This makes it possible for our medi- members of VDMA’s mining branch benefited from the mining um-sized companies to actively participate, which we could not super cycle that has recently stalled. “Looking back at an unri- do in the past. This approach has resulted in orders, which is a valed history of success, we nearly tripled our revenues during positive development for our branch.” the past 10 years. In the past year alone [2012], we have grown 28% to €6.2 billion [$8.5 billion],” Rhinelander said. “For the Regional Markets current year [2013], we expect, based on the figures of the first In Europe, Germany is by far the largest market, but that pales nine months, further low single-digit growth, maybe a 1% to 2% in comparison to the groups’ exports. For 2013, the VDMA was increase to about €6.3 billion [$8.6 billion].” At that point, expecting a decrease of revenues for the European market of Rhinelander believes their group has reached the peak of a cycle. about 4% to €430 million ($589 million). Revenues related to He has predicted a two-digit percentage decrease for 2014 surface mining remain relatively constant and the group expects before business stabilizes or rebounds in 2015. a similar outcome in 2014, an additional decline of 4% with While this forecast for immediate business seems a bit dire, total revenues dropping to €400 and €430 million. one has to consider the context; this small group of mostly pri- “A large portion of future revenue will be affected by vately held, medium-sized companies actually performed quite Germany’s new energy law and how the government will handle well compared to its peers during the last five years. The mining this,” Rhinelander said. “Lignite-fired power plants are running sector felt the impact of the recession brought about by the U.S. at full capacity and coal consumption has decreased. Mine real estate meltdown and European debt crisis, but it recovered operators in the region are looking at different ways to cut costs quickly. Unlike the manufacturing and construction industries, and save money. In addition to that, the few hard-coal mines that which