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BEST OF GERMANY
2017
Mining Equipment
and Technology
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 GmbHTorgauer Straße 33604347 Leipzig, [email protected]
TAKRAF is a key equipment and systems partner
for open pit mining and bulk handling, having
provided hundreds of complete systems, as well
as individual machines, to clients all over the
world. Based upon more than a century of
experience and know-how, the product range
stretches from overburden removal, raw material
extraction, conveying, processing, comminution,
homogenizing, blending and storage to onward
transport or shipment.
TAKRAF has committed to both environmental
and social sustainability in their business
interactions and has adopted a Zero harm
approach to safety under the SAFETY FIRST
promise of the Tenova Group.
Tenova, a Techint Group company, is a worldwide partner
for innovative, reliable and sustainable solutions in the
mining and metals industries. www.tenova.com
This is what our engineers say:
«We continue to innovate and our
conveying solutions often push the
boundaries in terms of what’s been done
before across such areas as installed
drive power, direct-drive technology,
distance between pulley centers,
belt quality, overall distance
and capacity.
My engineering team
enjoys a challenge!»
VDMA 12017 • VDMA MINING SUPPLEMENT
Foreword: Committed to the Mining SphereWelcome to the 2017 edition of the Best of Germany, which highlights the expertise of the companies
that provide equipment and services to the mining and mineral processing industries worldwide. We
believe the mining industry will soon experience a positive change after several years of austerity.
The member companies of the Mining Equipment Association of the German Engineering
Federation (VDMA Mining) have had to apply similar conservative measures to cope during this period
as well, and they are looking forward to an improvement in the mining business. Most VDMA Mining
members are diversifi ed, privately held companies that relied on their fi nancial resources to maintain
the needed skill sets. And, today, we can say with pride that the member companies have managed
to retain the craftsman and engineering expertise to produce high-quality equipment.
It’s true. We have competitors who offer less expensive equipment and services. This approach
lessens the immediate capital outlay. Mining projects, however, are designed to operate 15 years
or more and, when one considers the total cost of ownership, it’s diffi cult to compete with German
craftsmanship.
One of the recurring themes in the Best of Germany 2017 is the use of technology to enhance
operations. The dip in new equipment sales allowed VDMA Mining members to focus their attention
on potential effi ciency improvements for mining and milling operations and to possibly rethink future
production strategies.
The VDMA Mining members did not give up on the global mining business and they are now better
prepared to deliver when the industry recovers once again. Committed to the mining sphere, Germany
remains a step ahead. This edition of the Best of Germany highlights the direction VDMA Mining
members have taken, and we hope that you fi nd value in this publication.
Glückauf!
Dr. Michael Schulte Strathaus
Chairman
VDMA Mining
Table of Contents:
Your Contacts in the Mining Equipment Association ......................................................................... 2
VDMA Mining Looks Past the Recession ............................................................................................ 4
Surface Mining: Increasing Reliability and Productivity .................................................................... 6
Health and Safety: A Safe Haven Underground................................................................................ 15
Underground Mining: Where Power Meets Safety ............................................................................. 18
Material Handling: Moving Minerals................................................................................................ 25
Mineral Processing: Recovering More With Less .............................................................................. 32
Innovations: Renewable Energy Reduces Mining Costs ................................................................... 34
Vendor Matrix and Buyers Guide ...................................................................................................... 38
A Special Supplement to:
Engineering & Mining Journal (E&MJ)
and Coal Age
Produced by:
Mining Media International Inc.
11655 Central Parkway, Suite 306
Jacksonville, FL, 32224, USA
Tel: +1-904-721-2925
Fax: +1-904-721-2930
www.mining-media.com
Copyright 2017 Mining Media Int’l, Inc.
Sponsor:
German Engineering Federation Verband
Deutscher Maschinen und Anlagenbau
(VDMA) e.V.
Lyoner Str. 18, D-60528 Frankfurt/Main
Tel: +49-6966-031262
Fax: +49-6966-032262
www.vdma.org
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, please contact Mining Media International Inc. ([email protected]).
EQUIPO | INGENIERÍA | TECNOLOGÍA
Published by Mining
Media International
in cooperation with
VDMA Mining
VDMA 2 VDMA MINING SUPPLEMENT • 2017
Joachim Schmid Managing Director
Phone: + 49 69 6603-1261
Fax: + 49 69 6603-2261
Email: [email protected]
Helmut Schgeiner Director
Technology, standardization and research,
markets Europe, Africa, USA and Canada
Phone: + 49 69 6603-1680
Fax: + 49 69 6603-2680
Email: [email protected]
Christoph Danner Manager Markets
Latin America
Phone: + 49 69 6603-1254
Fax: + 49 69 6603-2254
Email: [email protected]
Alexandra Landgraf Assistance
Phone: + 49 69 6603-1577
Fax: + 49 69 6603-2577
Email: [email protected]
Rajesh Nath Chief Representative
VDMA Representative Offi ce India
Phone: + 91 33 40602364
Fax: +91 33 23 21 70 73
Email: [email protected]
Sven Flasshoff Chief Representative
VDMA Representative Offi ce Russia
Phone: + 7 499 41803-71
Fax: + 7 499 41803-72
Email: sven.fl [email protected]
Your Contacts in theMining Equipment Association
Klaus Stöckmann Deputy Managing Director
Economy and statistics, trade fairs,
markets Asia and Australia
Phone: + 49 69 6603-1270
Fax: + 49 69 6603-2270
Email: [email protected]
Monika Bind Manager Markets
CIS and Russia
Phone: + 49 69 6603-1262
Fax: + 49 69 6603-2262
Email: [email protected]
Jörn LehmannManager Standardization
Phone: + 49 69 6603-1134
Fax: + 49 69 6603-2134
Email: [email protected]
Yvonne Golle Assistance
Phone: + 49 69 6603-1577
Fax: + 49 69 6603-2577
Email: [email protected]
Thomas JunqueiraAyres Ulbrich Chief Representative
VDMA Representative Offi ce Brazil
Phone: + 55 11 430580-42/-43
Fax: +55 11 3078 4335
Email: [email protected]
Claudia BarkowskyChief Representative
VDMA Representative Offi ce China - Beijing
Phone: +86 10 87 73 02 12-8 08
Fax: +86 10 87 73 02 09
Email: [email protected]
Joachim Schmid Managing Director
Phone: + 49 69 6603-1261
Fax: + 49 69 6603-2261
Email: [email protected]
Helmut Schgeiner Director
Technology, standardization and research,
markets Europe, Africa, USA and Canada
Phone: + 49 69 6603-1680
Fax: + 49 69 6603-2680
Email: [email protected]
Christoph Danner Manager Markets
Latin America
Phone: + 49 69 6603-1254
Fax: + 49 69 6603-2254
Email: [email protected]
Alexandra Landgraf Assistance
Phone: + 49 69 6603-1577
Fax: + 49 69 6603-2577
Email: [email protected]
Rajesh Nath Chief Representative
VDMA Representative Offi ce India
Phone: + 91 33 40602364
Fax: +91 33 23 21 70 73
Email: [email protected]
Sven Flasshoff Chief Representative
VDMA Representative Offi ce Russia
Phone: + 7 499 41803-71
Fax: + 7 499 41803-72
Email: sven.fl [email protected]
Klaus Stöckmann Deputy Managing Director
Economy and statistics, trade fairs,
markets Asia and Australia
Phone: + 49 69 6603-1270
Fax: + 49 69 6603-2270
Email: [email protected]
Monika Bind Manager Markets
CIS and Russia
Phone: + 49 69 6603-1262
Fax: + 49 69 6603-2262
Email: [email protected]
Jörn LehmannManager Standardization
Phone: + 49 69 6603-1134
Fax: + 49 69 6603-2134
Email: [email protected]
Yvonne Golle Assistance
Phone: + 49 69 6603-1577
Fax: + 49 69 6603-2577
Email: [email protected]
Thomas JunqueiraAyres Ulbrich Chief Representative
VDMA Representative Offi ce Brazil
Phone: + 55 11 430580-42/-43
Fax: +55 11 3078 4335
Email: [email protected]
Claudia BarkowskyChief Representative
VDMA Representative Offi ce China - Beijing
Phone: +86 10 87 73 02 12-8 08
Fax: +86 10 87 73 02 09
Email: [email protected]
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VDMA 4 VDMA MINING SUPPLEMENT • 2017
Last year was a difficult year for the mining business and the com-
panies that serve it. Coal production and consumption, which rep-
resents the largest investment by commodity, declined significantly
in both China and the U.S. While the situation for metal/nonmetal
mining was not nearly as stark, many of the mining companies took
a conservative approach to capital spending, opting for efficiency
improvements and brownfield expansions rather than greenfield
construction and purchasing new equipment.
Following a decline in turnover of approximately 21%, down
to EUR 2.8 billion in 2016, German equipment suppliers foresee
stabilization in 2017 and they are preparing for improved business
in 2018.
Speaking at its annual meeting at the Zollverein coal mine in
Essen, Germany, during November, Chairman of the Mining Equip-
ment Association of the German Engineering Federation (VDMA
Mining) Dr. Michael Schulte Strathaus said he believes that rising
raw material prices and the mining industry’s willingness to invest
again will bring an end to the days of two-figure declines in turn-
over. “In the third quarter of this year, mining equipment manufac-
turers registered a 12% increase in incoming orders in comparison
to the same period the previous year,” Schulte Strathaus said. “The
respective index rose over the same period from 61 to 80 points.
However, the period from the receipt of an order to its settlement can
run up to 15 months. The renewed increase in turnover can therefore
be anticipated in early 2018.”
Statistics indicate that the industry has reached the bottom of
the cycle. Mining companies are realizing profits again and soon
they will invest in more machinery and equipment.
Managing Through the TroughRegarding the significant drop in revenues, comparing the first nine
months of 2016 against 2015, revenues in Germany fell 36% to
around 200 million euros and 21% for exports to just under 2.6
billion euros. “Growth rates of more than 10%, as we had in 2012,
will hardly be possible in the foreseeable future,” Schulte Strathaus
said. “We will more likely be talking about 2%-4%, but we expect
the mining market to stabilize this year and begin to grow again.”
Despite this not exactly simple situation, the companies have
succeeded in maintaining a steady workforce of 12,000 employees.
“Our member companies have, by dint of strenuous efforts, kept
their permanent staff,” Schulte Strathaus said.
VDMA Mining’s domestic business continues to decline. Schulte
Strathaus ascribes the domestic decline to missing contracts in the
hard coal industry. The last German hard coal mine will close in
2018. Brown coal, potash and salt and stone are still mined.
“Germany operates a small-scale, incalculable energy policy
that is not always understandable in terms of energy economics,”
Schulte Strathaus said. “Although no substitute is available, the en-
ergy supply guaranteed by brown coal is undermined. Incomprehen-
sible decisions on energy policy are made based on national environ-
mental requirements that go well beyond European or international
agreements. What the politicians lack is a reasonable plan and it is
affecting manufacturing in Germany with higher electrical costs.”
Healthy Prospects WorldwideThe largest export market for German mining equipment man-
ufacturers is the European Union, which represents 20% of the
mining-related exports. In the past, this fact has shifted into the
background due to the large single markets in China, Russia and
VDMA Mining Looks Past
the Recession
VDMA 52017 • VDMA MINING SUPPLEMENT
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For more information, visit www.beumergroup.com
the U.S., Schulte Strathaus explained. Business is robust with the
United Kingdom, Italy and France. Demand exists in particular for
machinery used in tunnel construction. At a minimum, similar turn-
over is assumed for the coming year.
Schulte Strathaus also reported robust business with Turkey. In
terms of raw materials, the country is increasingly investing in self-
sufficiency to reinforce its economic foundations and to reduce its de-
pendence on imports from abroad. This is relevant with respect to en-
ergy supply from coal as well as to manufacturing industrial metals.
The second most important turnover region, with a share of
11%, is Africa, Northern Africa in particular. Since 2014, VDMA
Mining exports to this region have almost tripled. The largest mar-
kets are Egypt and Algeria. Sales are based first and foremost on
machinery and plants related to infrastructure projects. “It’s not
about machines and equipment for the mining industry, but mainly
for infrastructure projects, such as the four road and railway tunnels
underneath the new Suez Canal,” Schulte Strathaus said. “Africa
is developing further and further, not least with massive financial
and human support for China. For the coming year, however, we are
expecting further moderate increases in exports.”
The third largest market is the U.S. Approximately 10% of ex-
ports make their way to the U.S. Sales are based mainly on pro-
cessing technology and excavating machinery. Schulte Strathaus
expresses doubt as to whether mines will continue to close and coal
mining will continuously be reduced under the new administration.
“President Trump has not only promised to preserve jobs in this sec-
tor, but to even create new ones,” Schulte Strathaus said, and VDMA
Mining assumes that its share of U.S. exports will grow in 2017.
Latin America is VDMA Mining’s fourth-largest export des-
tination, accounting for about 7% of total exports. These mining
operations have seen profits recover along with improving metals
prices. “Higher liquidity and the prospect of further profits does not
necessarily lead to more investment,” Schulte Strathaus said. “Po-
litical stability is important. This can be seen especially in Brazil
and Venezuela, when compared to Peru, Mexico and Chile.”
In China and Russia, which ranked 6% and 5%, respectively, for
VDMA Mining, the situation is quite different. German-Russian rela-
tions in the mining sector can still be described as good and intact.
After the imposition of sanctions, many of VDMA Mining’s customers
sought equipment and services from China. “That has not worked
out as promised,” Schulte Strathaus said. “For a number of compa-
nies, Russia continues to be of great importance as a sales market.”
This is also true for China, he explained. “There is, however, con-
siderable uncertainty among our member companies about how the
country will evolve,” Schulte Strathaus said. “China must balance
increased environmental protection and rising energy demand. The
views of VDMA Mining is divided. On the one hand, they expect it to be
better and on the other, they expect business to get worse. The latter
sentiments mostly apply to underground mining, especially coal.” It’s
different for open-cast mining. Here, good orders are still expected by
VDMA Mining, but overall they expect a slight decrease in exports.
Schulte Strathaus sees the increasing diversification among
companies represented by VDMA Mining as a positive step. New
products are increasingly brought into the market and new export
regions are also being established. Meanwhile, virtually all the
renowned manufacturers that sold exclusively to coal are offer-
ing machinery for hard rock mining. This is resonating positively
among purchasers on the whole. Schulte Strathaus announced a
Europe-wide networking of companies. Thus, it should become pos-
sible among other things to bring new products into the market to-
gether, with greater impact.
VDMA 6 VDMA MINING SUPPLEMENT • 2017
By any standard, the machines employed by modern open-pit mines
to extract, load and haul rock are some of the largest pieces of
equipment on Earth. Moreover, these machines are expected to per-
form at the same optimum level as any other operation. Reliability
is extra important. Having a bucketwheel, a dragline, a shovel or
a couple of haul trucks down for even a shift can be an incredibly
costly proposition.
These large pieces of equipment also rely on a host of support
equipment. With conventional mining processes, dozers clear the
bench for the shovels, while front-end loaders keep the loading area
clean, reducing tire damage on the trucks. Sometimes those same
loaders can be the primary loading tool.
Engineers today are looking beyond conventional load-and-haul
strategies to more continuous material handling methods, such as
in-pit crushing and conveying (IPCC). These systems could also be
used in connection with continuous mining systems, such as sur-
face miners and bucketwheel excavators.
The theme of this edition of the Best of Germany is “Commit-
ment to the Mining Space,” and Liebherr Mining identifies strongly
with that. The company is privately held with a long-term vision and
they support the mining industry during good times and the not so
good times, albeit with a bit more diversification than others.
For the open-pit mining sector, Liebherr supplies equipment for
loading, hauling and pushing rock. This type of equipment requires
an extended lead time to manufacture. Similar to a mining opera-
tion, an equipment manufacturer cannot simply turn the truck or
excavator factory on and off at the flip of a switch. For the last
few years, Liebherr managed to keep most of their people in place
and they also invested in their manufacturing facilities and a few
new service and support facilities in mining districts. When miners
return to the market for new equipment, they will be prepared.
In the meantime, the company has also been working to improve
its service and customer support strategies. Liebherr continues to
integrate vertically. A prime example is the expanded use of the Li-
ebherr electronic (or Litronic) system, which integrates the AC drives
with the drivetrain in the case of the haul truck. Last year, they also
unveiled the new V-diesel engine D9812, which has a power rating
up to 2,700 hp (2,015 kW). “The real message here is that we con-
tinue to invest in the development of our own components,” said Dr.
Joerg Lukowski, executive vice president, mining equipment, for Li-
ebherr. “Next door to the excavator factory in Colmar, we have built a
high-horsepower engine factory. Since we have started to introduce
the Liebherr engines in our 100-ton diggers, we have more and more
customers already asking for Liebherr engines in the larger diggers
and in the trucks. People are excited about them, but we need to
prove the engines are reliable and fuel efficient.”
Liebherr invested in a new service center in Adelaide, an iron
ore support center in Newman, a parts facility in Perth, a new ser-
vice center in Siberia and a new facility for the oils sands in Fort
Mackay, Alberta. “We have target markets and we continuously
invest in those regions,” Lukowski said. “Liebherr Australia for
example is already well-established throughout the continent, but
still we continue to invest. We needed a remanufacturing facili-
ty in Adelaide and we decided to build one. In the Americas, we
do not have as great a presence as we would like and so we put
focus here to expand our project base. If we have an individual
project somewhere that needs support, we will make an on-site
investment with a repair facility and spare parts. If more projects
appear nearby, we may decide to invest in a full-service facility. In
markets where we have critical mass, we usually then finally build
a Liebherr-owned company.”
Surface Mining: Increasing
Reliability and Productivity Ultimately, the lowest cost per ton prevails
Liebherr’s T 284 haul truck has a 400-ton payload, the highest in the industry.
Ground engaging tools (GET) has been a very successful aftermarket item
for Liebherr.
Liebherr T 264 – Technology for Your Excellence
Superior speed on grade through highly efficient power train
Low fuel burn due to efficient Litronic Plus drive system
Class-leading fuel economy extends operation
Simplified design for reduced maintenance time and increased service interval
OEM quality engineered and built components deliver maximum uptime
Experience the Progress.
Liebherr-Mining Equipment Colmar SAS49 rue Frédéric Hartmann - CS 5003868025 Colmar CedexPhone: +33 369 49 20 00E-mail : [email protected]/LiebherrMiningwww.liebherr.com
VDMA 8 VDMA MINING SUPPLEMENT • 2017
Liebherr introduced the R 9200 hydraulic excavator to the North
American mining market at MINExpo 2016. Equipped with an ad-
vanced package of ground engaging tools (GET), the 9200 has a
16.3-yd3 (12.5-m3) bucket capacity, which offers the biggest pay-
load in its class. This new 200-ton machine is designed to match
mining trucks with payloads of up to 140 tons. “The GET has been
a very successful aftermarket item for us and it has been received
well by many customers,” Lukowski said.
Liebherr has also added high-performance kits for its hydrau-
lic excavators. Lukowski explained: “We have also used a targeted
approach to reduce the weight of the attachment while maintaining
the lifetime of the components. We have seen as much as a 13%
gain on the large mining excavators.”
The Litronic systems for the haul trucks has been developed
through a similar evolutionary process that started with the 282
and then became available with the 284 and the 236. “It’s different
systems working together, it’s not just one element or one part in
a haul truck,” Lukowski said. “It’s a combination of several com-
ponents that increase productivity and efficiency. We have demon-
strated it on the 284 where the Litronic Plus AC drive system also
includes the drivetrain.”
The T 284 haul truck offers the highest payload in the industry
(400 tons) and with intelligently designed systems and components,
it could serve as a platform for future advances in mining truck
technology. Buyers can select the engine that will allow the truck to
meet productivity targets while minimizing fuel consumption.
Liebherr-Mining Equipment has developed an advanced soft-
ware tool to improve troubleshooting efficiency, the Troubleshoot
Advisor. It detects the cause of breakdowns for mining trucks and
excavators and proposes a procedure based on the results of diag-
nostic tests. “This software tool is currently supporting field service
teams in more than 20 countries, and they have been able to reduce
fault finding and trouble-shooting by a factor of five,” Lukowski said.
Lukowski expects the cost per ton to remain a hot topic. “Some
purchasing managers tend to focus on initial capital costs rather
than the cost per ton,” Lukowski said. “At the end of the day, what
counts is the lifetime equipment costs per ton. And that is where
uptime and high productivity of our machines also plays a major
role.” Looking toward the future, he sees smaller machines doing
the same work as larger machines, where a 400-ton machine is
producing as much as a 600-ton machine today.
Digital Asset CareSince it was established in 2015, RWE Technology International
(RWE TI) has developed into a leading independent consulting and
engineering company, providing services to various energy markets
including mining, thermal generation, renewables and grids. The
company provides services to the global mining industry with a spe-
cial emphasis on continuous open-cast mining and in-pit crushing
and conveying (IPCC) Technology.
“Our mining expertise covers minerals and solid fuels and
spans exploration, development, operations and rehabilitation,”
Over a period of 6 days and five nights, a team of 24 technicians, electricians and supervisors worked around the clock to complete the R 996 B engine module
changeover at Yancoal’s Moorlarben site.
VDMA 92017 • VDMA MINING SUPPLEMENT
RWE Technology International
PUSHING THE LIMITS
EXPANDING YOUR PROFITRWE Technology International is the world’s leading consultant for technical
and operational expertise in open-cast continuous mining systems. RWE TI’s
expertise is based on its experience in operating 230 km of the largest and
fully shiftable conveyors with capacities of up to 37,500 t/h.
T +49 201 12-28742
I www.rweti.com
said Arie-Johann Heiertz, sales manager, mining, RWE TI. “We draw
on the extensive operation and engineering knowledge as well as the
practical experience of our mother company RWE.” RWE operates
five coal operations, mining 120 million metric tons (mt) of lignite
and moving 900 million mt of overburden. In total, the company
operates and maintains more than 230 km of conveyor systems.
Even though RWE’s equipment mines coal in a highly energy-ef-
ficient and cost-effective manner, it is still susceptible to heavy
wear and tear. The mining equipment operates 24/7, deals with
abrasive materials and is exposed to all kinds of weather. It is con-
tinually maintained to ensure minimal downtime.
More recently, RWE collaborated with IBM to develop an
award-winning analytics driven app to ensure that the maintenance
procedures of complex, large equipment and assets are adequately
performed. Asset Care will be the first in a suite of apps that RWE
and IBM will jointly develop and deploy to RWE’s field forces using
iPads to improve maintenance efficiency for mining operations.
“Efficiency is a key interest when it comes to operation and
maintenance of our heavy equipment,” Heiertz said. “The new tool
gives RWE’s employees real-time access to constantly monitor the
equipment and to forecast situations more precisely when a ma-
chine might be running into an unplanned outage.”
The Asset Care App running on an iPad mini will actively support
RWE’s maintenance engineers, technicians and craftsmen by pro-
posing the specific maintenance tasks previously determined to pre-
vent outage or damage. Currently, all expert crews must complete
forms to initiate and keep record of the maintenance jobs required.
The handwritten information is then transcribed to a traditional
plant maintenance software system.
“Asset Care eliminates this manual process by streamlining
tasks and allowing field workers to instantly capture repair informa-
tion in the app, including image and video files, so they can easily
identify equipment issues and complete tasks more efficiently and
safely,” Heiertz said. Field technicians are equipped with mobile ac-
cess to real-time updates of manuals, maintenance and operational
history, and also GPS-based location systems for monitoring and
The Asset Care App running on an iPad mini supports maintenance engineers.
VDMA 10 VDMA MINING SUPPLEMENT • 2017
tracking of equipment and field workers, resulting in a reduction in
equipment downtime and cost of maintenance.
Both IBM and RWE have identified that Asset Care is an in-
dustry solution that could support the transformation of how main-
tenance operations are delivered in industries with large and com-
plex assets.
Maximizing Coal RecoveryMost coal operations measure the particle size distribution (PSD)
of the plant feed to determine the suitability of the feed for their
process. Fine coal can present a problem and understanding the
origin is helpful, but few mines measure the PSD. Comparing that
information with the plant feed data, the mine could optimize the
processes in between the face and the plant to reduce the fines
in the run-of-mine (ROM) coal, which could generate savings and
benefits, such as:
• Reducing the costs associated with fines recovery;
• Decreasing the load on the tailings storage facility;
• Complying with customer specifications;
• Reducing coal dust and its associated problems; and
• Decreasing the moisture the fines retain.
Coal breakage occurs throughout the production process and
generally the amount of breakage behavior depends on the ge-
ology and how the coal is mined and handled. Wirtgen recently
performed several large-scale field tests on material degradation
and found that surface miners offer surprising advantages when it
comes to coal fines generation.
A Wirtgen surface miner is a crawler-mounted mining machine
with a rotating cutting drum and a slewing system for loading
trucks or windrowing product. The cutter drum is located near the
machine’s center of gravity, which transforms the machine’s full
weight into rock penetrating force. The machine can cut layer by in-
dividual layer. The cutting depth can vary with the seam thickness.
Even seams as thin as 10 cm can be mined and precisely separated
from interburden. This is a selective, cost-effective form of surface
mining that does not involve drilling and blasting.
In recent years, Wirtgen has conducted several large-scale
field tests on PSD and material degradation. Coal and sedimentary
ore from eight different pits were analyzed to obtain PSD. Almost
8,000 metric tons (mt) of material were screened to compare the
material produced by surface miners and conventional mining
methods.
In one coal mine, Wirtgen surface miners operate alongside doz-
ers that employ the conventional rip-and-stack method. In view of
the current coal prices, the mine was optimizing every step of the
operation. This included optimizing the process for target size ma-
terial, enabling most of the material to be processed in the cheaper
coarse circuit of the processing plant. They also were keen on reduc-
ing crushing costs.
The surface miner delivered coal with a lower percentage of
fines and more target size material than the conventional dozer rip-
and-stack method. In fact, out of the 1,500 mt/h of coal delivered
from the dozer to the processing plant, 225 tph are fines (less than
2 mm). With the surface miner, the fines amounted to 185 mt/h,
22% less coal was washed in the fines circuit. Looking at the ultra
fine material (less than 1 mm), the plant sees 33% less of that size
fraction when working with surface miner coal.
The surface miner delivered more than 70% target size coal (2
mm-40 mm), while the dozer ranges at less than 58%. Additionally,
savings are generated in the crushing stage: only 17% of the mate-
rial coming from the surface miner needs to be crushed, as opposed
to more than 26% when processing ripped coal.
Another trial location was a sedimentary ore deposit that is
mined using surface miners vs. a conventional drill-and-blast
method. There, the surface miner continually produced feed materi-
al with a minus 1-mm size fraction as low as 15% to the processing
plant. The normal plant feed (includes material of drill-and-blast
and surface miner operation) contained 25% and more fines less
than 1 mm.
Re-handling contributes significantly to the material degra-
dation occurring during the mining process. Simulating the re-
handling of material, Wirtgen conducted a study to establish the
Wirtgen surface miners — here the 4200 SM — cut and crush the rock with a special cutting drum and load it onto dumpers in a single pass via conveyor
system. Wirtgen is the only manufacturer that can offer a performance range up to 3,000 t/h with direct loading by conveyor belt.
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VDMA 12 VDMA MINING SUPPLEMENT • 2017
amount of material degradation that does occur. For simulation
purposes, 80 mt of material were loaded by a wheel loader and run
through a screening plant several times. With every throughput,
the amount of fine material increased significantly. During five test
cycles for coal, the amount of minus 4-mm coal increased from
19% to 26%, representing an increase of 34%. A similar result
was found with sedimentary ore: the fine fraction increased by 24%
during five test cycles.
None of the steps in this re-handling simulation (loading,
transport to the screen deck, sizing on the screen deck itself) in-
volves the high material stress levels that would be induced, for
example, by a dozer moving on stockpiled material. Nevertheless,
significant material degradation was measured during the simu-
lation. One can assume that the material degradation that takes
place during stockpiling results in an even higher increase of the
fine fractions.
Keeping in mind that even this kind of “soft” re-handling
causes significant material degradation and that a lot of re-han-
dling steps occur all along the mining process, it is important to
minimize the number of re-handling steps. What is more, every
re-handling step itself results in additional costs. This is where
Wirtgen surface miners offer a twofold advantage: Material mined
with a surface miner has not been blasted, but cut out of the
ground by the rotating cutting drum, thus the level of fines is
already low. But as the material is loaded straight onto a truck,
re-handling is kept to a minimum and thus the level of fines stays
as low as possible.
Looking at the complete mining operation, using a surface min-
er simplifies mining operation and reduces the number of process
steps, resulting in immediate cost savings.
Direct Conveyor Drives Offer High AvailabilityDeclining ore grades, leading to increased material transport and
plant throughput requirements, is one of the major challenges in
the current mining environment. With direct conveyor drive systems,
mining operators can overcome the mechanical limits of conven-
tional drive systems, and benefit from economies of scale — as
demonstrated in several projects in South America.
A direct conveyor drive system comprises a low-speed syn-
chronous motor, a cycloconverter or voltage source converter, drive
control, power distribution, an E-House and a cooling system. Elim-
inating various components of the drive train reduces maintenance
costs and spare part inventories, and allows the system to offer a
uniquely high degree of availability.
Even in challenging applications, direct conveyor drives
can achieve a benchmark availability of more than 99% — as
confirmed by real-world data from the Antapaccay mine in Peru.
There, the belt system transports approximately 5,260 metric
tons per hour (mt/h) of ore from the mine to the processing
plant over a distance of 6.5 km. The Siemens drive system for
the belt conveyor consists of two low-speed synchronous motors,
each with a power rating of 3,800 kW, and the associated Sinam-
ics SL150 cycloconverters, E-House cooling system and convertor
transformers.
The 2.5-km overload conveyor system at the Las Bambas copper mine in Peru uses a drive system developed by Siemens that consists of two low-speed
synchronous motors with a total power of 4,400 kW.
VDMA 14 VDMA MINING SUPPLEMENT • 2017
In 2015, Siemens commissioned direct conveyor drive systems
for two additional copper mines. One was for one of the largest cop-
per mines in the world, which is located in Chile (5 x 5,000 kW).
For the overland conveyor supplied by thyssenkrupp with a length
of more than 10 km, Siemens supplied five direct-drive systems
(for a total of four conveyors) with the largest conveyor motors pres-
ently in operation.
The overland conveyors at Las Bambas copper mine in Peru
were designed and supplied by thyssenkrupp and have been in
operation since the fall of 2015. Each of the two overland con-
veyors is approximately 2.5 km long with a lift of almost 300 m
and transports ore from the mine to the processing plant. The belts
are 1,830 mm wide, travel at 6.5 m per second, and are designed
to transport approximately 9,400 mt/h. The stockpile at the end
of the conveyor system is more than 50 m high and can supply
the processing plant with up to three days’ worth of copper ore
for processing. The drive system for each of the two overland
conveyors comprises two low-speed synchronous motors — each
with a total power of 4,400 kW — and the associated Sinamics
SL150 cycloconverters.
The overland conveyors at Las Bambas were commissioned
very quickly and the conveyor system is now in operation. “The
project has been very successful and we are running the conveyors
at nominal capacity with only a very few open issues. The gear-
less drives are beneficial from a service point of view, given that
there are no motor bearings or gearboxes, which simplifies ongoing
maintenance requirements,” said Timothy Mess, project director
for thyssenkrupp.
Peter Mizera, MMG’s general manager for Las Bambas project
delivery, shared a positive view of the project outcome. “Las Bam-
bas has been a great success, and Siemens was a large contribu-
tor to this outcome,” Mizera said. “Siemens provided solid support
during construction, precommissioning, and commissioning, and
as a result, we were able to complete the overland conveyor com-
missioning very quickly — in just under two months. This was a
fantastic achievement.”
Following Las Bambas, Siemens recently supplied the world’s
highest-powered direct conveyor drive system to the Cuajone mine
in Peru. The modernization project will entail the installation of a
new gyratory crushing and conveyor system from thyssenkrupp by
2016 (See Material Handling, p. 25). Siemens proposed an Integrat-
ed Drive System with direct conveyor drives to power this conveyor
system, which has a total power output of 12,000 kW.
The conveyor belt system comprises three individual sections
that are equipped with a total of five Integrated Drive Systems.
For the largest of the belt sections, Siemens is supplying two drive
systems with an output of 6,000 kW each, comprising a low-speed
synchronous motor and a Sinamics SL150 cycloconverter. The two
smaller feed and discharge belts will be driven by two 500-kW
low-voltage motors powered from Sinamics S150 converters with
regenerative feedback capability and one 1,200-kW medium-volt-
age motor. The converters and motors as well as the gearboxes and
couplings for these drives are all supplied by Siemens.
The automation components and the drive and power distribu-
tion technology are provided in modular electrical rooms. Over the
years, Siemens has improved and optimized the cooling system, the
modular design of these electrical rooms, the power distribution,
and the automation and drive control so that they perfectly address
the mining industry’s specific requirements.
At Cuajone, Siemens will continue the company’s impressive
track record of successful projects in South America — and rein-
force its position as one of the leading suppliers of electrical and
automation systems for the global mining industry.
Fuel Filtration SystemTo ensure reliable performance for Series 4000 mining engines
operating in harsh conditions where fuel standards are difficult
to uphold, MTU engineers designed a new upgrade to the fuel fil-
tration system. The goal was to improve the system’s ability to
remove particle contaminants in the fuel before they reach the
injection system.
The first aspect of the upgrade involves replacing the filter el-
ements within the primary and secondary filtration unit with new
MTU high-efficiency filtration elements. This ensures that filtered
fuel meets the standards required by the Series 4000’s common rail
injection system. To achieve such high efficiency, the filter elements
are embedded with extremely fine glass fibers, which enable a very
high separation with maximum dirt holding capacity. The MTU High
Performance Fuel Filtration kit includes two primary and two sec-
ondary filter elements.
The new filters are designed to have similar change-out in-
tervals as the original filters. In extreme conditions, a significant
increase in filtration is often accompanied by a reduction in filter
lifetime within the primary and/or prefiltration system. To compen-
sate for these reductions, MTU developed additional upgrades for
both pre- and primary filtration units.
To test the MTU Fuel Filtration Upgrade Kit, prototypes were in-
stalled in 20-V 4000 MTU engines in 360-ton Liebherr T-282 mine
haul trucks, at three mine sites: North Antelope Rochelle mine (Wy-
oming, USA), Kaltim Prima Coal (Indonesia) and Mount Arthur Coal
(Australia). As a benchmark, a standard fuel filter was installed in
a similar truck at each site. Both trucks at each site endured a full
7,000 hours of operation under the same conditions.
After the testing period, all the injectors were inspected and
the results showed the new filtration offered significant improve-
ments. Injectors showed less wear at 7,000 hours than at 3,000
hours with the original filtration system. Most cases showed a
50% to 60% improvement in longevity. In some cases, injector life
was doubled.
Removing the necessity of an injector change just once over
the lifetime of an engine offers significant savings. In harsh con-
ditions, several changes can be avoided. With the high-efficiency
fuel filtration upgrade kit, reaching the expected life of the injector
components is possible, even when fuel quality standards are dif-
ficult or impossible to meet. In addition, fuel efficiency is improved
and the risks of engine damage by worn injectors and other com-
ponents are minimized.
One of the first mine operations to choose the new upgrade
kit was the Radomiro Tomic copper mine in Chile, one of the most
challenging sites in the world to meet stringent fuel standards. Lo-
cated 9,800 ft above sea level, dust is ever-present and fuel must
go through multiple transfers on its long trek to the site. Previously,
injectors achieved nearly 4,000 hours of life. With the installation of
the new upgrade, they are now achieving more than 8,000 hours.
Unexpected equipment downtime has been dramatically re-
duced as well. In addition to solving the problems associated with
fuel contamination, the upgrade kit enabled the mine to keep fol-
lowing the same exchange intervals as the previous series produc-
tion filters. Many haul truck engines at Radomiro Tomic work more
than 20 hours a day. Every time equipment is down, it costs the
mine operator money. Reducing maintenance time pays off expo-
nentially over time, and across many vehicles in the fleet.
VDMA 152017 • VDMA MINING SUPPLEMENT
The new Mine Refuge Chamber (MRC) 5000 attracted a lot of atten-
tion at MINExpo last year. A total life support system, this cost-ef-
fective chamber was completely designed by Dräger — from the
seal-welded steel structure and redundant air supply system, to the
soda lime cartridges and gas detection devices.
“Because we design and build most of the individual compo-
nents, we created a well-integrated, technically advanced life sup-
port system,” said Brad Rekuc, sales manager, mining, for Dräger.
“The MRC can be leased or purchased, and is totally supported by
Dräger Service with local maintenance and repair to ensure that the
chamber is always operational.” Because every mine is different,
Dräger also offers engineered chambers that are designed and built
to customer-specific requirements.
Several systems work together in the chamber to provide a safe
breathing environment. The chamber can be connected to an exter-
nal air supply. Oils, water and small particles are filtered from the
air. A constant positive pressure of between 150 and 200 Pa in the
chamber prevents contaminated air from entering the main room.
This safety feature is automatically sustained and controlled by the
Dräger Breathing Protection Unit (BPU).
Armed with positive pressure and a reliable air supply system, a
gas-tight door prevents contaminated air from entering the cham-
ber. The Dräger Airlock has an air purging system that dilutes any
contaminated air that enters. This allows miners to enter and exit
the chamber multiple times, while minimizing the risk of noxious
gas and smoke entering the chamber.
Dräger gas detection systems continually monitor the air inside
the chamber, which allows miners to adjust the system depending
on the values for carbon dioxide (CO2) and oxygen (O
2). The chamber
is a self-sufficient underground emergency chamber, meaning that
it does not depend on external air or power supplies to keep miners
safe. The air inside the chamber is regenerated by the CO2 scrubbing
process in the breathing air regeneration system.
CO2 is removed (scrubbed) from the interior air by easy-to-use
Drägersorb soda lime cartridges, which eliminate direct contact
with soda lime dust. Miners simply remove the caps, break the foil
seals and insert the cartridges into the top of the BPU. This pour-
free scenario eliminates the possibility of soda lime dust exposure in
a small space. The BPU has a dedicated battery backup system, and
each fan works independently and can be adjusted for the number
of occupants.
In self-sufficient operations, high-pressure cylinders replenish
O2 levels. Dräger’s proprietary gas detection equipment continuously
monitors the internal atmosphere for the presence of CO2 and CO,
as well as O2 levels. If gas concentrations fall outside preset limits,
audible and visual alarms warn the miners so they can adjust sys-
tems and maintain a safe atmosphere. An air conditioning system
keeps the chamber’s interior temperature and humidity at comfort-
able levels. In addition, a fixed external gas monitoring system that
measures the CO and O2 concentrations outside of the chamber and
displays results inside the chamber can be installed as an option.
The electrical system for the MRC 5000 includes batteries for all
electrical functions, the air conditioning system, and green and red
external status lights. Together with the inverter/charger system,
battery backup ensures continuous power for up to a minimum of 24
hours (extended times are optional).
With a history that dates back to 1889, Dräger is an internation-
al leader in the fields of medical and safety technology. The com-
Health and Safety: A Safe Haven
Underground
The MRC 5000 is a self-sufficient underground emergency chamber.
VDMA 16 VDMA MINING SUPPLEMENT • 2017
pany’s portfolio of mine safety products including gas detection
solutions, personal protective gear, innovative firefighting equip-
ment, and thermal imaging cameras.
Flameproof Technology Improves Safety and ProfitabilitySafety and cost effectiveness are always a challenge with regard
to underground mining and tunneling. For almost 50 years, the
Hermann Paus Maschinenfabrik GmbH has been focused on these
issues and optimizes almost standard vehicles as well as customer
requests for the best solutions.
This year, the Paus LHD (PFL 30S) got a new face lift and is
flameproof designed for more safety and mobility. Paus excels in
lift technology, construction machines, industrial vehicles and, of
course, underground mining and tunneling support worldwide. The
company offers an all-in-one production with an increased aware-
ness of safety and support.
“The people who care,” is the Paus philosophy. To care for cus-
tomers’ needs was the main issue when Hermann Paus founded his
manufacturing company in 1968. He realized the special needs of
this diversified mining industry and that was the first step in today’s
main business. Over the years, the Paus family has developed an
impressive range of mining vehicles, trucks, loaders, scalers, grad-
ers and customized solutions — always with a focus on safety first.
Regarding safety and innovation, all the company’s manufacturing
is centrally located, guaranteeing optimum one-source craftsman-
ship. The same applies for the new flameproof technology, which was
developed at the Paus facilities in Emsbüren.
The LHD (PFL 30S) has had several safety and ergonomic
improvements. The drivers have more stability and comfort with
more space. To enter, the miners use a direct side entrance in-
stead of having the confrontation with the articulated joint behind
the kinematic.
The kinematic itself also changed from the former parallel link-
age to the new z-kinematic to give more power and to increase speed
of dumping. That means easy handling and efficient operations. The
line of sight aspect for underground miners is always a concern. The
Paus design team turned this disadvantage around and developed
a solution that is impressive. They reduced the flameproof rear and
made the motor-block more compact so that the driver’s cab will be
high enough for a better sight toward the rear.
Making a more compact machine is not easy, especially when
it comes to managing temperatures. Under EU Atex regulations, the
motor temperature can be no higher than 150°C. Paus engineered
a five-step cooling system to meet this standard. Exhaust gases
are cooled through inside and outside lines. This awesome system
can cool exhaust gas temperature down to 70°C. Additional flame
barriers placed at the exhaust gas and air intake lines further guar-
antee safety in addition to encapsulated electric parts. For gassy
mines, Paus has added intelligent sensors to the driver’s cab to
signal when gas has been detected.
Paus produced a couple of these Atex flameproof LHDs (PFL 30S)
in 2016 and now they have delivered a Universa 50 as a flameproof
vehicle. The Universa 50 is a chassis onto which many modules
can be attached, such as a tire handler, maintenance unit (with an
optional crane), a charging system for blasting agents, a concrete
mixer and sprayer, or a scissor lift.
Innovative vehicles are Paus’ strength and in related news, the
MinCa 5.1 is now available as a hybrid. It transports five miners
and offers even more space for mining or tool equipment because
of the self-supporting chassis. All-wheel-drive, extremely stable
axles and more stability through oil-immersed multiple disc brakes
reflect the care about safety in mines. The 4-m length shortens the
MinCa 5.1’s turning radius, making it very agile. With mining and
tunneling, there are always challenges and solutions and always
“people who care.”
With safety in mind, Paus designed the MinCa 5.1, which can transport five miners and their gear.
For generations, miners have relied on Dräger and our quality products. We remain
committed to supplying innovative and integrative safety concepts to improve mine safety.
Passion and Know-How perfectly linked together. www.draeger.com/mining
Your safety, our solutions – perfectly linked together.
VDMA 18 VDMA MINING SUPPLEMENT • 2017
The safety consideration for underground miners is a top priority.
With bulk commodities, such as potash and coal, both of which
have faced considerable downward price pressure recently, the
competitive advantage is determined on a cost per ton basis. The
capital and operating costs to extract and transport ore (and coal)
to the surface can be signifi cant, especially over the course of a 20-
year mine life. So, it’s important to choose the right system.
Similar to their counterparts on the surface, underground min-
ers need more power to grow production. They are vitally interest-
ed in automation and they frequently turn to technology to protect
workers and reduce costs. Most of the underground mining special-
ists in Germany are working to meet those needs.
High-end, Shaft Hoisting in CanadaMosaic, a market leader in the fertilizer business and a potash pro-
ducer, partnered with SIEMAG TECBERG to supply and install large,
modern shaft hoisting equipment for its new K3 mine site located in
Esterhazy, Saskatchewan. At a depth of approximately 1,100 meters
(m), the K3 project consists of two shafts. It is one of the largest
potash projects in Canada and is designed to hoist millions of tons
per year. Production is slated for 2018.
The K3 hoist tower contains two advanced technology SIEMAG
TECBERG winders with supporting rope sheave assemblies. The
2011 contract for these machines was awarded by Mosaic to an
international consortium of SIEMAG TECBERG Germany and Con-
verteam (now GE). The order included engineering, manufacturing,
delivery, erection, commissioning and post-project maintenance ser-
vices. SIEMAG TECBERG Germany provided the mechanical equip-
ment and used its U.S.-based offi ce in Milwaukee for local support.
The winder and sheave designs and reviews started in 2011
and continued until mid-2012. The equipment was evaluated using
fi nite element modeling (FEM) tools and designed to comply with
multiple international and local standards including Saskatchewan
Mining Regulations, Canadian CSA, German TAS and consultant re-
quirements similar to South African SABS. In addition, the hoist was
customized to incorporate Mosaic-specifi c hoist experiences and
“lessons learned” to maximize its effi ciency and maintainability.
The six-rope 6-m Koepe production winder handles a 55-
metric ton (mt) payload using a twin drive of 11 megawatts (15,000
total horse power). When operational, it will be the fl agship Koepe
winder within the SIEMAG TECBERG Group and a world leader for
hoisting production.
Both the Koepe and Blair winders are equipped with custom
SIEMAG TECBERG equipment specifi cally designed for mine winder
applications. The Koepe winder is equipped with the BG 100, the
company’s largest slide bearing size (1,000-mm seat), and the
Blair hoist features the BG 90 (875-mm seat). Both winders have
12 BE200 brake element pairs and four-channel closed-loop elec-
trohydraulic brake control systems (providing constant retardation
brake) with SIL3-level components.
SIEMAG TECBERG supplied a six-rope 6-m defl ection sheave
set for the Koepe production winder. A new generation 4-m com-
pensation sheave was developed (patent application in process)
for the Blair service hoisting system. The sheave compensation
system consists of two independent and vertically guided sheaves
connected to two hydraulic cylinders. This arrangement maintains
similar force in the two Blair ropes to prevent unsymmetrical loads
(with direct improvement for safety and rope life). The sheave com-
pensation unit includes a specially designed hydraulic station with
electrical control system, which drives and controls the operation of
the sheaves.
Manufacturing of the equipment was largely completed during
2012. Workshop assembly and factory acceptance tests were com-
pleted in the fi rst quarter of 2013. Following this, the equipment
was packed and shipped to Canada and stored until May 2016
awaiting installation. The SIEMAG TECBERG six-rope 6-m Koepe production winder for Mosaic K3
during installation in November.
The headframe for Mosaic’s K3 shaft rises above the Saskatchewan prairie.
Underground Mining Where Power Meets Safety
VDMA 20 VDMA MINING SUPPLEMENT • 2017
Installation began in May 2016 and erection is scheduled to
be finished in early 2017. Cold commissioning (without loads) will
follow this, and hot commissioning (with loads) is scheduled for
later in 2017. This multiyear project required diligent and flexible
management in all phases of the project.
SIEMAG TECBERG’s comprehensive role included hoist and
sheave design, engineering review by third-party consultants, man-
ufacturing with ongoing quality assurance, factory assembly and
acceptance testing, and packaging and transoceanic shipment to a
controlled environment for long-term storage.
Extensive site work follows for SIEMAG TECBERG’s hoists spe-
cialists and crews to install and commission the two hoists and
corresponding sheaves.
Maintaining Engineering Excellence Whenever coal operators face challenging conditions, Eickhoff
has the solution. The German-based equipment manufacturer
has successfully placed its longwall shearer loaders and con-
tinuous miners in some of the most adverse mining conditions.
While excellence in experience and service plays a big role in the
company’s success, Eickhoff also has its own foundry where it
has developed special alloys for tough mining purposes to realize
durability, stability and ease of refurbishment. Eickhoff as a pri-
vately held business has maintained its high engineering stan-
dards for building mining equipment while some of its publicly
held competitors abandoned the coal segment. Fortunately, the
company has diversified into many areas, such as the specialized
gearing for windmills, which allowed them to carry on with min-
ing-related developments despite the global commodity trough.
This allowed the company to prepare for the return of the mining
business. The company has been concentrating on automation
and it retained its software development teams to prepare for the
eventual recovery in the coal market. With multilayered technical
improvements and new developments, Eickhoff is now prepared
for a market upturn in 2017.
“We recently had some customers from eastern Europe revisit
our office for the first time in many years and, as I was explain-
ing the benefits of working with Eickhoff, they stopped me and ex-
plained that they have an Eickhoff shearer loader that has been
running for 30 years,” said Dr. Johannes Krings, director of sales
of mining equipment at Eickhoff. “There was no need to explain to
these gentlemen from the mining industry why they should spend
their money on premium equipment and the concept of least total
cost of ownership.”
Last year, Eickhoff introduced the low-profile Eickhoff SL 300 L
shearer loader and it successfully passed all testing for this fully
automated machine. “We will place it underground in a high perfor-
mance operation soon,” Krings said.
At the other end of the spectrum, Eickhoff is also building a
new version of its SL 1000 with an impressive 8.8-m cutting height
for China. “This is a major step for Eickhoff because it will be the
largest shearer loader the company has ever manufactured, and it
will be the largest shearer loader in the world,” Krings said.
“We are working on continuous sophistication and upgrading of
the whole Eickhoff product portfolio behind the scenes,” said Krings.
“As an example, we are developing more sophisticated alloys in the
foundry. That’s why we are able to engineer such a compact and
powerful shearer loader and that’s also why miners from all over the
world buy the state-of-the-art Eickhoff shearer loaders.”
In December, Eickhoff announced two new orders for SL 300
shearer loaders for the Kakanj and Raspotocje mines in Bosnia.
That increased the current population up to eight Eickhoff shearer
loaders for the Balkan region. This news followed the delivery of
shearer loaders to the Breza and Banovice mines also in Bosnia.
In addition to longwall mining equipment, Eickhoff also sup-
plies continuous miners and they have become quite popular in
South Africa. A well-established South African contract mining
company recently began cutting coal with an Eickhoff CM2H-30
continuous miner at Universal Coal’s New Clydesdale Colliery in
South Africa. Exxaro Coal Central, which currently produces 3.9
South African miners together with the Eickhoff team stand proudly before the CM2H-30 continuous miner before it is deployed at the New Clydesdale Colliery.
VDMA 212017 • VDMA MINING SUPPLEMENT
LIFE CAN
BE SO SIMPLE
EICKHOFF SL SHEARER SERIES
Highest reliability combined with state of
the art automation features make work at coal
faces the most productive and safest ever.
Eickhoff SL Shearer series represent the
apex of longwall shearer technology.
Even in diffi cult applications and harshest
mining conditions, the most powerful
and reliable solutions are attained
through Eickhoff.
We continually demonstrate why
longwall operators rely on us.
Input
Output
Experience has no substitute · Eickhoff since 1864
WWW.EICKHOFF-INTERNATIONAL.COM:
AUSTRALIA · BELORUSSIA · CHINA · GERMANY · POLAND ·
RUSSIA · SOUTH AFRICA · USA
million mt/y from one surface mine and two underground mines,
recently purchased a CM2H-30 for its Dorstfontein Complex, which
operates three continuous miner sections. Eickhoff now has a total
of 13 continuous miners currently operating in South Africa. Eickhoff
continuous miners are also working in China, Russia and Belarus.
“There are some interesting developments at the Dorstfontein
Complex,” said Dr. Uli Lange, deputy director of sales for Eickhoff.
“They are running our 30-type continuous miner next to a competitive
low-profile prototype machine. The performance of these two ma-
chines is being watched closely by all of the underground coal oper-
ators in South Africa. This Exxaro trial is very high on our agenda and
it looks we’re again defining the performance and TCO benchmarks.”
Eickhoff also had the brand new 36-type continuous miner (3.6-m
cutting height) shipped recently to South Africa. The machine weighs
83 metric tons (mt) and has 2 x 180 kW cutting power. “There is great
potential for these machines,” Lange said. “We took an existing 37
model, which is shorter and lighter, and modified the mainframe
making it longer and heavier for the South African market. The coal
in this region has a high compressive strength. So, we modified the
kinematics of the mainframe as far as the hinge point of the cutter
boom, which allows the operator to apply more power at the face.”
Eickhoff’s South African continuous miner fleet will significantly
grow in 2017 — besides that local success, they see a promising
global market for hard coal equipment sales.
Eickhoff tests a fully automated low-profile 300 SL shearer loader at its fac-
tory in Bochum, Germany.
Looking at the low-profile shearer loader from the deck of the armored face
conveyor, one can see that Eickhoff has engineered it in such a way that it
still has the clearance for high-capacity production.
VDMA 22 VDMA MINING SUPPLEMENT • 2017
Advancements in Underground HaulageWhen it comes to haulage, mines have three options: rail, rub-
ber-tired machinery and conveyor system. While the mining industry
drifted away from rail haulage, Matthias Pütz, sales manager for
Schalke Eisenhütte, emphasized it is still a competitive option for
transporting ore. Schalke manufacturers locomotives that are cus-
tom-designed for underground haulage systems.
Schalke is currently negotiating with China on a major pro-
ject. The company shipped the first locomotives to Freeport-
McMoRan’s Grasberg mine in Indonesia in June. Even though
the project was delayed, they installed a test track on the sur-
face to get operational approvals. “A total of 10 locomotives were
ordered for Grasberg,” Pütz said. “The last two will be produced
in the fourth quarter of 2017. When the locomotives begin operat-
ing underground, they will start with diesel-powered systems until
the catenary system is constructed, then they will switch over to
electricity.”
More recently, Schalke has been working with project developers
to reinforce rail haulage as an option at the prefeasibility stage.
“We have been involved with several scoping studies, including the
expansion at Olympic Dam,” Pütz said. “They recently decided to go
with rail and they have started the second stage of the study.”
Pütz has also worked on scoping and bankable studies for
smaller mining companies. “The Seabridge KSM gold mining project
in British Columbia was planning a conveyor system through the
mountain to the mineral processing plant, but we have now con-
vinced them to use rail haulage, especially as it relates to reduced
operating expenses,” Pütz said.
Schalke received its first order in North America last year and
it sees a lot of potential in that market. “In May, we received an
order from Manitoba to replace three old Goodman locomotives with
a semi-automated system,” Pütz said.
Currently, Schake is developing a new locomotive in the 10- to
20-ton range, which could be used for service as well as production.
It would be based on Schalke’s Modutrac system and has the same
parts as a standard locomotive, such as the frame and the driver’s
cabin. This avoids the long delivery times associated with a cus-
tom-made locomotive.
For the last two years, Schalke has been working with the Insti-
tute for Mineral Resources Engineering at the University of Aachen
to develop an inexpensive Excel-based tool to compare the capital
and operating costs associated with the three main haulage sys-
tems. Pütz said it was nearly finished and are awaiting the results.
Energy-efficient Pump Stations for Powered Roof SupportsModern roof supports require higher pressures, bigger cylinder
diameters, and faster advance rates than their predecessors. All
these requirements depend on the high-pressure pumps. At the
same time, longwall operators are looking for ways to significant-
ly reduce noise levels and improve energy efficiency. In response,
KAMAT has developed a new series of speed-controlled plunger
pumps for pressures up to 3,500 bar and motor ratings up to 800
kW. The company combined an upgraded mechanical drivetrain with
a variable speed controller, which allows one system to replace mul-
tiple small pumps with one bigger and well-controllable high-pres-
sure pump or with a master-slave combination.
The forces introduced into powered roof supports are increasing
considerably along with longwall face lengths and the depth of min-
ing. As a result, the hydraulic pressures and cylinder diameters of
the shields are increasing as well. The higher cutting speeds of the
shearer loaders additionally require a faster advance of the shield
supports. All these factors are setting high requirements for the ef-
ficiency of the hydraulic stations in use.
Adding to this are new, more stringent requirements for the en-
ergy efficiency and noise levels. The pump stations are located more
and more often in the immediate vicinity of the longwall controls in
the headgate. While total cost of ownership and energy costs are
a concern, longwall operators are also looking for more compact
design because of the confined space.
KAMAT understands these conditions and has successively
developed a new pump series that features a new drivetrain. It is
based on the high-pressure plunger pumps, which have been used
by the mining industry for decades.
“The reduced noise level requirement was difficult to meet with
the existing drive concept of the KAMAT pumps because the crank-
KAMAT combined an upgraded mechanical drivetrain with a variable speed controller. The new system replaces multiple small pumps with one larger pump.
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shaft, which moves the plunger via crossheads, had to be asymmet-
rical to accommodate it in the previously undivided housing,” said
Dr. Andreas Wahl, CEO, KAMAT. “The asymmetry resulted in stronger
vibrations, which made it difficult to achieve acoustic decoupling by
means of damping elements.”
The new drivetrain features a split housing in which a symmet-
rical, balanced crankshaft takes over the power transmission be-
tween the drive and the plunger. “The newly designed double-helical
gearing also helps to improve the smoothness in operation and to
reduce the noise emission from the pumps,” Wahl said.
The new design is now incorporated in the triplex pumps of the
performance classes from 80 kW to 400 kW. It also forms the basis for
the design of the quintuplex pump drives in the performance classes
from 530 kW to 800 kW, which KAMAT has developed for series produc-
tion and has the potential to bring about significant cost savings from
an operator’s point of view when large volume flows are requested.
The mechanical part of the drive creates the prerequisite for a
demand-oriented, variable speed control of the pumps, which is one
of KAMAT’s core competencies. The power transmission design de-
tails include large surfaces for a low surface pressure and the amply
dimensioned crosshead. “They ensure an excellent, hydrodynamic
lubrication of the pump drive at the spots with the highest loads
even at a low rotational speed,” Wahl said. “Since KAMAT plunger
pumps are working at full operating pressure over a speed range
from 10% to 100%, the plunger pumps are operated in an ener-
gy-efficient and demand-oriented way at partial flow.”
The first KAMAT quintuplex pumps for pressures up to 3,500 bar
were another development stage on the basis of the redesigned,
energy-efficient triplex plunger pumps, Wahl explained. “This de-
velopment was initiated in response to the fact that the (water)
hydraulic systems of various high-pressure plunger pump applica-
tions — and notably those on longwalls in the mining industry and
descaling systems in the steel industry — are getting larger and
larger,” Wahl said.
Today, the operators are using multiple large triplex pumps giv-
en that the volume flow of these pumps is limited by design, but
also for reasons of the high pressures involved. The cylinder volume
is limited by cavitation, which implies that it only makes sense to
produce triplex pumps with ratings of “only” about 400 kW.
The basic design of the new triplex pumps then opened up the
option to develop, on their basis, the first quintuplex (five-cylinder)
New double-helical gearing reduces the noise emissions from the pumps.
VDMA 24 VDMA MINING SUPPLEMENT • 2017
pumps with a rating of 530 kW or 800 kW and the capability to
reliably deliver distinctly larger volume flows than triplex pumps.
The advantages for the operator result from the “economy of
scale.” A large pump is working far more cost-effectively than two
or three smaller ones, and clearly needs less space — an important
argument in most modernization projects.
A lot of detailed design work was, however, required to transfer
the basic concept of the triplex design to the quintuplex pump. The
crankshaft, for example, is supported by multiple bearings, and the
crossheads are oil-spray lubricated rather than splash lubricated
so that sufficient lubrication of the center crossheads is ensured as
well. The crankshaft is supported in special split bearings. KAMAT
has managed to keep spare parts stocking economical by using
many common triplex pump parts.
The new quintuplex pumps offer the same advantages as the
redesigned triplex pumps. They operate at extremely low noise and
low-vibration levels and they work at full operating pressure over
a speed range in conjunction with speed-controlled drives. Thus,
they can ideally be adapted to the respective volume flow require-
ments, and one single pump is sufficient due to a very large speed
control range.
“This is primarily achieved through the pump’s capability to
rotate slowly without affecting the hydrodynamic lubrication of
the highly loaded drive elements of the crosshead in particular,”
Wahl said. “The corresponding design prerequisites are, among
others, amply dimensioned crossheads with large surfaces, which
absorb a high-surface pressure and preserve the continuity of the
lubricant film.”
Operators see another advantage in the fact that the flow rate
of KAMAT pumps is not controlled through circulation valves in on/
off technique but through an electronically controlled speed change
of the pump. As a result, wear is significantly reduced since the
pump, the pipes and the valves are subjected to far less load. Since
the valves of circulation valve controls tend to switch multiple times
within a few seconds under certain circumstances, extremely high
loads are imposed on the entire pump system thus generating pres-
sure shocks.
The first 530-kW quintuplex pump was followed by an 800-kW
model. The two versions are already produced in series, and the
operators benefit from significant cost savings in terms of ener-
gy consumption and maintenance and service bills: Three 800-kW
pumps — one each as a master, slave and standby unit, a common
constellation — are able to generate even very large volume flows
at maximum pressures up to 3,500 bar, and thus typical face pres-
sures of 350 bar to 380 bar, at highly economical rates.
Another control combination, which is also quite common: The
master pump is speed-controlled via frequency converters when two
high-pressure pumps are in use. The slave pump takes over the basic
load once the requirements exceed the delivery capacity of the mas-
ter unit. Therefore, only one single-speed-controlled pump is needed
to cover a very large control range, which is a substantial cost benefit
especially for the mining industry considering the expenses caused
by an ATEX-compliant frequency converter, which is approved for use
in underground mines. The option of operating all pump models also
in the vertical position creates the prerequisite for a space-saving,
vertical installation in pump stations close to the face.
The next development stage is already under preparation: In the
medium term, KAMAT will add a quintuplex pump with a rating of
1,200 kW to its portfolio.
New Ultraclass LHD
The latest development of GHH Fahrzeuge is the Load Haul Dumper
(LHD) LF-21H with a payload of 21 metric tons (mt). The LF-21H is
the most powerful and efficient machine and the largest LHD in its
class, according to the manufacturer.
The LF-21H is equipped with the latest generation of GHH’s
hydrostatic drivetrain, the Efficient Drive System (EDS). The EDS
is optimized for the rough conditions of underground mining and
achieves both significant efficiency as well as productivity gains
compared to conventional hydrodynamic drivetrains. In combination
with an intelligent monitoring system, it guarantees simple opera-
bility as well as maintainability.
Reduced fuel consumption, very low brake and tire wear as well
as high robustness of the system minimize the operating costs. The
eco-friendly engine complies with the latest standards, EU Stage IV
and EPA Tier 4 final, and thus minimizes the underground ventila-
tion requirement and provides 375 kW power.
The focus is on ergonomics with a large foot box, two-pedal
control with an inch-function and controls adjustable for all oper-
ator sizes.
The LF-21H is available in different cabin variants for highly
efficient mining in low seam applications of min. 2.5 m. A Z-link
for hard rock applications is designed for high breakout forces and
loading of matching dump trucks. A low profile version of this Z-link
and the lowest machine height of its class provide superior visibility
even in confined spaces.
A great variety of optional assistance systems such as collision
avoidance systems and the automatic loading mode grant a high
safety standard and simple operation.
www.paus.de
VDMA 252017 • VDMA MINING SUPPLEMENT
Last year was a big year for thyssenkrupp Industrial Solutions. They
announced several new pieces of equipment and services at bau-
ma and MINExpo. Then the company embarked on a reorganization
plan where its business units were restructured and focused more
strongly on sectors and customer groups. All of these moves were
not only made to reduce costs and improve service, but to also con-
sider step changes as to how projects are engineered and managed.
“We now have a dedicated organization for project manage-
ment and engineering and other central services regarding project
execution such as commercial project management, logistics and
procurement,” said Thomas Jabs, executive vice president, mining
systems for thyssenkrupp Industrial Solutions. “All of that is now
combined into one entity, which is referred to as a Network of Excel-
lence. The idea was to strengthen the focus of the company’s core
plant engineering business by combining all these project execution
disciplines into one entity, making us more competitive and flexible
in terms of resource utilization.”
thyssenkrupp Industrial Solutions has eight business units and
one of those is Mining Technologies. Service is another business
unit. “Service will be a cornerstone of the new organization,” Jabs
said. “The target is to offer our clients technical solutions as well as
services for the whole lifecycle of a plant, and at the same time, to
Material Handling: Moving
Minerals Engineering Modern Crushing and Material Handling Installations
Designing crushing and conveying installations, such as this truck dump, which handles two haul trucks, thyssenkrupp’s semi-mobile installations avoid the
concrete work to a great extent and allow for pre-assembly of large modules, reducing the initial cost.
VDMA 26 VDMA MINING SUPPLEMENT • 2017
expand our local proprietary business. The service business unit will
include service centers, spare parts business, upgrade refurbish-
ments and asset management.”
The Mining Technologies business unit has three different
operating units: mineral processing (crushing, grinding and pyro
processing), materials handling (stockyards and port handling sys-
tems) and mining systems (continuous mining including the large
crawler mounted machines and heavy-duty conveying including
overland conveying systems). “Each operating unit has global re-
sponsibility for its projects and products,” Jabs said. “In the future,
our performance will be solely evaluated by the combined global
success of the project.”
This is a new concept within thyssenkrupp Industrial Solutions
and they are eager to prove it will work. They recently submitted a
proposal for two large conveyor systems for two different customers
in Asia, most likely using gearless drive technology.
New Approaches to CrushingLast year, thyssenkrupp unveiled the huge 63-130 gyratory crusher,
first at bauma and then at MINExpo and the first two machines have
been ordered. The crushers will be supplied as part of semimobile
crushing plants for a copper ore mine. “The tendency with crushing
installation investments is to focus on operating expenses,” said
Frank Drescher, head of product division crushing technology, thys-
senkrupp. “We are currently working on several in-pit crushing and
conveying (IPCC) projects, and this new gyratory crusher, which is
lower in weight and higher in capacity, represents a new path for-
ward for us.”
One of those major projects that combines conveying systems
and crushing plants is the Cuajone project in Peru. “At this instal-
lation, a gearless conveyor serves one of the largest semimobile
crushing installations in the world,” Drescher said.
When thyssenkrupp began development on the 63-130, they
were expecting positive feedback because it opens new possibilities
for plant design. “We can place in those modular plants a choice of
crushers from the 75 to the 130,” Drescher said. “That gives us a
great deal of flexibility to respond quickly to requests.”
Many of the competitive mining-class gyratory crushers on the
market today are being used for installations with concrete founda-
tions. Other manufacturers were not as much concerned with out-
of-balance forces, but thyssenkrupp had a keen understanding of
them because they were using gyratory crushers to large extending
semimobile steel structures.
“That’s where we have a tremendous advantage,” Drescher
said. “The extremely efficient operation of the gyratory crusher pro-
longs the lives of these semimobile installations. With the 130, we
have been focused not just to make the equipment bigger and more
powerful, but managed also to reduce the forces substantially,”
Drescher explained.
The semimobile installation avoids the concrete work to a great
extent and allows for pre-assembly of large modules, which reduces
the initial cost. “Further, these systems provide the option to relo-
cate the crushing plant within the mine following the excavation
and to reduce the truck fleet and cost involved thereof,” Drescher
said. “This could be the deciding factor for many projects.”
In the last 10 years, the majority of thyssenkrupp’s underground
crushing installations have been designed with gyratory crushers
mounted in a stationary system, many of them with thyssenkrupp’s
split shell design to reduce component dimensions and weight for
transportation. Most are complete systems that include conveyors
and the company only sees that number growing.
“More and more mines today prefer the packaged crushing
plant based on the raw feed capacity and feed required by the pro-
cessing plant,” Drescher said. “That approach puts us in more of an
OEM system supplier position.”
Maintaining a certain level of technology, thyssenkrupp has
managed to optimize pricing to a point where they can compete
in the standard machine business. “We are working directly
with local markets and dealers and that’s a fundamentally differ-
ent view from the ‘tailor-made’ mining business. It’s a different
approach to engineering as well as keeping equipment in stock,”
Drescher said.
Jabs explained that the tailor-made solutions for mining are
part of the company’s DNA. “That’s how we roll,” Jabs said. “But
now thyssenkrupp is trying to transfer that DNA also to the mass
mining market. Some of these smaller cone crushers and other
items are sold as a commodity.” The custom-made mindset has
prevented the company from competing for the business in these
markets in the past.
“We have dedicated teams serving this market now,” Drescher
said. “Local business units have adopted this very quickly and it’s
a driving element to be closer to the customer and to provide those
services quickly.”
Bridging GapsWith Grinding TechnologyUsing the expertise within the business area, thyssenkrupp can en-
gineer systems to mine and transport phosphate and fertilizers from
pit to port. “Working with our colleagues in Dortmund, who design
fertilizer plants, thyssenkrupp can design the entire beneficiation
process as well as the ship-loading process,” said Uwe Schuh, head
of department grinding technology mineral processing, thyssenk-
rupp. “We are currently looking at several projects in North Africa.”
Phosphate can be exported as ore (phosrock) or a liquid (phos-
phoric acid). India imports a lot of phosrock; other destinations,
such as Brazil, would rather receive phosphoric acid.
thyssenkrupp has been looking at fine grinding as a way to re-
duce water and energy consumption (See Minerals Processing, p.
32). Using the experience gained with phosphate grinding in dry
regions, the company believes it can parlay that into savings for
other metal recovery plants. They recently received an order from
Ma’aden in Saudi Arabia to install crushing and dry grinding equip-
ment within a fertilizer plant in a very dry region. “This will be the
first HPGR application for phosphate ore,” Schuh said. “They have
limited water resources and this installation will come online during
the first quarter of 2017.”
Developments with grinding have helped bridge the gap
with thyssenkrupp as it relates to its service initiatives. “Our service
center in Chile was developed to support HPGR refurbishments,” Jabs
said. “Today, however, it is acting as an equipment rebuild facility. We
recently had a shovel undercarriage in for a rebuild. There is no limit
to the services that we can provide.” The company could also say that
about their service centers, located near Perth and Johannesburg.
Reducing or Eliminating TrucksThe Mining Technologies business unit within thyssenkrupp contin-
ues to develop solutions to eliminate or reduce the use of trucks.
“When we discuss new projects with mining clients, the first thing
they want to evaluate is whether it is possible to mine and transport
ore without trucks — that is a significant change in thinking from
just a few years ago,” Jabs said. “Even customers in the oil sands
have started to investigate new mine developments without trucks.
Whether they can accomplish it or not is yet to be seen, but at least
VDMA 272017 • VDMA MINING SUPPLEMENT
they are thinking about it at an early stage. That increases the re-
quirements for fully and semimobile crushing stations.”
The backbone for all these techniques is the conveyor system.
“We have brought forward many developments with gearless drive
systems and we continue to build our position,” Jabs said. “During
2016, thyssenkrupp acquired the Overland Conveyor Co. in Denver
and this brings even more conveyor expertise onboard.”
The company is still refining solutions for steep-angle convey-
ing. “Right now, we see the greatest potential with the Megapipe for
steep angle conveying,” Jabs said. “Working together with Contitech
and Siemens, thyssenkrupp has made a significant investment in
terms of tests and prototyping. We conducted a lot of tests and we’re
sure that this is something that is going to fly quickly.”
Beyond that, thyssenkrupp is always on the lookout for other
solutions, Jabs explained. “There is conventional conveying and then
we have some big ideas, but we need something to bridge the gap,”
Jabs said. “The imagine gap between what miners are accustomed
to seeing and the possibilities that are out there. It’s two extremes.
The Megapipe is definitely in between what currently exists and the
extreme steep angle conveying solutions.” IPCC was a revolutionary
change 10 years ago, Jabs explained, and now steep-angle convey-
ing will be the next game changer.
Conveyor Ensures Dust-free Transportationof Ore ConcentratesTransportadora Callao S.A., the logistics operator of a special cargo
terminal at the Port of Callao in Peru, relies on a pipe conveyor to
transport zinc, copper and lead concentrates from the warehouse to
the terminal. With its ability to navigate curves in three dimensions,
the conveyor could be optimally adapted to its 3,000-m routing
course. More importantly, the conveying system prevents the con-
centrates from escaping into the environment, ensuring dust-free
transport to the ship’s holds. The Beumer Group handled the engi-
neering, procurement (including the steel structure), construction
management and commissioning of the system.
Located on the Pacific Ocean, Callao is a large Peruvian city,
with the largest airport in the country and one of the most import-
ant fishing and commercial ports in South America. A modern ship
loading terminal for ore concentrates was built in this port and it is
operated by Transportadora Callao S.A.
About 75% of Peru’s imports and exports pass through Callao.
To satisfy the increasing demand for these valuable materials, the
Peruvian government decided to expand the port. Besides addition-
al storehouses, the plans also foresaw the largest, most modern
ship-loading terminal in the country. Peru also wanted to change the
way the raw materials were transported to the ship-loading areas.
Before the construction of the special terminal, trucks were used to
transport the concentrates from the warehouses to the port terminal.
“Since Transportadora Callao started its operation, they could reduce
the truck transports by 130,000 per year,” explained Victor Sam, CEO
at Transportadora Callao S.A. The company, a consortium comprising
five enterprises from the mining and port industries (manufactur-
ers and warehouse logistics operators), obtained a license from the
state of Peru for building and operating the necessary infrastructure.
The mines in central Peru transport their concentrates to the
warehouses about 3 km from the port. That distance required a fully
enclosed material handling system. Transportadora Callao opted for
the Beumer pipe conveyor. “Together with the responsible persons
from the port, we developed a solution that is perfectly adapted to
the routing and the ambient conditions,” said Helmut Wolf, pipe
conveyor engineer for Beumer.
www.koeppern.de
Köppern roller presses have been proven successful
throughout the world in plants specializing in the
cost‑saving high pressure comminution of various
ores like iron, copper, gold, diamond, molybdenum
and lithium ore. The Köppern Hybridur® tires
feature an extremely wear‑resistant surface that
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VDMA 28 VDMA MINING SUPPLEMENT • 2017
The pipe conveyor not only protects the environment, it also
conveys over long distances and navigating tight turns, which re-
duces or eliminates transfer towers and the associated costs. The
engineers use different dimensioning programs to determine the
ideal belt design. They calculated the tractive forces and forces that
arise during acceleration and deceleration and also determined the
possible curve radii. Special idlers and bearings reduce noise levels.
“This improves the quality of the employees’ day-to-day work envi-
ronment,” Wolf said.
“Noise measurements along the pipe conveyor resulted in values
that are consistently far below the permitted limit values,” Sam said.
Beumer supplied and installed a pipe conveyor with a cen-
ter-line distance of 3,195 m. “Due to the system design and the
required system capacity, we designed it with a diameter of 400
mm,” Wolf said. “The conveyor transports 2,300 metric tons per
hour (mt/h), at a speed of 4.5 m/s and is driven by three 650-kW
motors. We equipped the system with filters, strippers, a dedusting
unit and a control system.”
Trucks or trains offload concentrate at the storage area, where it
is transported to an open access station. “A big challenge for us was
integrating the pipe conveyor into the existing network,” Wolf said.
The pipe conveyor is the connection between individual belt conveyors
from various manufacturers.” The concentrate is received by a 43-m
feeding conveyor that transfers it to the pipe conveyor at a height of
6 m. A dedusting unit ensures that no material is emitted during this
process. At the end of the route, the conveying system runs along the
seaside in the naval port of Callao to the transfer tower. Here, the
belt opens automatically and transfers the material to another belt
conveyor that conveys the ore to the ship-loading system.
“This modern system, in operation now for more than 17
months, has increased concentrate loading times by 500% and
reduced the ship’s waiting time until loading by more than 80%,”
Sam said. “These advantages passed savings on to the exporters
and has improved the competitiveness of the Peru’s mining sector.”
Transportadora Callao is now able to handle ships for bulk products
of up to 60,000 DWT without obstructing the work in the other termi-
nals of the Port of Callao.
Automation & DigitalizationA pioneering technology leader for open-pit mining and bulk materi-
al handling systems, ABB Germany through its Center of Excellence
in Cottbus offers decades of expertise in electrification and auto-
mation of the entire mining chain, from pit to port. The ABB team
provides integrated products, services and solutions to help mining
customers optimize the value chain.
A great example of this expertise is successful, long-term
partnership with Joy Global, a leading mining equipment supplier.
During the last 10 years, ABB Germany has equipped 75 electric
shovels with AC multidrive lineups, which are specifically developed
for the most adverse conditions in open-pit mining. Daily, these
shovels encounter high shock and vibration loads as they crowd and
load rock from the face in some of the most challenging environ-
mental conditions from the top of the Andes to the Arizona desert.
ABB’s proven ACS800 low-voltage drive systems are specifically de-
signed and modified for the requirements of loading equipment.
ABB is also participating in the electrification and automation of
a 13-km-long conveyor system at the historic Chuquicamata copper
mine. Once the project is completed, the conveyor system will be one
of the world’s largest and most complex systems and will deliver cop-
per ore from the new underground mine directly to the concentrator.
ABB engineered the gearless drives, motors, instrumentation and power
supply for the 13-km overland conveyor at Chuquicamata.
With its ability to navigate curves in three dimensions, Beumer recently installed a 3-km pipe conveyor to transport concentrate to a new terminal at the
Port of Callao in Peru.
VDMA 292017 • VDMA MINING SUPPLEMENT
Chuqui is one of the largest open-pit copper mines and the
second deepest open-pit mine, located in the Atacama Desert in
northern Chile. The mine has been operating since 1910 and today it
is operated by Corporación Nacional del Cobre (Codelco) — Chile’s
national copper mining company and the leading copper producer.
To cover both steep gradients and long distances, the conveyor
fl ights will be powered up to 20 MW and 55 MW in total. In the fi nal
stage, the system will transport more than 11,000 tons per hour of
material, the same freight as approximately 158 railcars per hour.
ABB’s delivered a complete power and automation solution,
which includes gearless drives, motors, instrumentation and power
supply products. The equipment will be custom-engineered to on-
site requirements to optimally power, control, measure and actuate
the conveyor system. The solution will fully integrate the belt’s power
and automation through ABB’s fl agship 800xA control system, com-
bined with a Mining Conveyor Control Program (MCCP) to ensure
optimum power quality and control across the entire system.
A key part of ABB’s delivery is the gearless conveyor drive sys-
tem. This is a state-of-the-art solution to meet the extremely high
load requirements and the necessary power availability, which
would not have been achievable with a conventional drive solution.
This gearless conveyor drive system eliminates the gearbox from the
motor, thus signifi cantly reducing the number of main wear parts,
resulting in less maintenance needed and ensuring a longer lifes-
pan of the solution. Other advantages are the considerable reduc-
tion in the drive system’s footprint and the amount of instrumenta-
tion required. Less parts increases the reliability and effi ciency of
the overall conveyor system by several percentage points.
StockyardManagementSystemDemonstrating the trend toward increasing digitalization, ABB
offers a fully automated terminal management system or the
stockyard management system (SYMS). The fi rst SYMS has been
running at an iron ore distribution hub in Malaysia for two years
now and the results have shown that it performs better than
manual operations.
The Teluk Rubiah Maritime Terminal is Vale’s fi rst fully au-
tomatic operating port, which uses its ERP System (GPV Portos)
to create work orders for the port and yard operations, delegate
them as jobs for material movement to the control system, and
execute them by unmanned operating yard machines. The SYMS
receives production data from Vale’s Production Information Man-
agement System (PIMS) and distributes it to the Process Control
System (PCS) to control the machinery. The scope of supply also
included the design, engineering, delivery, installation, testing
and commissioning of ABB’s 800xA PCS to manage all plant
equipment at the terminal, including all ship unloaders, conveyor
belts, stackers and reclaimers. The unmanned yard machines are
assisted by 3-D pile scanners and a GPS positioning system to
ensure the highest level of accuracy and precision in order to
achieve highest productivity.
Before any material movement starts, all planned activities are
validated by the SYMS for the correctness of the selected material
quality, suffi cient space at the assigned destination to stack, or if
enough reclaimable material is available to fulfi ll the job. In case
of a valid status, the import, export and blending jobs are executed
by the unmanned operating yard machines, which are fully auto-
mated. The movement of the material is monitored by a material
tracking feature and provides the operators real-time information of
the stock and material movement status. A reporting feature with a
mass balance and material movement overview, as well as a 3D-Cli-
14. MiningForum
01. & 02.06.2017
Estrel Berlin
Mining is the Future
Register now!
NEW: Schedule
is online!
Accompanying
trade fair
MININGFORUM
www.the-miningforum.com
Partner:
Follow us on:
VDMA 30 VDMA MINING SUPPLEMENT • 2017
ent, enables easy management and maximizes performance. With these features, an accurate ratio control in blending operations en-sures the highest material quality standards. The reclaiming rates will be monitored and controlled to meet the strict quality require-ments of Vale customers.
ColombianCoalLoadingSystemLast year, FAM Förderanlagen Magdeburg commissioned a coal handling system for the Port of Mamonal in Cartagena, Colom-bia. The use of modern conveyor technology now helps to transportand load coal effi ciently, safely and in a more environmentally friendly method. Addressing the crowd at the opening, Colombian President Juan Manuel Santos referred to the $160 million project as an “infra-
structural revolution” that will expand the export opportunities of his country and immensely improve its competitiveness. The new port has created some 500 new jobs and another 470 directly or indirectly connected with port operations. The system consists of a 750-mt/h stacker and two 2,750-mt/h scraper reclaimers. A network of fi ve 2,750-mt/h conveyors move coal from the reclaim piles to a 2,750-mt/h radial-type quadrant shiploader. The stacker has a cascade chute installed at the tip of the boom that not only helps to decrease dust but also to optimize the fl ow velocity of the material and to facilitate a softer landing to ensure that the grain size of the bulk material remains largely un-damaged. The shiploader can fi ll ships up to 70,000 DWT without moving them.
Colombian President Juan Manuel Santos addresses the crowd at the grand opening of a $160 million project to improve coal handling systems. Designed and engineered by FAM, the system consists of a stacker and two scraper reclaimers (inset photo). A total of five conveyors move coal from the reclaim piles to the 2,750-mt/h shiploader.
Teluk Rubiah Maritime Terminal in Malaysia is Vale’s first fully automatic operating port. ABB’s process control system manages all plant equipment at the terminal, including all ship unloaders, conveyor belts, stackers and reclaimers. The unmanned yard machines are assisted by 3-D pile scanners and a global positioning system.
LONGWALL USAExhibition & Conference2017
WWW.LONGWALLUSA.COM
2017 LONGWALL USA:
STANDING STRONG.
June 13-15, 2017 • David L. Lawrence Convention Center, Pittsburgh, PA USA
Longwall USA returns to Pittsburgh from June 13–15, 2017, and
we’re planning a great event. Political and social pressure
against the industry are stronger than ever before, but we are
proud of the role we play in powering America’s industries and
bringing energy to the homes of millions of our fellow citizens.
For 2017, we have expanded opportunities for exhibitors and conference
attendees and we will be celebrating the unique role that coal has played
throughout U.S. history. This is your invitation to join us as an attendee,
exhibitor, sponsor, or speaker.
Visit us online or call us today to find out how you can take
part in this important show.
This is Your Invitation to Participate
Contact for More Information:
Michael Schoppenhorst
Show Director
Ph: +1 678 822 9801
VDMA 32 VDMA MINING SUPPLEMENT • 2017
Water and energy savings have become more and more important
for miners worldwide. “We introduced HPGR to the mining industry,”
said Uwe Schuh, head of department grinding technology mineral
processing, thyssenkrupp. “We still consider ourselves to be the
market leaders.
Borrowing a concept from the cement industry, thyssenkrupp
is proposing dry grinding up to approximately 150 microns. “This
concept would eliminate the conventional milling stages and report
directly to the downstream beneficiation processes,” Schuh said.
“The concept consist of a combination of HPGR and air classifiers,
and it would be of particular interest to iron ore processing plants.”
Eliminating part of the wet circuits (grinding) would signifi-
cantly reduce water consumption.
“For the fine grinding (down to 20 microns) of disseminated
ore to liberate metals, tower mills could be an option, according
to Schuh. Recently, thyssenkrupp signed a cooperative agreement
with Eirich, the company that invented the tower mill. “Eirich’s up-
per limit for tower mills was 1,500 hp and under the agreement,
we will develop a 6,000-hp tower mill,” Schuh said. “In the future,
we see the combination of the HPGR with a tower mill positioned
downstream.”
Selecting the Proper Pump to Handle Concentrate Many gold operations process ore through autogenous grinding
mills. Ground ore is classified for size through hydrocyclone sepa-
rators. Ball mills regrind the coarse material. The undersize reports
to flotation where the sulfide minerals are separated, concentrated
and sent to a thickener-filter press circuit prior to roasting.
The thickener-filter press circuit reduces the amount of wa-
ter in the flotation concentrate, which is typically handled using
horizontal centrifugal pumps. The use of this type of pump can be
counter-productive because water must be added on the thicken-
er cone bottom to assist transport by the pump. Also, gland seal
water must be added to the centrifugal pumps in the two pump-
ing stages. In total, the volume of water introduced back into the
Mineral Processing: Recovering
More with LessMinimizing the Use of Water and Energy
After introducing high-pressure grinding (HPGR) technology to the mining industry, thyssenkrupp plans to integrate its use with tower mills to reduce water
consumption at mineral processing plants.
VDMA 332017 • VDMA MINING SUPPLEMENT
thickened underflow fed to the filter press can be increased by as much as 25%.
One gold operation in Nevada recently replaced the centrifugal thickener underflow pumps with ABEL series EM 100 electromechan-ical diaphragm pumps. Cone water additions and gland seal water were no longer required. Also, the maintenance costs associated with the thickener underflow pumps were greatly reduced.
This same plant’s filter press used centrifugal slurry pumps for its feed pumps. The wear on the centrifugal pumps was consider-able with pump wet ends wearing out as often as every two weeks, and costing as much as $20,000 to replace each time. Downtime and lost production mounted with each repeated occurrence.
To mitigate the problem, the centrifugal filter press feed pumps were supplemented by ABEL series HMD-G-80-1000 piston-dia-phragm pumps. The ABEL pumps employ a hydraulically balanced elastomeric diaphragm, ideal for moving abrasive slurry at higher pressures. By working in parallel, the centrifugal pump “fast-fills” the filter press at lower pressures, then hands over consolidation of the press cycle to the ABEL. The resulting pump maintenance costs and downtime were greatly reduced. Filter cake quality improved due to the positive displacement action of the ABEL pump.
The plant has since added another thickener-filter press process train to increase gold production. ABEL EM 100 pumps were speci-fied for thickener underflow and ABEL HMD-G-80-1000 pumps were specified for filter press feed duty.
The ABEL HM series pumps are hydraulically driven piston-di-aphragm pumps. Reciprocating the motion of the piston moves an elastomeric diaphragm by means of a hydraulic end. Ball checks and seats on the product end are available in various materials. This characteristic design allows the pump to transfer abrasive slurry or sludge at pressures up to 1,450 psi (10 MPa).
Aspirational FlotationA lot of mineral processing professionals are classifying the flotation technologies into three groups: mechanical agitator flotation, pneu-matic flotation and column flotation. This is a mistake as column flotation is a form of pneumatic flotation, explained Lutz Markworth, head of product management flotation for MBE Coal & Minerals
Technology. “A lot of different pneumatic flotation technologies are available on the world market,” Markworth said. “The flow direction of the feed and the air is important. Some technologies use a con-current flow, while others rely on a counter-current flow. And the flow
of aerated feed pulp is arranged as downstream, upstream or in a tangential direction into the separation vessel.”
Other important considerations for pneumatic flotation are the needs for a high efficient reagent conditioning process prior to the separation vessel, the creation of perfect air bubble size range and amount, as well as the high efficient attachment of the air bubbles to the mineral particles.
The upstream pneumatic flotation principle, realized in MBE’s PNEUFLOT cell, generates the air in a special designed Venturi-based aerator on top of the separation vessel, Markworth explained.
To float fine and coarse particles simultaneously with improved efficiency, MBE Coal & Minerals Technology developed in 2015 and installed in 2016 a new designed froth channel discharge system for potash, reverse iron ore and coal flotation with excellent results in terms of recovery and yield.
The PNEUFLOT technology, according to Markworth, is the only one using upstream flotation process in one machine. “After leaving the ceramic nozzles with an upward motion into the separation ves-sel, coarse particles that are not perfectly attached to air bubbles at that stage are ‘shot’ into the froth zone, making contact with bigger air bubbles and are discharged properly into the new designed froth channel system,” Markworth said.
The coarse particles are discharged into the froth channels be-fore any sedimentation can take place. Froth discharge velocity can be controlled and set to an optimal condition for all kinds of froth characteristics. Markworth believes the froth channel discharge system could improve recovery by 6%-8% in the same machine at the same flotation time for potash and silica flotation as well as 9% more yield in coal flotation.
An ABEL EM 100 pump is being used as a thickener underflow pump.
The new channel system discharges froth for reverse iron ore flotation in Brazil.
VDMA 34 VDMA MINING SUPPLEMENT • 2017
Last year, Innogy announced its plan to acquire Belectric Solar and Battery Holding GmbH, a world leader in system design and engineering, procurement and construction (EPC) services for large-scale solar, storage and hybrid systems since 2002. The acquisition was expected to close in early 2017. Belectric has designed and implemented hybrid energy solu-tions since 2009. Those systems include a combination of photovol-taic power plants, diesel gensets and other energy storage options. In the development of the hybrid systems for mining applica-tions, Belectric is relying on the vast experiences of Innogy’s sister company RWE Technology International GmbH, a world leading consultant for continuous mining and in-pit crushing and convey-ing (IPCC) systems. Supplying electricity to remote mine sites often requires a signifi cant capital investment and operating expenses related to both fuel costs as well as operation and maintenance (O&M) costs for diesel gensets. Hybrid energy systems, which combine different electricity sup-ply sources, offer a cost-effective energy supply solution for mining operations, especially if the mine is located in an extremely sunny location. Once installed, the cost for solar power does not fl uctuate. Moreover, the O&M costs of the solar and storage systems are in general much lower than the diesel system. The hybrid system is managed by a plant controller, which guarantees a stable and reliable electricity supply regardless of the source of energy used at any given moment. Inexpensive solar energy is consumed at fi rst priority while the remaining energy is supplied by the higher-cost diesel system. The system dynamics can further be enhanced by adding a battery storage system.
Solar inverters provide reactive power day and night, supporting voltage stability for the mine’s power grid. This can be a signifi cant additional benefi t for weak power grids where voltage fl uctuations may lead to unexpected downtime. The hybrid system design targets the lowest possible cost of en-ergy as the main objective while considering technical, operational and commercial constraints. The system is scalable and modular and it’s relatively simple and cost-effective to install. Partly con-tainerized, it could be easily relocated together with all other infra-structure at the mine site. Belectric conducted a case study recently on a mine site in Southern Africa. The mine site operated eight diesel generators with a total capacity of 24 megawatts (MW) and consumes 134 gigawatts per hour (GWh) each year at an expected average cost of $0.31/kWh over the mine life. A hybrid system at this mine site would reduce the costs related to diesel energy by 24% with a total energy cost savings of approximately $56 million over the mine life. “As was demonstrated in multiple hybrid energy projects and case studies in the mining sector conducted by Belectric, hybrid energy systems can be a signifi cant enabler for the obvious need of mining companies to reduce their operational costs and to limit their fuel price exposure,” said Gal Bogin, Belectric’s chief sales offi cer. “The current maturity of the solar and hybrid technologies together with Belectric’s design and implementation experience mean this is the right time for mining companies to benefi t from cheap and reliable solar energy.”
Navigation Technology for Marsand the MinesThe German Aerospace Center has developed a navigation technology for future Mars missions, which is capable of navigating without GPS satellites. This innovative technology has been further refi ned by DMT.
Navigation with the DMT Pilot 3-D works similar to the human eye; an inertial measuring cell determines the actual position of the device while two cameras observe the motion relative to the environmental setting — these are the “eyes” of the system. A high-performance processor uses this data to calculate the position and orientation in real-time. As the system operates in-
Innovations: Renewable Energy
Reduces Mining Costs
The hybrid system delivers the most cost-effective source of power.
The containerized hybrid energy system (inset) stores energy and manages power supply sources.
VDMA 352017 • VDMA MINING SUPPLEMENT
ABEL GmbH, 21514 Buechen, Germany, [email protected] ABEL Pumps L.P., Sewickley, PA 15143-2339, USA, [email protected]
He likes it
we pump it
For difficult pumping of tailings, slurry
or paste, meet the ABEL heavy duty
HM series piston-diaphragm pump.
Designed for the most challenging tasks
in mines throughout the world.
Learn more about our mining competence
at www.abelpumps.com
dependent of light or horizon line-of-sight, it is ideal for precise
navigation in closed environments without GPS access such as un-
derground mines. It had the ability to assess the surrounding area
underground and provides digital images for 3-D documentation.
In addition to system technology development and manufacturing,
DMT also coordinates worldwide distribution. They will present the
technology at the 2017 Mining Forum in Berlin (June 1-2, 2017).
More information on the 2017 Mining Forum is available online at
www.the-miningforum.com.
Vision for Process AutomationBased in Aalen, Baden-Württemberg hema designs customer-spe-
cifi c camera systems for a wide range of applications. Automated
processes and equipment warning systems depend on reliable vi-
sion systems, and with that in mind, hema electronic has designed
the seelectorICAM HO1 camera system for the mining industry. A
robust design, high dynamic range and superior quality video were
integrated during the development. An ethernet interface allows the
digital camera to be easily installed in digital networks.
A unique feature of the seelectorICAM HO1 is the high-dynamic
range video imaging. A more than 120-dB dynamic range combined
with a high-quality color image of 1.3 megapixel exceeds what is
available in existing systems. The plant manager or equipment op-
erator can now see and detect people and obstacles next to fl ood-
lights even in dark areas.
Reliable detection has taken on an added importance as more
mining operations consider autonomous operations. With this type
of camera installed, remotely operating machines and the use
of unmanned aerial vehicles (UAVs) is within reach. Not only for
proof of concept, but also for safety and security in deep mining
operations. All the systems already in use could benefi t from these
camera options.
The robust electronics and the IP67 housing ensure a safe op-
eration. The reliable optics and cabling complete the system. The
camera adapts easily to existing digital networks using standard-
ized digital interfaces such as Ethernet or wireless connections.
The new camera has been tested on construction machines.
It was used in rear-view camera applications on excavators
and wheel loaders. The results show the exquisite image quali-
ty. The system was then tested on rear-view mirror applications.
Operators reported good results even at sunset. Now hema
hopes to test the seelectorICAM HO1 in mining and material
handling applications. These modern cameras with HDR sensor
technology could add another layer of safety and security to ex-
isting operations.
hema has designed a robust camera for mining operations.
The DMT Pilot 3-D navigates without GPS.
VDMA 36 VDMA MINING SUPPLEMENT • 2017
PFREUNDT GmbH | Robert-Bosch-Str. 5 | 46354 Südlohn | [email protected]
www.pfreundt.de | Phone +49 (0) 28 62 / 98 07-0
Weighing system solutions ‚Made in Germany‘
Precision is our passion.
Weighing system solutions
WK60
Linear Booster Drives for ConveyorsLast year, the Prosper-Haniel coal mine installed a TT Drive on its
H2 belt conveyor without interrupting operations, achieving a com-
prehensive solution. A subsequent installation of another TT Drive
resulted in further cost reductions for the mining company.
Owned by RAG Deutsche Steinkohle, Prosper-Haniel produces
about 3 million metric tons (mt) of coal per year. The H2 conveyor
transports raw coal 1,270 m with a lift of 186 vertical m. Its operat-
ing speed amounts to 3.2 m/s with a capacity of 2,000 mt/h.
With the installation of the first TT Drive, Voith made it possible
for the Prosper-Haniel mine to carry on using a heavily damaged
steel cord belt (ST5000) until the next scheduled downtime and pre-
vented an unplanned shutdown and corresponding production loss.
During the next downtime, Voith installed a second TT Drive in the
H2 conveyor. This reduced more belt tension and Prosper-Haniel has
since been able to operate the conveyor with a cost-saving fabric
belt (PVG2000/1).
Project managers Ralf Dohle and Wolfgang Kosiuk from RAG
Deutsche Steinkohle are completely satisfied with the booster
drives and the project execution. “Voith’s solution has provided
us with a dual benefit,” Dohle said. “Not only did we manage to
avoid an unplanned shutdown because of the damaged belt, we
are now able to use a textile belt instead of an expensive steel
cord belt for the system.”
The Voith TurboBelt TT Linear Booster Drive is a high-perfor-
mance secondary drive for belt conveyors. It extends the use of belts
in existing systems and increases their available power. In new belt
conveyor systems, it reduces the requirements on belt quality, lead-
ing to considerable cost savings.
Dynamic Weighing SystemsWhen it comes to mobile weighing systems, Pfreundt continues
to improve its product line for wheel loaders, and they have some
great ideas for mining applications as well. The company is one of
the leading international producers of integrated weighing systems
with 40 agencies worldwide.
The actual weighing system WK60 has been available for about
two years now. “Improvements in technology and materials have
allowed us to develop the WK60 and the user interface looks a lot
like an iPad, except that it’s 6-cm thick,” said Bruno Reckmann,
director of sales and marketing for Pfreundt. The back of the device
is equipped with a plug-and-play connection simplifying the instal-
lation. “A technician needs to calibrate the system, but it’s relatively
simple to assemble and install,” Reckmann said. “The electrical
connections on its predecessor, the WK50, were much more compli-
cated with different plugs and cables. Now the cable ends attach to
color-coded positions.” The system calculates the load in the bucket
based on hydraulic pressure and the bucket lift.
“The WK60 operates well within the hydraulic limits of large
wheel loaders used in open-pit mining operations as well as the
large LHDs found underground. Because they only have 30 cm to
50 cm of lift, LHDs presented a problem at first. But now we have
The Voith TurboBelt TT Linear Booster Drive allowed RAG to replace a steel cord belt with a cost-saving fabric belt.
VDMA 372017 • VDMA MINING SUPPLEMENT
www.erlau.com Erlau AG | Erlau 16, 73431 Aalen, Germany | Tel +49 7361 595-0
ERLAU TYRE PROTECTION CHAINSPower of steel plus passion of man for advanced asset protection.
•Reducing your operating costs•Lowering your downtime•Increasing your productivity
resolved those issues and the system
works very well,” Reckmann said.
Pfreundt recently announced some
improvements to its WK60 electronic
weighing system, which will play an
integral role in its “Speed Weigh Tech-
nology” for wheel loaders. This form
of dynamic weighing allows a weight
determination without disrupting the
production process. Technology improve-
ments have extended the measurement
range to the point where the system
can get an exact weight indication with
a minimal bucket height, which could
prove useful underground.
In April, Pfreundt will unveil the
WK60-XS, which will have an even
smaller display, 5 in. compared to the
7 in. “This is important for confined
operator cabins such as those found in
mining,” Reckmann said. Pfreundt will
present this new weighing system for
the first time at Conexpo in Las Vegas
in March. The display for the WK60 mobile weighing system looks a lot like today’s tablets.
VDMA 38 VDMA MINING SUPPLEMENT • 2017
GERMAN VENDOR MATRIX
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Extraction (lo
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Ventilation & air-c
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Stowing Extraction in open pits (continuous)
Extraction in open pits (tr
uck/shovel)
Special equipment for open pits
Dewatering (underground & open pit)
Blasting equipment
Conveying & haulage underground
Shaft winding equipment
Winches & hoists
Trackless underground vehicles
Preparation plants
Crushers & millsSizing equipment
Sorting equipment
Dewatering, proportioning, m
ixing eq.
Briquetting & granulation equipment
Dedusting, water treatment
Dewatering plant
Coke oven plant equipment
Continuous conveyor & components
Feeding & withdrawal equipment
Stockpile equipment
Driving aggregates
Control equipment
Power supply Communication, navigation
Pneumatic & hydraulic tools
Compressors Accessories, wear parts
Mine safety Services Consulting/Engineering
Software
VDMA 392017 • VDMA MINING SUPPLEMENT
GERMAN VENDOR MATRIX
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Roof support/Shaft &
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Extraction (lo
ngwall)
Extraction (vein, ro
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ining)
Ventilation & air-c
onditioning
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Extraction in open pits (tr
uck/shovel)
Special equipment for open pits
Dewatering (underground & open pit)
Blasting equipment
Conveying & haulage underground
Shaft winding equipment
Winches & hoists
Trackless underground vehicles
Preparation plants
Crushers & millsSizing equipment
Sorting equipment
Dewatering, proportioning, m
ixing eq.
Briquetting & granulation equipment
Dedusting, water treatment
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Coke oven plant equipment
Continuous conveyor & components
Feeding & withdrawal equipment
Stockpile equipment
Driving aggregates
Control equipment
Power supply Communication, navigation
Pneumatic & hydraulic tools
Compressors Accessories, wear parts
Mine safety Services Consulting/Engineering
Software
VDMA 40 VDMA MINING SUPPLEMENT • 2017
GERMAN VENDOR MATRIX
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Shaft sinking
Deep well drilli
ng equipment
Roadway driving/Heading
Roof support/Shaft &
roadways
Extraction (lo
ngwall)
Extraction (vein, ro
om & pillar m
ining)
Ventilation & air-c
onditioning
Stowing Extraction in open pits (continuous)
Extraction in open pits (tr
uck/shovel)
Special equipment for open pits
Dewatering (underground & open pit)
Blasting equipment
Conveying & haulage underground
Shaft winding equipment
Winches & hoists
Trackless underground vehicles
Preparation plants
Crushers & millsSizing equipment
Sorting equipment
Dewatering, proportioning, m
ixing eq.
Briquetting & granulation equipment
Dedusting, water treatment
Dewatering plant
Coke oven plant equipment
Continuous conveyor & components
Feeding & withdrawal equipment
Stockpile equipment
Driving aggregates
Control equipment
Power supply Communication, navigation
Pneumatic & hydraulic tools
Compressors Accessories, wear parts
Mine safety Services Consulting/Engineering
Software
VDMA 412017 • VDMA MINING SUPPLEMENT
GERMAN VENDOR MATRIX
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••
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Shaft sinking
Deep well drill
ing equipment
Roadway driving/Heading
Roof support/Shaft &
roadways
Extractio
n (longwall)
Extractio
n (vein, room & pilla
r mining)
Ventilatio
n & air-conditio
ning
Stowing Extractio
n in open pits (contin
uous)
Extractio
n in open pits (truck/shovel)
Special equipment for o
pen pits
Dewatering (u
nderground & open pit)
Blasting equipment
Conveying & haulage underground
Shaft winding equipment
Winches & hoists
Trackless underground vehicles
Preparation plants
Crushers & mills
Sizing equipment
Sorting equipment
Dewatering, proportio
ning, mixing eq.
Briquettin
g & granulation equipment
Dedusting, w
ater treatm
ent
Dewatering plant
Coke oven plant equipment
Continuous conveyor &
components
Feeding & withdrawal equipment
Stockpile equipment
Driving aggregates
Control equipment
Power supply
Communication, navigatio
n
Pneumatic & hydraulic to
ols
Compressors Accessories, w
ear parts
Mine safety Services Consulting/Engineerin
g
Software
VDMA 42 VDMA MINING SUPPLEMENT • 2017
ABB Automation GmbH
Geschäftsbereich Open Pit Mining
Hänchener Str. 14
3050 Cottbus
Web: www.abb.com/mining
ABEL GmbH
Abel-Twiete 1
21514 Büchen
Web: www.abel.de
AEM - Anhaltische
Elektromotorenwerk Dessau GmbH
Daheimstr. 18
06842 Dessau-Rosslau
Web: www.aemdessau.de
AIR LIQUIDE GLOBAL E&C SOLUTIONS
Germany GmbH
Olof-Palme-Straße 35
60439 Frankfurt
Web: www.engineering-solutions.
airliquide.com
Alimak Hek GmbH
Frauenbrunner Str. 25
75031 Eppingen
Web: www.alimakhek.de
allmineral Aufbereitungstechnik
GmbH & Co KG
Baumstr. 45
47198 Duisburg
Web: www.allmineral.com
ANDRITZ Ritz GmbH
Güglingstr. 50
73529 Schwäbisch Gmünd
Web: www.andritz.com
Andritz Separation GmbH
Dillenburger Str. 100
51105 Köln
Web: www.andritz.com
apc analytics GmbH
Daimlerstrasse 17
61449 Steinbach / Ts.
Web: www.apc-analytics.com
Atlas Copco MCT GmbH
Langemarckstr. 35
45141 Essen
Web: www.atlascopco.de
AUMUND Fördertechnik GmbH
Saalhoffer Str. 17
47495 Rheinberg
Web: www.aumund.com
AViTEQ Vibrationstechnik GmbH
Im Gotthelf 16
65795 Hattersheim
Web: www.aviteq.de
BARTEC Sicherheits- und
Schaltanlagen GmbH
Holzener Str. 35 - 37
58708 Menden
Web: www.bartec-mining.com
Bauer Maschinen GmbH
BAUER-Str. 1
86529 Schrobenhausen
Web: www.bauer.de
Becker Mining Systems AG
Walter-Becker-Straße 1
66299 Friedrichsthal
Web: www.becker-mining.com
Bell Equipment (Deutschland) GmbH
Willy-Brandt-Straße 4-6
36304 Alsfeld
Web: www.bellequipment.de
BEUMER Group GmbH & Co KG
Oelder Str. 40
59269 Beckum
Web: www.beumergroup.com
BHS-Sonthofen GmbH
An der Eisenschmelze 47
87527 Sonthofen
Web: www.bhs-sonthofen.com
VDMA 432017 • VDMA MINING SUPPLEMENT
BOCHUMER EISENHÜTTEHEINTZMANN GMBH & CO KGKlosterstr. 46
44787 Bochum
Web: www.be-heico.de
Bosch Rexroth AG Maria-Theresien-Str. 23
97816 Lohr am Main
Web: www.boschrexroth.com
BRÄUTIGAM Gear & Mining Tech GmbH & Co KGAm Schürmannshütt 8 - 18
47441 Moers
Web: www.braeutigam-group.com
CATERPILLAR Global MiningEurope GmbHIndustriestr. 1
44534 Lünen
Web: www.cat.com/mining
CATERPILLAR Global MiningHMS GmbHKarl-Funke-Str. 36
44149 Dortmund
Web: www.mining.cat.com
CFT GmbHCompact Filter Technic
Beisenstr. 39 - 41
45964 Gladbeck
Web: www.cft-gmbh.de
CIV Präzisionstechnik GmbHTuchmacherweg 11
39288 Burg
Web: www.civ-burg.de
Coal ControlGesellschaft für Automation mbHReisholzstr. 15
40721 Hilden
Web: www.coal-control.com
Cyrus GmbH SchwingtechnikAm Stadion 40
45659 Recklinghausen
Web: www.cyrus-germany.com
Deilmann-Haniel Mining Systems GmbHHaustenbecke 1
44319 Dortmund
Web: www.dhms.com
DEUTZ AGOttostr. 1
51149 Köln
Web: www.deutz.com
DMT GmbH & Co KGAm Technologiepark 1
45307 Essen
Web: www.dmt-group.com
Maschinenfabrik Heinrich Döpke GmbHStellmacherstr. 10
26506 Norden
Web: www.doepke-gmbh.de
Dräger Safety AG & Co KGaARevalstr. 1
23560 Lübeck
Web: www.draeger.com
DÜCHTING PUMPENMaschinenfabrik GmbH & Co KGWilhelm-Düchting-Str. 22
58453 Witten
Web: www.duechting.com
DURUM Verschleißschutz GmbHCarl-Friedrich-Benz-Str. 7
47877 Willich
Web: www.durmat.com
EEP Elektro-Elektronik Pranjic GmbHAm Luftschacht 21
45886 Gelsenkirchen
Web: www.eep.de
Eickhoff Bergbautechnik GmbHAm Eickhoffpark 1
44789 Bochum
Web: www.eickhoff-international.com
VDMA 44 VDMA MINING SUPPLEMENT • 2017
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Str. 5074736 HardheimWeb: www.eirich.com
EnviroChemie GmbH
In den Leppsteinswiesen 964380 RossdorfWeb: www.envirochemie.com
ESI ITI GmbH
Schweriner Str. 101067 DresdenWeb: www.itisim.com
FAM Förderanlagen Magdeburg
und Baumaschinen GmbH
Sudenburger Wuhne 4739112 MagdeburgWeb: www.fam.de
FELUWA Pumpen GmbH
Beulertweg 1054570 MürlenbachWeb: www.feluwa.com
Filtration Group GmbH
(Formerly MAHLE Industrial Filtration)Schleifbachweg 4574613 ÖhringenWeb: www.filtrationgroup.com
FLSmidth Wadgassen GmbH
Karl-Koch-Str. 166787 WadgassenWeb: www.flsmidth.com
FLSmidth Wiesbaden GmbH
Am Klingenweg 4a65396 WallufWeb: www.flsmidth.com
GEA Westfalia Separator Group
Werner-Habig-Str. 159302 OeldeWeb: www.westfalia-separator.com
Getriebebau Nord GmbH & Co KG
Getriebebau-Nord-Str. 122941 BargteheideWeb: www.nord.com
GHH Fahrzeuge GmbH
Emscherstr. 5345891 GelsenkirchenWeb: www.ghh-fahrzeuge.de
Gothe & Co GmbH
El.-Ap. Elektro-ApparateKruppstr. 19645472 Mülheim an der RuhrWeb: www.gothe.de
GreCon Greten GmbH & Co KG
Hannoversche Straße 5831061 AlfeldWeb: www.grecon.com
GTA Maschinensysteme GmbH
Loikumer Rott 2346499 HamminkelnWeb: www.gta.eu
H + E Logistik GmbH
Josef-Baumann-Str. 1844805 BochumWeb: www.helogistik.de
H. C. Starck Tungsten GmbH
Landsberger Str. 9880339 MünchenWeb: www.hcstarck.com
HADEF HEINRICH DE FRIES GmbH
HebezeugfabrikGauss Str. 2040235 DüsseldorfWeb: www.hadef.de
Hammelmann GmbH
Carl-Zeiss-Straße 6-859302 OeldeWeb: www.hammelmann.com
VDMA 452017 • VDMA MINING SUPPLEMENT
Hauhinco MaschinenfabrikGmbH & Co KGBeisenbruchstr. 10
45549 Sprockhövel
Web: www.hauhinco.de
HAVER NIAGARA GmbHRobert-Bosch-Str. 6
48153 Münster
Web: www.haverniagara.com
HAWE Hydraulik SEStreitfeldstr. 25
81673 München
Web: www.hawe.de
HAZEMAG MiningBrokweg 75
48249 Dülmen
Web: www.mining.hazemag-group.com
hema electronic GmbHRöntgenstraße 31
73431 Aalen
Web: www.hema.de
Herrenknecht AGSchlehenweg 2
77963 Schwanau
Web: www.herrenknecht.com
HYDAC INTERNATIONAL GmbHIndustriegebiet
66280 Sulzbach/Saar
Web: www.hydac.com
Ingeteam GmbHHerzog-Heinrich-Str. 10
80336 München
Web: www.ingeteam.com
JÖST GmbH + Co KGGewerbestr. 28 - 32
48249 Dülmen
Web: www.joest.com
KAMAT GmbH & Co KGSalinger Feld 10
58454 Witten
Web: www.kamat.de
Kleemann GmbHManfred-Wörner-Straße 160
73037 Göppingen
Web: www.kleemann.info
Komatsu Germany GmbHBuscherhofstr. 10
40599 Düsseldorf
Web: www.komatsu-mining.de
Maschinenfabrik KÖPPERNGmbH & Co KGKönigsteiner Str. 2
45529 Hattingen
Web: www.koeppern.com
Krummenauer GmbH & Co KGWellesweilerstr. 95
66538 Neunkirchen
Web: www.krummenauer.de
KSB AktiengesellschaftPumpen & Anwendungen FeststofftransportJohann-Klein-Str. 9
67227 Frankenthal
Web: www.ksb.com
KVT Kurlbaum AGSachsenring 4-6
27711 Osterholz-Scharmbeck
Web: www.kvt-group.de
Liebherr-Mining Equipment SAS49 rue Frédéric Hartmann
68025 Colmar, France
Web: www.liebherr.com
VDMA 46 VDMA MINING SUPPLEMENT • 2017
LOESCHE GmbH
Hansaallee 243
40549 Düsseldorf
Web: www.loesche.com
marco Systemanalyse und
Entwicklung GmbH
Hans-Böckler-Str. 2
85221 Dachau
Web: www.marco.de
MATO GmbH & Co KG
Benzstr. 16 - 24
63165 Mühlheim
Web: www.mato.de
MBE Coal & Minerals
Technology GmbH
Gottfried-Hagen-Str. 20
51105 Köln
Web: www.mbe-cmt.com
MESUTRONIC Gerätebau GmbH
Hackenfeld 13
94259 Kirchberg
Web: www.mesutronic.de
MTU Friedrichshafen GmbH
Maybachplatz 1
88045 Friedrichshafen
Web: www.mtu-online.com
J. D. NEUHAUS GmbH & Co KG
Windenstr. 2 - 4
58455 Witten
Web: www.jdngroup.com
Nilos GmbH & Co KG
Reisholzstr. 15
40721 Hilden
Web: www.nilos.com
oddesse Pumpen- und
Motorenfabrik GmbH
Am Pappelwald 12
39387 Oschersleben
Web: www.oddesse.de
Hermann Paus Maschinenfabrik GmbH
Siemensstr. 1 - 9
48488 Emsbüren
Web: www.paus.de
PFISTER WAAGEN BILANCIAI GMBH
Linker Kreuthweg 9
86444 Affing-Mühlhausen
Web: www.pfisterwaagen.de
PFREUNDT GmbH
Robert-Bosch-Str. 5
46354 Südlohn
Web: www.pfreundt.de
PLAKOMA GmbH
Bahnhofstr. 101
66809 Nalbach-Körprich
Web: www.plakoma.de
PLARAD Maschinenfabrik Wagner
GmbH & Co KG
Birrenbachshöhe 17
53804 Much
Web: www.plarad.de
PRAKLA Bohrtechnik GmbH
Moorbeerenweg 3
31228 Peine
Web: www.prakla.de
WOLFGANG PREINFALK GMBH
Im Oberen Werk 4
66386 St. Ingbert
Web: www.preinfalk.de
Pumpentechnik Erkrath
GmbH + Co KG
Max-Planck-Str. 28
40699 Erkrath
Web: www.pumpentechnik-erkrath.de
Putzmeister Solid Pumps GmbH
Max-Eyth.Str. 10
72631 Aichtal
Web: www.pmsolid.com
VDMA 472017 • VDMA MINING SUPPLEMENT
RWE Technology International GmbH
Huyssenallee 12-14
45128 Essen
Web: www.rwepi.com
SAMSON AG
MESS- UND REGELTECHNIK
Weismüllerstr. 3
60314 Frankfurt
www.samson.de
Sandvik Mining & Construction
Crushing Technology GmbH
Technologie Park Bergisch Gladbach
Friedrich-Ebert-Str. 75
51429 Bergisch Gladbach
Web: www.sandvik.com
SCHADE Lagertechnik GmbH
Bruchstraße 1
45883 Gelsenkirchen
Web: www.schade-lagertechnik.com
Schaeffler Technologies AG & Co KG
Georg-Schäfer-Straße 30
97421 Schweinfurt
Web: www.schaeffler.de/
rohstoffgewinnung_verarbeitung
Schalker Eisenhütte
Maschinenfabrik GmbH
Am Eickhoffpark 1
44789 Bochum
Web: www.schalke.eu
Schenck Process Europe GmbH
Pallaswiesenstraße 100
64293 Darmstadt
Web: www.schenckprocess.com
Schopf Maschinenbau GmbH
Parkstr. 19 - 21
73760 Ostfildern
Web: www.schopf-mining.com
F. E. Schulte Strathaus GmbH & Co KG
Fördertechnik - Dichtungssysteme
Runtestr. 42
59457 Werl
Web: www.schulte-strathaus.de
SEKA Schutzbelüftung GmbH
Im Höger 4 a
76829 Landau
Web: www.schutzbelueftung.de
SIEMAG TECBERG GmbH
Kalteiche-Ring 28-32
35708 Haiger
Web: www.siemag-tecberg.com
Siemens AG
Process Industries and Drives Division
Schuhstr. 60
91052 Erlangen
Web: www.siemens.com/mining
SMT Scharf GmbH
Römerstr. 104
59075 Hamm
Web: www.smtscharf.com
STEINERT Elektromagnetbau GmbH
Widdersdorfer Str. 329 - 331
50933 Köln
Web: www.steinert.de
GKN Stromag AG
Hansastr. 120
59425 Unna
Web: www.stromag.com
TAKRAF GmbH
Torgauer Str. 336
04347 Leipzig
Web: www.takraf.com
Thomas Magnete GmbH
San Fernando 35
57562 Herdorf
Web: www.thomas.magnete.com
VDMA 48 VDMA MINING SUPPLEMENT • 2017
thyssenkrupp Industrial Solutions AG
thyssenkrupp Allee 1
45143 Essen
Web: www.thyssenkrupp-industrial-
solutions.com
TLT-Turbo GmbH
Gleiwitzstr. 7
66482 Zweibrücken
Web: www.tlt-turbo.com
TML Technik GmbH
Daimlerstr. 14 - 16
40789 Monheim
Web: www.tml-technik.com
Tüschen & Zimmermann
GmbH & Co KG
Winterberger Str. 82
57368 Lennestadt
Web: www.tueschen-zimmermann.de
URACA GmbH & Co KG
Sirchinger Str. 15
72574 Bad Urach
Web: www.uraca.de
VELCO Gesellschaft für Förder-
Spritz- und Siloanlagen mbH
Haberstr. 40
42551 Velbert
Web: www.velco.de
Voith Turbo GmbH & Co KG
Voithstr. 1
74564 Crailsheim
Web: www.voith.com
VULKAN Kupplungs- und Getriebebau
Bernhard Hackforth GmbH & Co KG
Heerstr. 66
44634 Herne
Web: www.vulkan.com
WELLER Pumpen GmbH
Westicker Str. 44 - 46
59174 Kamen
Web: www.weller-pumpen.de
WILO SE
Nortkirchenstr. 100
44263 Dortmund
Web: www.wib.com
WIRTGEN GmbH
Reinhard-Wirtgen-Str. 2
53578 Windhagen
Web: www.wirtgen.de
ABB Automation GmbH.....................................................VDMA IBC
ABEL GmbH & Co KG ......................................................... VDMA 35
Beumer Group GmbH & Co KG ............................................. VDMA 5
Draegerwerk AG & Co KG a.A. ............................................ VDMA 17
Eickhoff Bergbautechnik GmbH......................... VDMA 21, VDMA 23
Erlau AG ............................................................................ VDMA 37
Hermann Paus Maschinenfabrik GmbH............................. VDMA 24
KAMAT Pumpen GmbH & Co KG .........................................VDMA BC
Maschinenfabrik Koeppern GmbH & Co KG........................ VDMA 27
Liebherr Holding GmbH ....................................................... VDMA 7
Longwall USA 2017 ........................................................... VDMA 31
Mining Forum (DMT).......................................................... VDMA 29
MTU Friedrichshafen GmbH............................................... VDMA 13
Pfreundt GmbH.................................................................. VDMA 36
RWE Power International GmbH........................................... VDMA 9
Siemag Tecberg GmbH ...................................................... VDMA 19
Siemens AG International.................................................... VDMA 3
Takraf GmbH .................................................................... VDMA IFC
Wirtgen GmbH................................................................... VDMA 11
ADVERTISING INDEX
—
Let’s write the future.
Greater transport capacity
with increased reliability.
Conveyors need to cover longer distances and ascend steeper gradients
in increasingly remote locations and harsher environments. The result is
ever more stressed and less maintained equipment which leads to additional
sources of error. To increase reliability, ABB developed a streamlined solution
which helps to overcome the mechanical limitations of the gearbox.
The new gearless conveyor drive (GCD) with a permanent magnet (PM) motor
delivers up to 50% more reliability and improves energy efficiency. In addition
to the eliminated gearbox, the PM torque motor can work without a complex
external cooling system, which avoids further system errors. For more
information, please visit us at www.abb.com/mining
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
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)
without boosterpressure
Operating Pressure 3500 bar (max)
HIGH PRESSURE
PLUNGER PUMPS
AND SYSTEMS
LESS IS
MOREWhere 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.
< 2000 mPas
800 kW (max)
3500 bar (max)
HIGH PRESSURE
PLUNGER PUMPS
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.