EST OF ERMANY Mining Equipment 2019 · TAKRAF, incorporating DELKOR and Tenova Advanced Technologies, is an integrated equipment and solutions provider to the global mining, bulk

BEST OF GERMANY

2019

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 Dry Stack TailingsTAKRAF offers state-of-the-art Dry Stalk Tailings (DST) systems to suit the unique requirements of each mine site and process plant. Based on DELKOR’s rich experience in dewatering and filtration and TAKRAF’s long proven capabilities in providing solutions to challenging material handling requirements, we can offer bespoke solutions to the dry stacking of a wide range of tailings with a prime focus on SAFETY, RELIABILITY and SUSTAINABILITY.

TAKRAF GmbHTorgauer Straße 33604347 Leipzig, [email protected]

Tenova, a Techint Group company, is a worldwide partner for innovative, reliable and sustainable solutions in the mining and metals industries. www.tenova.com

Let’s meet in Munich!Hall C2, booth 349

April 8-14, 2019

TAKRAF, incorporating DELKOR and Tenova Advanced Technologies, is anintegrated equipment and solutions provider to the global mining, bulk material handling and minerals processing industries, offering innovative technologies as well as mining and process solutions and expertise along industry value chains.

mailto:[email protected]

https://www.takraf.tenova.com

https://www.tenova.com/

VDMA 12019 ¥ VDMA MINING SUPPLEMENT

Foreword:If 2017 was the year of transition, 2018 was a period of recovery. The upswing in the mining industry

brought suppliers back to a better level. Turnover increased by more than 40% to reach some 3.6 billion

euro. The better environmental conditions allow companies to prepare more intensively for the future.

Where are the challenges? These depend on the raw material and the type of extraction. Cross-industry

challenges like standards for data and interfaces or data security or social infl uences were also mentioned.

We made a survey of operators and asked for the topics that are considered relevant for the future.

The list is long. Some of the many aspects are:

• Internationality of all participants. Technology development and cooperation are becoming more

international;

• Mastering leaps in technology and technology transfer;

• Connecting equipment and machinery to the mine’s digital infrastructure;

• Autonomous and remote-controlled machines, intelligent equipment;

• Close cooperation in service and maintenance (operator/OEM);

• Increasing profi tability requirements with increasing market volatility; and

• Increasing digitization and automation to autonomous machines.

We discussed these issues internally and formulated answers and proposals, respectively. A

summary of the statements was prepared and evaluated by the participants during the fi rst VDMA

Mining Technology Day. Finally, topic clusters were developed in a workshop with the board members

and then discussed at our annual sector meeting. This was the fi rst stage of our “Roadmap 2035” to

defi ne what mining companies/contractors need or want in the future.

The topics are being discussed this year and made available to members as guidelines. We are

convinced this work will give customers of German mining equipment manufacturers a competitive

edge — to their mutual benefi t and advantage. We hope you fi nd value in this publication, wherever

you are in the world.

Glückauf!

Dr. Michael Schulte Strathaus

President

VDMA Mining

Table of Contents:

Your Contacts in the Mining Equipment Association ......................................................................... 2

Beyond Quality, German Suppliers Offer Safe and Smart Solutions ................................................... 4

Solutions for Security by Design ........................................................................................................ 6

Recovering Minerals Cost Effectively ................................................................................................ 8

Advances in Surface Mining ............................................................................................................ 14

Sophisticated Systems Improve Safety and Productivity Underground ............................................ 24

Smart Approaches to Material Handling.......................................................................................... 33

Mining Equipment and Technology .................................................................................................. 36

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 306Jacksonville, FL, 32224, USATel: +1-904-721-2925Fax: +1-904-721-2930www.mining-media.comCopyright 2019 Mining Media Int’l, Inc.

Sponsor:German Engineering Federation Verband Deutscher Maschinen und Anlagenbau (VDMA) e.V.Lyoner Str. 18, D-60528 Frankfurt/MainTel: +49-6966-031262Fax: +49-6966-032262www.vdma.org

Articles in this publication were researched, edited and written by Steve Fiscor, publisher and editor-in-chief, Engineering & Mining Journal (E&MJ) and Coal Age.

For additional information about the articles or the manufacturers highlighted here, contact Mining Media International Inc. ([email protected]).

EQUIPO | INGENIERÍA | TECNOLOGÍA

Published by Mining

Media International

in cooperation with

VDMA Mining

http://www.mining-media.com

http://www.vdma.org


VDMA 2 VDMA MINING SUPPLEMENT • 2019

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


Christoph Danner Manager Markets

Latin America

Phone: + 49 69 6603-1254

Fax: + 49 69 6603-2254


Alexandra Landgraf Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Rajesh Nath Chief Representative

VDMA Representative Offi ce India

Phone: + 91 33 40602364

Fax: +91 33 23 21 70 73


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


Monika Bind Manager Markets

CIS and Russia

Phone: + 49 69 6603-1262

Fax: + 49 69 6603-2262


Jörn LehmannManager Standardization

Phone: + 49 69 6603-1134

Fax: + 49 69 6603-2134


Yvonne Golle Assistance

Phone: +49 69 6603 1256

Fax: + 49 69 6603-2577


Thomas JunqueiraAyres Ulbrich Chief Representative

VDMA Representative Offi ce Brazil

Phone: + 55 11 430580-42/-43

Fax: +55 11 3078 4335


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


Joachim Schmid Managing Director

Phone: + 49 69 6603-1261

Fax: + 49 69 6603-2261


Helmut Schgeiner Director

Technology, standardization and research,

markets Europe, Africa, USA and Canada

Phone: + 49 69 6603-1680

Fax: + 49 69 6603-2680


Christoph Danner Manager Markets

Latin America

Phone: + 49 69 6603-1254

Fax: + 49 69 6603-2254


Alexandra Landgraf Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Rajesh Nath Chief Representative

VDMA Representative Offi ce India

Phone: + 91 33 40602364

Fax: +91 33 23 21 70 73


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


Monika Bind Manager Markets

CIS and Russia

Phone: + 49 69 6603-1262

Fax: + 49 69 6603-2262


Jörn LehmannManager Standardization

Phone: + 49 69 6603-1134

Fax: + 49 69 6603-2134


Yvonne Golle Assistance

Phone: +49 69 6603 1256

Fax: + 49 69 6603-2577


Thomas JunqueiraAyres Ulbrich Chief Representative

VDMA Representative Offi ce Brazil

Phone: + 55 11 430580-42/-43

Fax: +55 11 3078 4335


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














PASSION FOR BENEFICIATION– Upgrading Manganese Ore from Georgia for the global market.

Halle B 2 | Stand 427

SEE MORE !


Whether they are building screening machines, high-pressure

pumps or hydraulic excavators for mining operations, the mes-

sage is very similar and clear. Last year was a good year and

2019 should be better. This year’s Best of Germany showcases

great examples of German companies supplying solutions for

mines around the world.

The German Engineering Federation (known by the acronym

VDMA) represents more than 3,200 mostly medium-sized com-

panies in the mechanical and plant engineering sector. With

1.35 million employees and sales amounting to approximately

EUR 226 billion, it is the largest industrial employer in Germany

and one of the leading German industrial sectors. The Mining

Division of the VDMA is a small, but important subset that has

about 140 members.

What separates these companies from their counterparts is

the German dedication to craftsmanship, their expertise and the

fact that many are privately held, which allows them to be nim-

ble in many areas, especially as to how they approach the mar-

ket and new product development. Combining the power of the

Internet of Things, or Industry 4.0, with real-time data analysis,

they have developed some great concepts for moving miners out

of harm’s way and improving efficiency.

Sadly, for German mining equipment manufacturers, their

domestic market is fading away and now only plays a minor role

in their business plans, with total turnover expected to decline by

22% to EUR 90 million in 2018. According to Dr. Michael Schul-

te Strathaus, chairman of VDMA Mining, the current policies

demonstrate little affinity to the business of raw materials, and

therefore mining, and are highly unlikely to provide any impetus

for domestic business. Similarly, little or no growth is expected

from German potash and salt miners, as Schulte Strathaus em-

phasized during the association’s annual press conference. The

sector expects a further decline on the domestic market in the

coming year, with the best-case that of a stagnating turnover.

Germany’s mining equipment industry is therefore becoming

increasingly dependent on foreign business. While Germany’s

last hard coal mine was closed recently, Poland is currently ex-

panding its hard coal mining activities to reduce its dependence

on imports. According to the forecast by VDMA, export revenues

will increase by 40% to approximately EUR 3.6 billion and 25%

of exports are delivered to countries in the European Union (EU),

a figure that has declined from the 31% in 2017. The biggest

customers are Italy, Austria, Poland, France and Belgium. As

Schulte Strathaus explained, the market is primarily marked

by major infrastructure projects that will gradually be complet-

ed, and there are currently no adequate replacements in sight.

VDMA is therefore expecting stagnant exports to EU countries in

2019, with a slight increase at best.

According to calculations by VDMA, the USA’s share of the to-

tal export volume will increase from 15% in last year to 17% this

year. Schulte Strathaus cited the changes made by President

Donald Trump’s administration regarding energy and regulatory

policies as the reasons for this development. A clear direction

on energy policy has led to an increase in the use of hard coal

in the USA. A shift in regulatory policy has created a better in-

vestment climate for mining in the USA. This has led to con-

siderable demand for machines that can increase productivity,

and consequently, profit; a development that benefits German

Beyond Quality, German Suppliers Offer Safe and Smart Solutions German mining equipment manufacturers are looking

forward to doing more in 2019

VDMA 52019 • VDMA MINING SUPPLEMENT

Mined raw materials travel along extensive transport routes.

Overland and pipe conveyors are an energy effi cient, reliable

and environmentally friendly way of transporting the

commodities over long distances to the plant or storage

area. We customise the curved belt conveyors to overcome

any challenging topographical circumstances. This minimises

the transfer points and the number of systems and reduces

investment, operational and maintenance costs.

For more information visit www.beumergroup.com

SOME THINK RAW MATERIAL TRANSPORT REQUIRES A COMPLEX INFRA-STRUCTURE. WE THINK DIFFERENT.

Visit us!

bauma, Munich, Germany

April 08 – 14, 2019

Hall B2, stand 413

manufacturers in particular. The industry is expecting a further

moderate increase in exports to the USA in the coming year.

German mining equipment manufacturers are also enjoying

healthy business with China, with the export share to the country

expected to increase from 7% to almost 10% this year. According

to Schulte Strathaus, policymakers in China have realized that

establishing high-performance mines can only be realized to a

limited extent when only domestic technology is used. German

manufacturers provide technologies that are either unavailable

in China or only available to a very limited degree. However,

China is making considerable efforts to close existing technology

gaps. “We still have an edge when it comes to extraction tech-

nology, especially in underground mining,” Schulte Strathaus

said. “However, we do not know how long we will be able to main-

tain our lead, or perhaps expand it.” The industry expects that

its exports to the People’s Republic of China will increase further

over the coming year.

The future for German mining equipment manufacturers lies

outside its domestic borders, Schulte Strathaus emphasized.

With the support of VDMA, the sector began increasing its activi-

ties abroad at an early stage. New markets were the subject of in-

tense exploration and development, and it is therefore no surprise

that the sector has an optimistic view of the future. The demand

for raw materials will continue to increase. Schulte Strathaus

pointed to an assessment by the OECD that found the demand

for raw materials will nearly double by 2060. This will have a

positive and sustained impact on business. Increased demand is

primarily expected by companies that extract raw materials to be

used in the production of alternative energy generation.

Roadmap Aims to Support CompaniesGerman mining equipment manufacturers will increasingly have

to deal with demands that society places on raw materials ex-

traction and thus the mine operators as customers of the equip-

ment manufacturers. The world is becoming a more transparent

place and the market no longer accepts raw materials from

questionable sources. Similarly, society continues to embrace

technology, not only in its handheld devices, but in homes, of-

fices and autos. The rush for the metals that will support this

greener lifestyle has already started with the search for specialty

metals and battery minerals, such as lithium, cobalt, graphite

and other rare earth minerals.

For the mining sector, the digital revolution has arrived.

What began in the processing plants has now moved into the

pits and underground. Today, mines employ large fleets of au-

tonomous vehicles. This edition of Best of Germany reveals many

other ways the mine operators can leverage data to improve op-

erations. Mining in the connected environment of the future will

require increased digitalization. Already, digitalization has in-

fluenced many aspects of mining from exploration to engineering

and design simulation to advanced process controls.

Schulte Strathaus summarized the situation with several

keywords: sustainability, green mining, and safe and healthy

working conditions. Together with VDMA, a roadmap is currently

in development, which is intended to support companies in iden-

tifying new challenges and reacting to them in line with market

requirements and thus successfully. The task is to now filter the

decisive parameters from the vast amounts of machine data col-

lected and make it usable for controlling the machines and, ul-

timately, the entire process. “This is exactly where our strengths

lie,” Schulte Strathaus said.

https://www.beumergroup.com/


In today’s connected world, data protection is more important than ever before. Yet, many mine operators lack the required expertise to identify risks and threats. The good news is that suitable solutions are now available that can be easily adapted to the individual proj-ect requirements to provide optimum security. What happened with the WannaCry ransomware, as drastic as the effects were, was but a warning shot to plant operators and systems integrators. The worldwide cyberattack is estimated to have affected more than 10,000 organizations and approximately 200,000 computers across as many as 150 countries. Especially troubling to IT and security experts is that the crypto worm used a known exploit that could have been closed with patches. However, many organizations had not applied them or were running legacy systems that could no longer be patched. WannaCry is just one example of a growing number of cyber-attacks — and while malware that specifically targets industrial control systems is still rare, automation and control systems are already more networked with general IT systems than many plant operators realize. Having good, regular and secure backups, using appropriate software, implementing good cybersecurity including isolating critical systems, and always having the latest security patches installed should be a given. In its whitepaper on cybersecurity, the ARC Advisory Group lists several barriers to improving cybersecurity in industrial environments. They include increasingly open industrial auto-mation, insufficient awareness among end-user management, increased use of commercial off-the-shelf IT solutions, inade-quately trained staff, and misconceptions concerning the cyber-security lifecycle. ARC believes organizations are reluctant to act on potential threats and to adopt security planning and implementation because the task appears too daunting. Furthermore, in the customized con-trol environment of an industrial site, it is difficult to predict how a newly introduced patch will impact the functioning of the control system, especially if the patch is not tested rigorously. Industrial security as specified in recent guidelines, such as the IEC 62443, should therefore be treated as a lifecycle concern con-sisting of five phases: product or system development, specifica-tion, integration and commissioning, operations and maintenance, and decommissioning.

The phases require clear accountability and coordinated com-munication between different roles and stakeholders such as sys-tem integrators, product suppliers and asset owners. A defense-in-depth security approach covering a heterogeneous and broad range of security topics — including network security, user authentication, secure configuration and the hardening of operating system, logging, encryption, and secure channels — is required. Technical solutions and tools are available, but project teams often lack the time and expertise to choose a suitable solu-tion for each security topic. Hence, a common pitfall is to focus on some topics in detail while overlooking others. In November 2018, Siemens became the first company to gain TÜV certification for the secure system integration of process automation and drives systems in compliance with the international standards. Based on this, Siemens has developed several blueprints for automa-tion and control systems engineering to facilitate security engineering and eliminate potential weak spots. These blueprints provide guidance in the form of references to specific resources and make sure that the engineering project produces all security documents. For example, the Siemens minerals solutions for conventional mill drives and gearless mill drives have been developed according to these blueprints. In the end, designs that fulfill IEC 62443 simplify information exchanges between stakeholders and deliver a complete set of doc-uments for acceptance tests and the security solution certification. The development of the secure framework and the secure proj-ect blueprints was driven by Siemens’ own experience. Key areas of importance include helping the asset owner identify critical assets and specify suitable protection goals; supporting the security life-cycle process through an efficient threat and risk analysis; imple-menting efficient and effective testing; and compiling and provid-ing the required documentation. Particularly in large projects where security affects different disciplines — such as network, software applications and firmware — the framework establishes a common language for engineers to work together on security. On an organizational level, the framework also facilitates the communication between units that develop com-ponents and those that work as system integrators and on service. The security framework combines the expertise of Siemens se-curity engineers and incorporates them into a reproducible process that yields reproducible results — thus mitigating project risks. As the blueprints are based on a comprehensive Simatic PCS 7 secu-rity standard, the secure solution can be easily designed to cover all required assets and security levels. Plant operators benefit by having a security solution engineered for their specific requirements that is ready for certification according to IEC 62443. During plant operation, the security documents support system maintenance. As cyberthreats become more frequent and more creative, in-dustry players are developing and deploying more sophisticated cybersecurity systems and procedures to meet ever-changing re-quirements. Supported by their own specialist organizations, a global network of experts for automation and cybersecurity monitors current and developing threats, analyses solutions for weaknesses, and develops suitable measures, thus making sure that their control and automation solutions are and continue to be secure by design.

Solutions for Security by Design Securing automation and IT systems against cyberattacks and manipulation should be a top priority

The industrial security concept Defense-in-Depth for industry from Siemens.

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Economies of scale are well-understood in the mining business.

Ordinarily, the larger the process stream, the more minerals are re-

covered. Availability is key. Oftentimes, water and power present a

problem. The plants are powered by electricity, which can be expen-

sive in the remote parts of the world where most mines operate, and

the mines usually have either too much water or not enough. Both

situations are less than ideal.

More recently, plant managers and metallurgists have turned

to technology to help them improve costs and reduce the demand

for water and electricity. Process improvements are based on site-

specific conditions. Sometimes the mills need to crush the process

stream to a fine consistency to liberate the metals, while others

want to produce a size fraction with a consistent quality.

Water is the traditional conduit for many of the processes and

that’s an expensive proposition in some of the more arid parts of the

world where mines operate. Likewise, tailings storage is a huge cost

consideration and, in some cases, an environmental liability.

Providing SolutionsBased in Duisburg, allmineral Aufbereitungstechnik GmbH cele-

brated its 30th anniversary last year. Over the years, this group of

engineers has established a market-leading position with several

pieces of mineral processing equipment, including the alljig jigging

machines, allflux fluidized bed separators, allair dry jigging systems

and the allgauss WHIMS (wet high intensity magnetic separator).

Today, some of the world’s largest iron-ore beneficiating plants

and coal preparation plants use the alljig. Selling more than 550

machines, allmineral would be considered the world’s market leader

in jigging technology.

The company not only focuses on wet processing, it also offers

expertise in dry processing technology. The allair air jig is used for the

beneficiation of coal and lignite in a dry environment. Since the indus-

trial introduction of this innovative technology in 2002, allmineral has

delivered more than 85 machines to coal operators worldwide.

“We are technology providers with extensive equipment knowl-

edge and mineral processing experience,” said Marco Steinberg,

managing director and CEO, allmineral. “These days our clients are

asking for more and we are providing in the form of ‘smart solu-

tions.’ They want more than just the equipment. They want the en-

tire solution and we are supplying turnkey solutions.”

Beyond the handover, customers have told them they would like to

have supervisory advice as far as the processes are concerned, Steinberg

explained. So, allmineral now provides an on-site specialist who looks

after the entire operation in terms of providing the products and meeting

the customer’s requirements. “This includes maintenance service and

plant availability,” Steinberg said. “Some of our customers operate in

regions with limited technicians. With this service, allmineral provides a

plant and a plant operations supervisor, who is employed by allmineral.”

allmineral is shifting from supplying equipment to providing

solutions. Steinberg defined solutions as everything around the equip-

ment, everything required to bring the equipment into operation and

at the end to get the final product recovered, adding a dewatering

process as an example. “But we would not do anything beyond that,”

Steinberg said. “This distinguishes us from an engineering company.

We are not an engineering company, we are a technology provider.”

For allmineral, most of their applications are for wet processing.

The company is currently involved with bringing three processing

projects online for manganese in Georgia, coal in Indonesia and

tungsten in Spain.

At the Chiatura mine, located near the town of Chiatura in cen-

tral-western Georgia west of Tbilisi, a complete plant designed by

allmineral is helping to process manganese ore to the world market

standard. With the turnkey processing plant, annual production is

set to increase to 700,000 metric tons (mt). The allmineral plant has

a rated capacity of 200 mt per hour (mt/h) of manganese ore. Pivotal

to the efficient processing are two alljig jigs, one allflux and an all-

gauss WHIMS high-intensity magnetic separator. Ore with grain siz-

es between 1 mm and 5 mm is conveyed into an air-pulsed, almost

entirely wear-free alljig F2200x3000 fine jig. Manganese ore with

grain sizes between 5 mm and 20 mm is fed to an alljig G1700x3000

coarse jig. Manganese ore of less than 1 mm is fed to an allflux 500.

Next, an allgauss WHIMS D-250 high-intensity magnetic separator

with up to 18,000 Gauss separates the paramagnetic minerals from

any weak magnetic minerals. The processing plant is designed to

enrich the manganese content in the products to more than 38% by

weight for a metal recovery of more than 90% by weight.

allmineral was recently awarded a contract to plan, equip and

supply a modern coal preparation plant for the SEKAKO mine in the

central Kalimantan region of Indonesia. The 500-mt/h plant is expect-

ed to go into operation by mid-2019. On this project, allmineral will be

assisted with the implementation of the project by its long-standing

partners and shareholders Citec Engineering and Hazemag. To meet

the growing demand in the world market, Indonesian mine operators

are tuning to cutting-edge processing technology to more efficiently

wash sub-bituminous and bituminous coal with varying sulphur con-

tent. The coal washing plant is equipped with a high-performance

feeder breaker from Hazemag, shareholder of allmineral. At the core

of the prep plant is a three-chamber alljig jig that will go into opera-

tion soon, meticulously grading up to 500 mt/h. Particle sizes ranging

Recovering Minerals Cost EffectivelyProcessing plants turn to technology to improve operations

For the Chiatura mines in Georgia, allmineral has designed a turnkey

700,000-mt/y manganese ore processing plant.


from 80 mm to less than 1 mm are to be efficiently separated, concen-trated and cleaned. The allmineral plant operates automatically.

Iberian Resources’ tungsten and tin mining operation, located near La Parrilla in southwest Spain, is using allmineral technology to optimize the quality of its raw material. Two high-output alljig fines jigs will serve as the core for a preconcentration process and help double the annual output to 5,000 mt per year (mt/y) and ensure a consistently high-quality product. The object is to achieve a precon-centration yield of at least 90% from the scheelite ore stream. This will also reduce the mass flow rate by 55%. Iberian Resources expects to see results when the project is commissioned in the beginning of 2019. In this case, allmineral is not just providing the preconcentra-tion plant. “We are providing the entire beneficiation plant, which also consists of spirals, shaking tables, dryers, electrostatic separators and flotation circuits,” Steinberg said. “We are also looking in the direction to possibly add more products in our portfolio by investing in R&D.”

Looking toward the future, Steinberg said allmineral is currently developing some new ideas. “Beyond adjusting equipment perfor-mance, we are looking at alternative technologies to replace the nuclear source at our fully controlled allair dry jig,” Steinberg said. “This would be a breakthrough because the miners would not have to deal with all of the safety regulations anymore.”

allmineral has also developed a prototype in-pit beneficiation plant that may increase coal recovery tremendously. “The focus on this in-pit beneficiation technology is currently for coal,” Steinberg said. “We have a relocatable unit that does everything in the pit. Our customers are telling us we are on the right track with this in-pit strategy.” Especially for this purpose, allmineral brought a mining engineer on board with mining and contractor experience to oversee the project. “When you take a close look at production costs, 90% is mining and 10% is beneficiation,” Steinberg said. “Currently, we can only save 2% to 5% off a very small slice. We could have a much bigger impact on the mining side. Looking at haulage alone, which is the largest cost, if we could make a 2% to 5% impact there, then we would be talking about a significant savings for the customers.”

When Steinberg joined allmineral more than two years ago, the market conditions were weak due to the cyclic nature of the industry. “At that time, we knew we needed to find a solution to offset these market swings and made the decision to migrate to the position of being a solutions provider,” Steinberg said. In 2017, the tide changed, the company increased its order intake, and they now have some air to breathe and can turn their attention to development.

Magnetic Separation and SortingFor 130 years, Steinert has been supplying large magnetic systems for industrial applications. The mining industry relies on magnetic separation to recover minerals as well as tramp metal from process-ing streams. More recently, the company has developed an extensive line of sorting equipment, which is another form of separation that uses X-ray technology (XRT). Sorting systems retrieve higher grade ores from the product streams, reducing the amount of rock that is processed and the costs associated with it.

Magnetic separators remain the most important product line for Steinert. “We recently received an order from BHP for the South Flank mine for a little less than A$1 million for three large magnets,” said Kai Bartram, head of mining, Europe, Asia and Africa for Steinert. “We worked with Jacobs on the Oyu Tolgoi mine in Mongolia and won an order for A$1.9 million for four big tramp metal-removal magnets. Magnets are our bread and butter.”

In the last two years, however, mining companies have shown greater interest in ore sorting. “For the mining sector, sorting is no

longer viewed as a niche product,” Bartram said. “We are seeing more mining companies include sorting in their mineral processing systems from the beginning. These companies are always looking for ways to improve efficiency and save energy or processing costs.”

Steinert now has nearly 100 sorters in the field. “They are real-ly popular with both gold and copper mining operations,” Bartram said. “One of the big advantages with Steinert’s ore sorting systems is that they are dry processes, which aligns well with the desire to reduce or eliminate water from any mining facility.”

Future low-grade sorting projects will require higher capacities. “The biggest challenge is not the capacity,” Bartram said. “Instead, the limiting factor will likely be the capability of the sensors to de-tect those lower grades.” By focusing on the sensors, or a combina-tion of sensors and different detection methods, Bartram believes that there is room for improvement.

For 18 years, Bartram has been on a quest to implement sorting in the mining business. He now takes solace in the fact that he no longer needs to convince mining companies as to whether it makes sense or not. Sorting is now an accepted tool that helps streamline the flowsheet and reduce the initial capital investment.

JOEST Celebrates 100 Years of Screening SuccessSimilar to many successful Germany companies, JOEST is privately held and this year it will celebrate its 100-year anniversary. After four generations, the Joest family, the namesake, sold the company 20 years ago to another private owner, who set the company on a course to become a truly international supplier of vibratory screen-ing equipment. At that time, JOEST was exporting machines and the company began to establish subsidiaries in foreign outposts. They started with an Australian subsidiary in Perth in 2001 serving the mining market, and today they have 10 subsidiaries outside of Ger-many — at least one on each continent.

“We took a very steady, deliberate path,” said Dr. Marcus Wirtz, managing director, JOEST. “A hundred years later, we are still mostly vibratory equipment and we’re the biggest. We started small and now we have a complete line of vibratory feeders and screening ma-chines, not just large screens, but small and medium screens, too, with all of the motions: linear, circular, flip-flow, etc.”

Wirtz knows screens and screening machines and he also un-derstands the many industries JOEST supplies. He is board member of VDMA metallurgy division and chairman of its department of pro-cessing technology. He spent a considerable amount of time estab-lishing those subsidiaries worldwide, including a center of excellence for mining in Perth, as well as an extensive assignment in Chicago

Sorting systems, such as the one from Steinert above, divert waste from the processing stream and reduce the load on the plant.


developing the company’s largest subsidiary. These subsidiaries

handle not only sales and service, they are stand-alone companies

with engineering and support services, Wirtz explained. As an exam-

ple, when it comes to the exchange of technical mining-related in-

formation, the Australian subsidiary takes the lead. “They have been

growing so fast and they have a wealth of experience,” Wirtz said.

In addition to investing abroad, JOEST has been investing at

home, too. In fact, during the past few years, they have invested

more than 10 million euros in the facilities at its headquarters in

Dülmen, Germany. They now have a total of 80,000 m2 with 65,000

m2 under roof. “With the exception of some carefully selected weld-

ing contractors, all of the work, including end-assembly and test-

ing, is done in-house here at this location,” Wirtz said.

JOEST has grown at a time when many companies have strug-

gled with soft economic conditions. Wirtz credited the company’s

success to its people and the investment it has made to understand

a customer’s needs. “The people selling our products to the mining

business have been hired from the mining industry,” Wirtz said.

“They know what they are talking about.”

JOEST also has a research and development team in Dülmen look-

ing at different new developments. “If we decide to go a completely

new route, they develop a prototype here,” Wirtz said. “However, it’s not

always new machines. We also look at improvements for existing ap-

plications. A lot of those decisions are driven by the projects and the

customers. We design a lot of custom projects for the mining business.”

Large mining screens are a prime example. At the end of Jan-

uary, following extensive design effort using JOEST Australia’s fi-

nite element analysis (FEA) methods, JOEST began building a sin-

gle-deck screen 4.88 m (16 ft) wide, 9.76 m (32 ft) long with a

screening area of 47 m2 (512 ft2). Weighing 36 metric tons, it will be

installed in a Pilbara iron ore process plant in July. “To date, this will

be the widest screen built by a company in the JOEST Group, and the

design has been based on successful developments over the years

to meet the demands for larger machines in the mining industry,”

Wirtz said. “We decided to do it when a lot of other people were

simply looking at it. We immediately embarked on a plan to execute.

We considered several approaches. Knowing that a 1-ft increase in

width could seriously alter the stress moments and increase the risk

for machine failure. The customer insisted on 5 m and, using the

FEA, we designed a system that we believe will perform well.”

Beyond iron ore, JOEST is also working with gold and copper

miners and it has developed equipment specifically for lithium and

they believe they are the front-runners in this area as well. “We have

been working with a number of the large mining houses for 20 years

now,” Wirtz said. “Successful suppliers in these cases are pre-qual-

ified. This is a status that has to be earned for the mining sector.”

Looking toward the future, Wirtz explained that research and de-

velopment is essential. “That is why we work together with various

universities, for example with the Technical University of Aachen,

the University of Applied Sciences of Muenster and TU Bergakade-

mie Freiberg-University of Resources,” Wirtz said. “We are looking

at new technology such as flame-cutting machines with integrated

machining centers. We also use welding robots to achieve productivity

at a consistently high level of quality. As the world leader in vibration

technology with manufacturing facilities on every continent, quality is

our top priority, no matter where in the world customers buy from us.

Therefore, we continue to focus on Germany and plan further expan-

sions, especially for quality-critical parts and components.”

Filter Press TechnologyIn the mining business in general and tailings treatment in particu-

lar, clogged filter cloths can be a significant factor in terms of both

costs and time, especially since scheduling of replacements has

always been an imprecise science. Now ANDRITZ, a global leader in

solid/liquid separation solutions, has developed the Metris Smart-

FILTERCLOTH that employs a radio-frequency identification (RFID)

system to track its use and replacement.

This increased transparency for filter cloth use will help op-

timize the process and the equipment’s availability. The system

consists of an RFID chip that is tagged to each cloth along with a

user-friendly software package. The machine operator can track the

use of and document any damage to the cloths digitally on a tablet.

The system enhances filter-press performance by monitoring

filter cloth life precisely and recording any damage for trouble-

shooting purposes. What’s more, operators can even read the RFID

chip during the filtration process. It can be used with all makes and

models of filter press, disc filter and drum filter.

The first tests were conducted in South America. “Since we started

using the new RFID-enabled filter cloths a few months ago, we have

collected a lot of data,” said Davidson Vale, service product manager

filter presses for ANDRITZ. “This means that we know much more about

the process than ever before, and the data analytics and software are

helping us transform this knowledge into concrete improvements. For

example, it enables us to schedule replacements ahead of time based

on current production demands. We have also been able to make some

tweaks to the equipment’s parameters to make the cloths themselves

last longer, which obviously cuts down on costs. We are pretty confident

that the efficiency benefits will offset the cost of this technology.”

Predictive maintenance facilitates optimized planning and

maximized up-time, leading to higher machine availability with

better performance. Additional smart sensors all around the filter Dr. Marcus Wirtz, managing director, JOEST.


press collect all the relevant operational data, and sophisticated

data analytics tools turn this into relevant information. The data

collected, analyzed, and processed by the system make both the

machine and the process perform better. Optimization is enabled

through self-monitoring operations, such as automatic mainte-

nance proposals and adjustment of parameters.

Taming Tailings to Protect the EnvironmentMine tailings are, potentially, the most environmentally hazardous

part of any mining operation. GEA has developed diverse technologies

that can significantly reduce the impact of tailings on the environ-

ment and help minimize water usage, while isolating and extracting

valuable minerals, which can become an additional revenue source.

Traditionally, mine tailings, in the form of a slurry containing fine

mineral particles, have been contained in large impoundments known

as tailing storage facilities (TSFs), where the solids are allowed to set-

tle and the water is decanted. However, this process is less than ideal.

Settling takes a long time, which means the TSFs can become quite

large. When these dams fail, it poses a serious environmental threat.

“By effectively managing their tailings streams, mineral companies

can reduce the amount of wastewater they produce and increase the

reusability of water, cut their waste disposal costs, and lower the overall

environmental impact of a mining operation,” said Tore Hartmann, se-

nior product sales manager for chemicals and minerals, GEA.

GEA’s decanter technology is well-established for dewatering

a wide range of sludge materials. In recent years, decanter capacity

has improved now making it effective for use in mining operations. For

A CENTURY

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100 years of experience in vibrating technology.

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your bulk material – worldwide.

Using ANDRITZ’s Metris system, a technician can track the use of and

document any damage to the cloths digitally on a tablet.

GEA’s crudMaster is used to dewater

pre-thickened slurries.


example, GEA machines can handle up to 100 tons of slurry per hour,

which makes them much more practical for this application.

A GEA Dewatering Decanter crudMaster, for example, is used

to dewater the pre-thickened slurry, rotating at application-based

centrifugal forces. Because the machine is lined to protect against

the abrasive nature of the feed, it is very robust — ensuring op-

erational excellence. Anionic flocculants are added to the process

to further agglomerate fine particles causing them to drop out

of solution. As a result of the additional high-speed centrifugal

treatment, the cleaned water — up to 90% — is returned to the

process, or if meeting the right standards, returned to the envi-

ronment. The solid matter, approximately 80% dry solids, is then

discharged on to a conveyor, ultimately producing a dry cake for

easy disposal or reprocessing.

For applications where the cleanest pos-

sible water is required, the integration of a

GEA nozzle disc stack centrifuge is an excel-

lent solution. This centrifuge separates the

process water from the fine particles and re-

duces, and can even eliminate, the need for

further storing the slurry. Superior separation

efficiency, at high throughput capacities in

continuous operation are the key product

benefits. During this process, customers also

have the opportunity to extract valuable ele-

ments — such as gold, silver, copper, lead

and zinc — which can be sold to generate

extra revenue. And because the process

takes place in a closed environment, the risk

of chemicals or other hazardous materials

leaking into the environment is restricted.

High-pressure Grinding RollsFurther to the company’s innovative and reliable equipment for mining,

bulk material handling and minerals processing, TAKRAF is increasingly

distinguishing itself as a complete service provider across the entire

value chain. At bauma 2019, visitors will, for the first time, be able

to have a complete overview of the company’s entire service portfolio,

which ranges from project development services to technical studies on

comminution and minerals processing, innovative fabrication solutions,

various technical services and comprehensive after-sales support.

With a view to further developing their capabilities within

the market of the comminution industry, TAKRAF continues to devel-

op their range of roller presses, with a scale model of a High-Pres-

sure Grinding Roll (HPGR) on display at the booth. Two of these

+49 4102–2197–671 www.steinertglobal.com/mining

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With ANDRITZ filter press technolo-gy and Metris addIQ control systems, you are prepared for the challeng-es of digitalization and IIoT – all to the degree that fits your individual needs. Metris addIQ control systems combine all our extensive operation, troubleshooting, and start-up ex-

perience in one tailored automation solution. With the broad portfolio of scalable automation solutions, ap-plicable for a wide range of purposes (e.g. predictive maintenance, process monitoring, troubleshooting, long-term trending, etc.), ANDRITZ is your full-service provider for filter presses.

TAKRAF continues to develop its range of roller presses.

https://www.steinertglobal.com/mining

https://www.andritz.com/separation


machines are currently being manufactured at the company’s spe-

cialized fabrication facility in Lauchhammer, Germany. These ma-

chines can each handle more than 1,000 tons of cement clinker per

hour, with each machine incorporating rolls with a diameter of 1,800

mm and a weight of more than 50 tons per roller. To meet the chal-

lenging longevity requirements of such a machine, each roll surface

is protected from wear by weld hardfacing for cement applications,

and with tungsten carbide inserts for ore processing.

With the integration of the well-known DELKOR and Tenova

Advanced Technologies (formerly Bateman Advanced Technologies)

brand of products into TAKRAF as specialized product lines, the

company’s portfolio for the minerals processing and beneficiation

sectors has been considerably enhanced. At bauma, visitors will be

able to focus upon the company’s capabilities in minerals process-

ing, including Solvent Extraction (SX) and lithium recovery, as well

as flotation, thickening, filtration and Dry Stack Tailings (DST).

Vertical Roller Mill Grinds Copper MatteLast year, LOESCHE delivered a vertical roller mill for grinding copper

matte to Aluminum Corp. of China (Chinalco). It was installed in

Southeast Copper’s newly erected smelter in Ningde, in the southern

Chinese province of Fujian — 500 km to the south of Shanghai. The

three-roller mill will grind 100 metric tons per hour (mt/h) of copper

matte to a fineness of 20% with a sieving residue of 0.074 mm.

Southeast Copper is managing this major project as a joint

venture together with the Fujian government, which is intended to

contribute to the supply of copper to Chinese industry. The plant in

Ningde Zhangwan Industrial Zone was completed in the second half

of 2018 and is expected to produce 400,000 mt/y of copper.

LOESCHE’s contract partner and the planner of this plant is

Changsha Nonferrous Metallurgy Design Institute Co. Ltd. from Chang-

sha, China. LOESCHE was able to convince its new customers not only

with its efficient vertical roller mill technology, but also with the fact

that in previous years various mills of the same type for industrial min-

erals were delivered to various different non-ferrous metal producers,

where today the grinding plants are in successful operational use.

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

provides enhanced roller protection when grinding

abrasive ores.

Köppern – Quality made in Germany.

» State of the art HPGRs and wear protection

» Process technology know‑how

» High plant availability

» Low maintenance cost

Pilot HPGR testing capabilities in Australia, Canada,

Germany and Russia

For further information please contact

[email protected]

Grind down your maintenance costs

Vertical roller mills from LOESCHE grind hard materials to a fine consistency.

http://www.koeppern.de



Nearly two-thirds of the world’s salable minerals are extracted by

open-cast mining methods. The pits at these surface mines are

designed to effectively move waste and overburden to recover the

ore or coal. The configurations differ from deep pits using benching

operations for copper and gold to large area stripping for deposits,

such as coal, iron ore and bauxite.

Despite their differences, these mines have a lot in common.

Safety is a primary concern. Lowering the cost per ton of material

moved is another major objective. For both, today’s mine operators

are turning to technology to achieve these goals.

Liebherr to Offer More Electric-powered OptionsServing the mining market for as long as it has, Liebherr understands

the cyclic demand swings and the impact of global trade tensions.

Despite these influences, the company has been steadily selling more

surface mining equipment these days. Last year, they debuted the

100-ton T 236 haul truck and the PR 776 dozer, which is gaining in

popularity, especially in Russia. This year, the company introduced

the R 9100B & R 9150B line of hydraulic excavators at bauma China.

“The B designation means that these machines have certain

technical improvements when it comes to the engine, machine

management and hydraulic systems,” said Dr. Joerg Lukowski, ex-

ecutive vice president for sales and marketing for Liebherr’s mining

equipment. “The Liebherr line of diggers includes nine models and

they differ depending on when they were placed in the field. One is

always a bit older than the others and we plan to steadily introduce

more models into the industry.” The company would like to upgrade

all the three-digit model excavators to the four-digit designation

during the next few years, Lukowski explained.

With the new R 9100B & R 9150B, Liebherr has placed a

priority on three areas: reliability, fuel efficiency and productiv-

ity. “We had some reliability issues with the R 9100 and R 9150

excavators when they were launched,” Lukowski said. “We made

several improvements. Among other things, we added a new

Liebherr engine. We were sure from the beginning that there was

huge potential in using our engines, but we had to overcome some

technical challenges, which we have now resolved. Customer

feedback confirms that the engines are now performing excellent.

We’re building a lot of engines by the way.” Last year, Liebherr

built 10,000 engines — obviously not all of those were for mining.

Liebherr established an engine-building plant in Colmar,

France. Not far from the factory where they currently build the ex-

cavators and the T 236 haul truck. “We will offer our own engine

in addition to those available from third-party providers for the

mining-class shovels, which require the bigger engines,” Lukowski

said. “Now that the Liebherr engines have logged some hours, we’re

starting to see superior performance and extended life. These new

Liebherr engines are extremely fuel efficient.”

The Liebherr engines are in operation for many years in our earth-

moving machines and on the smaller mining excavators (R 9100B

& R 9150B). And the first R 9400 with a Liebherr engine will head

to Australia soon. “That machine was field-tested here in Europe,”

Lukowski said. “We are gradually introducing the engines by machine

type. We will also continue to work with other engine OEMs with whom

we have long-term relationships.” Lukowski views the situation as

a friendly competition where Liebherr can learn from them and vice

versa. Ultimately, however, the engine is the customer’s decision.

Productivity is an extremely important consideration for hydrau-

lic excavators. The standard bucket capacity for the R 9100B has

been increased to 7.5 m3 and the R 9150B now has an 8.8-m3 buck-

et and, with a special attachment, it can be increased to 9.6 m3.

Lukowski sees huge potential for electrification and that in-

cludes the excavators. “Mining class excavators are stable oper-

ators that load a lot of material, but they don’t normally move a

lot,” Lukowski said. “The upside would be the electric engine. The

drawback would be the electric cable, which impacts mobility un-

less a clever system is developed for managing it.” In the next three

to four years, Liebherr plans to offer electrically powered models for

all the excavators from the R 9150 up to R 9800.

What drives the forwarding thinking at Liebherr today is digita-

lization. Liebherr’s TroubleShoot Advisor is becoming more and more

powerful, Lukowski explained. “We are collecting a lot of data from

the machines in the field related to downtime events,” Lukowski

said. “We analyze those events with the team and then we load all

the know-how in the TroubleShoot Advisor, which we make available

for the Liebherr service force and also for customers so they can

make use of mobile terminals for fault finding.”

Customers have told Liebherr that the tool has reduced

fault-finding procedures by a factor of five. “Those devices will

Advances in Surface MiningOptimizing operations to lower the cost per ton

The Liebherr PR 776 dozer has become a trusted piece of auxiliary equipment.

Liebherr introduces the B series excavators at bauma China.


eventually be replaced with units on the machine, but we don’t want

the operator to be overwhelmed with data,” Lukowski said. “The ser-

vice people should also have onboard functionality. With their key

card, they can access more data than the operator.”

When it comes to data, Lukowski said he routinely encounters

two types of customers — the ones that say they are interested

in all the data and another group that only wants actionable data.

“Our customers should not have to invest their time in deciphering

the data,” Lukowski said. “Using intelligent algorithms, we can pro-

vide the data to them in a more organized format. They can have

all the data if they want it. We are very open in the regard, but we

believe there is more value in actionable data. Knowing the oil tem-

perature was within limits for the last four weeks wouldn’t be useful.

Knowing when the oil temperature increases to over and above the

limits, however, would be important.”

Liebherr continues to build the large T 284 and T 264 haul trucks

in Newport News, Virginia, USA. “An important haul truck project for

us is trolley assist,” Lukowski said. “We have diesel-electric trucks

and they can be equipped with trolley assist. We have T 284s oper-

ating with trolley assist in Zambia and Panama. We also have some

trolley assist interest with the T 236 haul truck too.”

Looking toward the future, Lukowski marvels at the accelerating

pace of technology-related improvements, especially with the electric

drives and the sensors used in digital systems. “If we can improve the

performance of excavator and lower the operating costs for users, they

can consider higher stripping ratios,” Lukowski said. “Drones are be-

ing used extensively in agriculture to improve safety and productivity

and those technologies will likely influence the mining business. The

drones could be used to better assist the truck loading process.”

Meanwhile, Liebherr continues to strengthen its footprint in the

mining business. The company’s facility in the Kuzbass has been

completed and the company has made a significant investment in

its facilities in Western Australia. Last year, they built a small sup-

port shop in Panama for haul trucks. Liebherr has more project-re-

lated investments planned for 2019.

BWEs Offer Continuous Excavating, Conveying and StockpilingBucketwheel Excavators (BWEs) are continuous mining machines

designed for the extraction of overburden (semi-hard material, such

as clay, sand, gravel, marl, etc.), lignite or hard coal with an output

of up to 60 million bank m3/year. These gigantic machines represent

a true mechanical endeavor and they have steadily evolved since

they were launched in the early 1920s. TAKRAF, a Tenova company

and leader in the global mining, bulk handling and minerals pro-

cessing industries, is one of the world’s major players within this

technology space and boasts a long tradition of delivering BWEs for

specific material conditions.

A bottle of champagne broken against the bucket-wheel for good

luck was followed by the applause of the miners and the technicians

participating in the celebration. On November 17, 2017, TAKRAF BWE

SRs (K) 2000 No. 2147 resumed operations, after a comprehensive

refurbishment process at a coal mine in Kazakhstan. This ancient

ritual is usually practiced in occasion of the launching of vessels,

but it has also become a tradition for the commissioning of refur-

bished BWEs. In fact, such a machine deserves to be celebrated as

it represents a true mechanical endeavor. The gigantic size of these

machines is self-explanatory if one considers their application.

For the refurbishment project in Kazakhstan, TAKRAF employees

based at the Ekibastuz Service Office supervised the entire con-

struction phase, with active support from colleagues in Germany

who traveled to the site for final assembly of the BWE, balancing

of the excavator, and the commissioning of electrical and automa-

tion components. The machine, originally built in 1985, underwent a

comprehensive refurbishment process lasting several months, with

TAKRAF supplying several components manufactured at its own

Lauchhammer workshop in Germany, numerous spare parts and

almost all of the required electrical components.

This 33-year-old machine is a testament to the longevity of

these machines and their technology.

In the 1970s and early 1980s, TAKRAF delivered 13 BWEs, type

SRs (K) 2000, for the coal deposits found in the Ekibastuz region of

Kazakhstan. Almost all of these machines were designed for hard

overburden, interburden and hard coal, with uniquely designed buc-

ketwheels, with 32 buckets mounted on an 11-m wheel, suitable for

material up to UCS 40 MPa. By using an extremely high number of

buckets combined with a maximized cutting speed, TAKRAF man-

aged to create a smooth operation under hard coal conditions. These

machines — boasting a distinctive TAKRAF design — have been

operating with continued success for more than three decades.

BWEs can be employed across a wide-variety of commodities

covering a wide range of capacities, with TAKRAF offering BWEs

with rated capacities ranging from 500 to 20,000 m3/hr. In most

applications, the BWE is connected to a belt conveyor system or a

cross-pit spreader.

Most BWEs are designed to fulfill a client’s specific requirements

and incorporate various solutions according to their unique applica-

tion, including actual site conditions. As a result, either compact

or large-scale BWEs can be employed, depending on the required

cutting height, block width and length of the working bench. Com-

pact excavators are most suited to mines with short benches and

harsh, irregular operating conditions; whereas large machines are

more suited to working in flat mines with unconsolidated rock, large

benches and regular mineral deposits. Excavator design always

aims to meet specific demands and requirements of the project in

terms of optimization, standardization and maintenance.

TAKRAK recently refurbishes this 33-year-old BWE in Kazakhstan.


Leveraging its in-house Mining Technology Center (TMTC),

TAKRAF prepared conceptual and appraisal studies comparing

BWEs with different mining methods. The success of a BWE ap-

plication is highly related to a consistent design, according to the

project conditions. This represents a crucial aspect of the compa-

ny’s project philosophy. BWEs have been mainly employed in lignite

and coal mining operations. However, this technology has an inter-

esting future in alternative areas where large amounts of material

have to be (re)moved: larger-scale sand mining for construction, as

well as mineral sands projects. The continuous mining method also

provides an excellent opportunity for highly automated solutions.

In fact, TAKRAF has developed a toolbox of operator assistance and

operation planning and control features for BWE operations, based on

the real-time analysis of the cutting resistance. The understanding of

the instantaneous value of the cutting resistance provides invaluable

information regarding the geo-mechanical properties of the native

rock, state of tool wear, process efficiency, and much more. This in-

formation enables the visualization and modeling of geological struc-

tures, the monitoring of the wear state of cutting tools, as well as the

automation of slewing speed control. The ultimate goal is to maximize

production rates in compliance with stress limitations for equipment

and tools. Thanks to this solution, operators can finally take advantage

of the available drive capacity due to the natural heterogeneity of the

rock, and the risk of overload and shutdown of the slew drives caused

by local solidifications cause is minimized and/or avoided.

Using similar state-of-the-art maintenance solutions, low-wear

hydraulic systems for boom supports and travel control, as well as

the latest variable-frequency drive technology, the availability of a

giant BWE is now nearly 100%.

Tailored Training CoursesRWE Technology International (RWE TI) tailors OpEx-training pro-

grams to meet specific customer needs, covering technical, economical

and/or administrative aspects of mining and power plant operations.

“The tailored training solutions are designed to grow our customers or-

ganization through skilling its people and future staff,” said Dr. Martin

Schmid, senior mining engineer and training expert for RWE TI. “Many

of these classes are facilitated in collaboration with engineers and

operating staff from the RWE Group. Through sharing hands-on opera-

tional knowledge, we offer genuine value to our customers.”

The programs that RWE offers are mainly intended for engineers,

specialists, experts and middle managers, having several years of

working experience. Trainees profit from the vast expertise and knowl-

edge available within the RWE network, and gain valuable insights in

mine operation, power plant management, operation, maintenance,

health, safety and environment. Programs may include best-practice

exchange with RWE peers, lectures, workshops, seminars, discussions

in small groups, study visits, shadowing, case studies and mentoring.

“We also take pride in ensuring participants understand how to

use their new skills in practice to increase efficiency and optimize

operations and production back home,” Schmid said. “Therefore,

training courses may range from days up to months, with flexible

locations, depending on the content choice and individual training

needs. Trainings may take place in Germany at RWE offices and

sites, or at the mine site, depending on what is most cost-effective.

We offer experienced mine experts to join participants in their daily

work in-house at their company or on-site their plant site.”

In the case of RWE on-site trainings, the company assists its

customers with necessary conditions such as accommodations,

travel, and an interpreter to enable a comfortable and efficient

learning environment. As far as the training course content, cus-

tomers can always rely on their experts to advise on which training

scheme to adopt to meet training preferences and requirements.

During a typical training day, a small group (three to four people)

with similar learning objectives is guided by one of RWE TI’s facilitators

to meet and exchange best practice with RWE operational experts during

a workday. The day starts with a theoretical classroom session followed

by practical site visits in the afternoon, according to carefully prepared

learning schedules. To internalize the course content, RWE provides the

online learning platform MOODLE for participants to summarize their

lessons learned at the end of a training day. Participants are awarded

with certificates, recognizing attendance and course subjects.

Since 2015, RWE TI has been consulting with a major iron ore pro-

ducer developing a new opencast mine. Due to the proximity of the

mine site to the beautiful rainforest area, local environmental regu-

lations call for the strict reduction of emissions. Truck-shovel mining

methods generate significantly high emissions. So, the mine operator

decided to implement an In-Pit Crushing and Conveying System (IPCC)

powered by renewable energy from hydro power. RWE is well-known for

its more than 120 years mine and power operator heritage, with spe-

cific operator expertise in opencast mining and IPCC. In addition, RWE

TI has more than 50 years of consulting history in pooling and repro-

cessing RWE operator expertise from their own mine operations using

this knowledge in a structured way to help other companies worldwide

execute successful projects in raw material and energy production.

During mid-2016, RWE TI was asked to offer a long-term workforce

development program for the future mine operation, aiming to produce

90 million metric tons (mt) of iron ore annually by the end of 2020.

Guiding and mentoring an open-pit mining operation in pro-

duction ramp-up phase using new fully continuous mining equip-

ment was the key target. The partnership began by establishing

an on-site OpEx-training program to give the mining company’s

leadership team visibility to the operation’s KPIs, including gaps

between current and planned performance. So far more than 20% of

the respective operation staff have been trained by RWE TI in small

groups. Advanced training packages covered a variety of themes

aiming to optimize the mine’s organizational structure, production

processes and overall performance, focusing on continuous mining,

bulk material transport, shiftable belt conveyors and a technical

understanding of continuous mine operation planning.

Trainings took place either on the job with the equipment at

the mine sites or at RWE’s facilities, supplemented by classroom

sessions with RWE operator staff. In addition, RWE TI embedded

An RWE TI training group visits the Hambach mine during a belt shift operation

with a German-Portuguese interpreter.

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technical assistance at the customer’s mine sites, to implement

changes as part of the customer’s teams and transfer key skills to

the staff. Key suppliers and development partners for belt conveyor

components provided technical visits to factories, explaining valu-

able insights of high quality and durable products.

Extracting Bauxite With Surface MinersWest African Guinea is known for its large high-quality reserves of

bauxite. This potential has prompted the country to continually expand

its bauxite mining sector in recent years, making substantial invest-

ments. Wirtgen surface miners are playing a decisive role in this de-

velopment process, as many of the country’s bauxite mining operations

rely on Wirtgen’s technology as their standard extraction technique.

Wirtgen supplies surface miners in a variety of performance classes

for the selective mining of raw materials, such as coal, limestone, baux-

ite, gypsum, salt and phosphate. In addition to mining, these machines

can also carry out routing operations for the construction of mining

service roads and railway tracks, the rehabilitation of roadways and

installation of tunnel floors. The range of applications further includes

the precise cutting of trenches and channels as well as surface leveling.

In 2001, the first Wirtgen surface miner was commissioned in a

mine close to Kindia, a small town 120 km from the capital, Cona-

kry. At this time, drilling and blasting was the main bauxite mining

technique in use. Since then, however, the process has shifted to the

more economical, safe and environmentally friendly surface mining,

and today Wirtgen surface miners extract 100% of the ore. Since

2001, the Wirtgen technology has proven its additional benefit to

the growing bauxite mining industry in Guinea, where 25 Wirtgen

machines are currently in operation.

The most commonly used models for bauxite mining in Guinea

are the 2200 SM and the 2500 SM. The first is compact yet pow-

erful, with a 2.2-m-long cutting drum and 708-kW engine power.

The machine can cut rock with unconfined compressive strengths of

up to 50 MPa, ideal for medium-sized mining operations. The larger

model, the 2500 SM, guarantees higher production rates and offers

a cutting width of 2.5 m, 783-kW engine power and can economically

mine rock with an unconfined compressive strength of up to 80 MPa.

Both models demonstrate their advantages in both productiv-

ity and product quality, guaranteeing lower production costs per

ton compared to conventional mining. On average, 1.25 million mt

of bauxite are extracted each year with the 2200 SM and 3 million

mt with the 2500 SM. These figures are achieved because the ma-

chines work 24/7.

The figures are all the more impressive considering Guinea’s hu-

mid climate, with a monsoon season that lasts from June to Novem-

ber and is a major challenge for mining companies. During periods of

heavy rainfall, cutting-to-ground or drilling and blasting expose the ore

to precipitation, resulting in high transportation costs due to the ore’s

high moisture content resulting in other negative downstream effects.

Wirtgen surface miners, which are equipped with a discharge

conveyor, minimize such climactic effects by cutting and crushing

the material with a special cutting drum and placing it alongside

the machine (sidecasting) ensuring constant productivity while min-

imizing the environmental impact. The use of a surface miner also

has a positive effect on water management in an opencast mine.

The cut surfaces are leveled and can be cut at an angle. This further

improves drainage and reduces water seepage into the ground.

During side-casting, Wirtgen surface miners leave high stockpiles

allowing a superb bucket fill. This protects most of the mined material

from the rain and allows gravity to drain the piles. The major cost fac-

tor in opencast mining is haulage. Mining with Wirtgen surface miners

produces level surfaces that serve as stable roadways, supporting the

rapid transport of material. This increases the transport capacity of the

entire truck fleet. Even the wear on tires, frame and suspension is re-

duced thanks to the quality of the roadways, also allowing the use of

standard on-highway trucks. As a result, reduced transportation costs

allow mining companies to achieve lower per-ton production costs.

Mine operators benefit from several cost reductions when using

surface miners. “Our machines allow efficient extraction of material

from mines that could not be economically exploited with traditional

techniques, creating added value for the industry. For the mining

companies, this translates into significant financial advantages for

mining and processing,” said Dr. Ing. Erik Zimmermann, product

manager for surface miners at Wirtgen.

By using surface miners instead of drilling and blasting, raw

materials can also be extracted effectively in the vicinity of residen-

tial areas, public roads, villages, rivers or other infrastructure e.g.,

pipelines or power lines. It is also possible to mine resources located

in buffer and safety zones, maximizing bauxite yield within the con-

cession area, generating significant additional revenue for the mine.

In most cases, the planning and execution of blasting opera-

tions is associated with considerable effort, high costs and regu-

latory restrictions. In fact, eliminating drilling and blasting relieves

the people responsible for several challenges. The Guinean mine op-

erators using surface miners no longer need to spend time obtaining

the required permits, hiring certified blasting personnel or compiling

the relevant documentation. What is more, dispensing with drilling

and blasting has a very positive impact on public opinion, meaning

that opencast mining operations can gain wider acceptance.

In addition, Wirtgen machines enable mining companies to im-

prove material quality. The material size produced by these surface

miners is ideal for shipment by truck and rail, eliminating the use of

the primary crushers commonly used when drilling and blasting.

As Africa’s top bauxite producer, Guinea has increased its pro-

duction from year to year. In addition to the customized machine

equipment, Wirtgen is providing factory-level local customer sup-

port through an office in the capital, Conakry, which offers complete

on-site services such as technical assistance and service contracts

using qualified personnel from Wirtgen’s headquarters in Germany.

Technical support is provided directly at the mine. Wirtgen experts

are also able to support customers around the clock with custom-

ized, on-site project planning specially tailored to their needs.

The Wirtgen Surface Miner sidecasts bauxite, producing high windrows.

The leveled sidecast material is clean, stable and ready to be transferred

on to trucks with wheel loaders or excavators.

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Powering Haul Trucks at the World’s Highest MineAnyone who has ever experienced high-altitude mountain conditions

knows the feeling — the air is thin and breathing is difficult. The

amount of oxygen in the air falls with every extra meter. Even at around

3,000 meters, the conditions may not worry experienced mountain hik-

ers but those used to life at lower altitudes can already start to experi-

ence breathing difficulties at 1,500 meters. However, the high-altitude

environment at the Julong Copper mine in Tibet presents no such prob-

lems for the MTU Series 2000 engines currently driving haul trucks

from Chinese manufacturers XCMG and NHL. And the remarkable

thing is that they operate with absolutely no reduction in power.

“We already knew our engines are ideal for operation at altitude

and we specifically set them up to ensure they deliver 100% power

under those conditions. Nevertheless, we were still surprised by just

how much better they are than other engines operating in the mine,”

said Alexander Richter, the MTU applications engineer who conducted

commissioning operations in Tibet for haul trucks from both manu-

facturers. “I had much bigger problems acclimating to the environ-

ment myself,” he admitted. For one thing, he had to work more slowly.

“Right from the start, I had to get used to working at a more measured

pace.” The rarefied air is low in oxygen and the human body constantly

demands a readily available supply. As a result, people working at

altitude have to breathe faster and tend to be constantly out of breath.

Richter and his Asian coworkers used a Landcruiser for their

daily commute between the Tibetan regional capital Lhasa and the

mine. At first, the 1,700 meter difference in altitude proved a chal-

lenge for them all, causing constant headaches. “We found it hard

to understand how the Chinese and Tibetan mineworkers were able

to work in the thin air at that altitude.” But eventually they got used

to the conditions. “After three days, we were acclimated and work-

ing was no longer as difficult,” said Richter.

Unlike the crew, the MTU engines were on top form from the start

— thanks to cutting-edge engine technology. Smart coordination

between two-stage turbocharging, exhaust gas recirculation and

high-pressure common rail injection systems meant that the engines

met Tier 4 emissions regulations without any need for exhaust gas

aftertreatment. “The engines’ two-stage turbocharging technology is

the crucial factor for operation at altitude,” explained Richter. Unlike

older units with single-stage turbocharging, the latest engines utilize

two-stage technology to ensure adequate compression and air-feed

for combustion. The air first undergoes precompression in a low-pres-

sure turbocharger before it is cooled and then further compressed in a

high-pressure turbocharger prior to final cooling.

As a result, the air is so highly compressed that when it reaches

the combustion chamber it again contains all the oxygen the engine

needs for combustion. Consequently, no hardware modifications to

the engine were needed and MTU engineers simply adjusted the en-

gine control using the “virtual engine” facility. Every MTU engine mod-

el has a computerized thermodynamic simulation model validated on

the basis of measured data from test stand trials. This enables MTU

developers to pre-calculate and program the correct engine control

settings for every conceivable set of environmental conditions. These

then only need to undergo on-site testing and fine adjustment.

The engines’ environmental pressure sensors are especially

vital for operation at altitude. These measure barometric pressure

to allow the engine control system to select exactly the right perfor-

mance maps that relate to operation at the appropriate altitude.

“In theory, we knew it would work,” said Richter. Nevertheless,

commissioning in Tibet was still a tense process. “Here on site, the

engines have to operate at 5,500 meters and we had no relevant

practice-based data for that,” he explained. At these altitudes, en-

gines from our competitors have had problems with serious power

loss and heavy smoke. Engine damage is frequent. That does not

happen with MTU engines.”

In their very first tests in Tibet a year ago, MTU engines demon-

strated their outstanding altitude-performance capability. Chinese

construction machine manufacturer XCMG tested and commis-

sioned a vehicle powered by a 16-cylinder MTU Series 2000 engine.

The company has already ordered a further 10 engines and for the

last few months another Chinese construction machinery company

NHL has been running altitude trials in Tibet involving two MTU Type

12V 2000 C66 mining engines. “So far, the results have been very

impressive,” said Richter.

Haul trucks from both companies are now in full, regular daily op-

eration carrying 90 and 110 ton loads of copper and spoil at the mine.

Their crews may quickly get out of breath in the thin air, but their

MTU engines definitely do not. Capable of traveling uphill significantly

faster than other trucks at the mine, the MTU-powered vehicles deliver

greater productivity than other haul trucks at the site.

Driven by Digital InnovationToday’s highly competitive mining environment is characterized by

depleted reserves, volatile commodity prices and increased ore vari-

ability. Digital solutions that offer both visibility and control across

the entire mine to market value chain constitute a potentially criti-

cal commercial advantage.

The ABB Ability MineOptimize portfolio of pit to port digital

technologies, incorporating the open industrial internet technology

platform, ABB Ability, gives mining operators smart solutions to re-

al-world problems, allowing them to make informed decisions that

reduce OPEX and CAPEX, improve safety, automate machinery opera-

tion, and facilitate predictive rather than preventative maintenance.

Visitors to this year’s bauma conference in Munich, Germany,

have the opportunity to witness first-hand how advancements in the

industrial internet of things (IoT), artificial intelligence (AI)-driven

analytics and machine learning are informing a new generation of

hyper-connected technologies. On its stand (Hall C2, Stand 348)

ABB will demonstrate how its Ability MineOptimize encompasses

optimized engineering, electrification and automation solutions,

digital applications, and collaborative services proven to reduce

cost, minimize risk and improve efficiency.

“At bauma 2019, ABB is proud to showcase its specialized min-

ing motors and drives for mining equipment, as well as our ABB

Ability MineOptimize portfolio, incorporating the ABB Ability Stock-With their new MTU engines, the Chinese NHL trucks at the Julong Copper

mine are more productive.


yard Management System,” said Peter Muehlbach, ABB’s vice-pres-

ident of process industries, Germany.

Informed by ABB’s proven heritage of providing electrification

and automation for open-pit mining and bulk material handling ap-

plications, the ABB Ability Stockyard Management System (SYMS)

can now address the challenge — particularly at integrated lignite

mine and power systems in Europe — of different mines feeding a

nearby thermal generation plant without additional coal processing.

Influenced by non-ideal coal seam sources, the quality of the

mined lignite in terms of calorific value, ash and sulphur content is

highly variable. In order to ensure an efficient combustion process,

the coal feed has to be homogenized at stockyards using selective

mining and blending processes.

ABB’s Ability SYMS uses belt scales and online analyzers to

monitor the quantity and quality of excavated coal directly on con-

veyer lines. The system begins by comparing the parameter from the

production planning system — based on the geological model of the

coal deposit — with the real measured values.

It then creates a feedback loop to the production system, calcu-

lates new excavating and blending process parameters, and trans-

mits them directly to the mine’s control system and the stockyard.

“Fueling a power plant relies on a blended mix of different coal

qualities, which is normally done on a stockyard,” Muehlbach said.

“Tracking the quality and volume of the coal, and then carrying out

the blending process remotely on the conveyor line on the way from

the mine to the power station, is really something new, especially in

terms of commercial lignite production.”

Following implementation at Vale’s iron ore distribution hub

in Malaysia, the SYMS can now deployed apart from terminals and

ports also in continuous coal mining operations.

The application integrates all relevant systems with dozens of

features in order to facilitate proactive production planning, qual-

ity management, production controlling, fully automated yard ma-

chines and semi-automated mine operation.

ABB’s global footprint can also be perceived in Chile, where it

partners with TAKRAF Tenova Chile to supply large-scale gearless

conveyor drives (GCDs) to state-owned Codelco for use in the exten-

sion of the Chuquicamata copper mine. The Chuquicamata Under-

ground project is home to the world’s largest conveyor system (55

MW installed power) connecting the subterranean operation directly

to the concentrator.

GCD installations such as these, with up to 6MW single motor

power, promise to improve reliability and system efficiencies, as well

as profitability and safety resulting from reduced maintenance.

While large conveyor installations are stationary, open-pit or IPCC

conveyors have to be moveable as they shift with the bank — as a

result, they require a different approach to gearless drive design.

ABB’s solution for the medium power range (1 to 3 MW per mo-

tor) incorporates a permanent magnet motor specifically designed

for mining applications, making the technology economically feasi-

ble for a broader range of conveyor equipment, including on mobile

equipment, as Ulf Richter, product manager, conveyor systems at

ABB Process Industries, Mining, explained.

“ABB’s new GCD for medium power with permanent magnet

(PM) motor reduces the drive train’s failure rate by 50% and im-

proves energy efficiency,” he said. “Different mounting variants

enable application-optimized use in both, new or retrofit conveyors.

“A test project established the feasibility of installing GCDs on

mobile mining machines and shows the suitability of permanent

magnet torque motors to drive conveyors. The results reveal that

GCDs are viable alternatives to conventional geared drives.”

Operatio nal Excellence Training.RWE Technology International (RWETI) tailors Operation

Excellence (OpEx) training programs adapted to customer

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Unlike a conventional gear motor assembly, no additional infra-structure is required for installation, and eliminating the gearbox from the motor significantly reduces the number of main wear parts, increasing the GCD drivetrain’s expected lifespan by more than 10 years compared with traditional geared systems. Upfront invest-ment may be up to 30% higher, but savings in maintenance, energy costs and downtime equate to an typical return on investment of less than one or two years. During one year of operation, ABB measured a 6% energy saving and 100% availability of the drive with just two hours inspection. “The results from the first project reveal the solution’s wide ap-plicability,” Richter confirms. “It is designed to work in all mines.

The drive assembly has a relatively compact footprint which is smaller than a conventional gearless system with a synchronous motor. That allows a GCD system with less weight and footprint.” Leading-edge drive technology is also the driving force behind ABB’s partnership with Komatsu. The Japanese multinational de-ploys next-generation ABB low voltage drives in its electric rope shovels. The AC Drives with direct torque control (DTC) provide more power in the same footprint, fulfilling the highest dynamic require-ments, and resulting in an efficient load cycle and dig time. Komatsu reports faultless performance and maximum uptime for two 4100XPC machines powered by ABB’s new ACS880 series drives in operation under full load production since last November. “ABB has supplied the most powerful mining machine available on the market to Komatsu during the companies’ successful 15-year cooperation, and continuous improvement has led to a highly reli-able system with an effective global service,” said Boris Rathmann, ABB product manager for shovels and draglines. The company now has more than 100 shovel and dragline AC drive units in operation worldwide, including over 90 with Komatsu and P&H Mining, and has carried out the successful implementa-tion and operation of the next generation of mining drives on the global product platform ACS880. “The mining version of the industrial product platform ACS880 has also been modified with about 30 different items to offer a more robust solution for extreme conditions in hard rock mining,” explains Rathmann. “In particular, the IGBT Power Semi-Conduc-tor has been adapted with a special sealing against dust and humidity; this is essential for the high requirements for live time of the equipment.” ABB envisages the mine of the future to be digitalized and autonomous with an minimized CO

2-footprint. Digitalization could

save the sector $373 billion by 2025, boosting productivity and safety, and reducing waste. ABB supplies leading-edge drive technology to Komatsu for its rope shovels.

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Underground mining continues to evolve from manned mechanized

processes to autonomous systems that provide better reliability.

At the same time, underground mines are looking at different ap-

proaches to development. Techniques differ considerably depend-

ing on the nature of the geologic formation and the strength of the

rock. Both hard- and soft-rock rock mining, however, have much in

common. Among others, a high concern for safety, ventilation re-

quirements, getting salable minerals to the surface effectively, and

ever-increasing travel times to the face. Those concerns have led to

a large transition to battery-powered equipment.

Supporting the Coal Business WorldwideWhat does record Russian longwall production have in common with

new underground mines in India? The answer is: Eickhoff.

The Siberian Energy and Coal Co. (SUEK) set three consecutive

longwall production records between the summer of 2017 and the

summer of 2018. In August 2018, the V.D. Yalevskogo mine produced

1.672 million metric tons (mt) per month. “The SUEK miners had only

been operating their Eickhoff SL900 shearer loader for three months

when they reached the first record of 1.407 million mt/month, then

two months later they recorded 1.567 million mt/month,” said Thom-

as Hürmann, sales director-CIS for Eickhoff. “Most people underesti-

mate the ability of Russian miners and assume that they are working

with outdated equipment and technology, but that’s not the case.”

When Hürmann started working with Eickhoff in the late 1980s,

good longwall production averaged 500,000 mt/month. Then, as

China emerged, average production steadily grew to 1 million mt/

month. “No one believed that SUEK could achieve those records so

quickly, but they have found a good balance in managing production

and downtime,” Hürmann said. “They know the keys to turn to realize

the production. Like most coal operations, they have methane and

they are using degasification techniques to maintain safe opera-

tions. Without it, there would be no production records. They are also

consistently keeping development ahead of longwall production.”

SUEK will soon be looking to purchase six additional longwall

faces. “They are focused on standardization,” Hürmann said. “We

see this when we have to adapt our shearer loaders to a longwall

face provided by another company. It’s like a puzzle, trying to figure

out what needs to be done.”

“Eickhoff opened a service center in Vorkuta last year,” Hür-

mann said. “We are one of few companies with such a facility in the

region. We will open another facility in the Kuzbass later this year.

The steel framework is already erected. This will certainly strength-

en our position for the after-sales market, as far as rebuilds, spare

parts and service activities.”

While the Eickhoff machines in Russia hold records for daily and

monthly production, China remains the biggest and most important

market for Eickhoff’s longwall shearer loaders. “Even though sales

have slowed to 10 machines per year from 20 to 25 machines per

year a decade ago, it’s an incredibly important market for us,” said

Wolfgang Schröter, director of sales, China, for Eickhoff.

Today, it’s estimated that there are more than 500 longwalls op-

erating in China and there are as many as 700 Chinese equipment

manufacturers supplying this market. “For shearer loaders alone,

there are more than two dozen Chinese manufacturers, but none

have mastered the quality of the Eickhoff shearer loader,” Schröter

said. “Eickhoff has been selling to China since the late 1960s. We

cover the whole range from 1.5-m to 8-m seam heights and we pro-

vide a high-performance piece of equipment for a reasonable price.”

Mines can easily justify higher priced equipment if they achieve

higher production levels. “The purchase decision also depends on the

conditions underground,” Schröter said. “If the geology is difficult, they

need a good machine that can handle those conditions. The local Chi-

nese providers can provide equipment for low- and mid-seam applica-

tions, but we excel in the really low and the really high applications.”

Even though the cost to them for European equipment is higher,

Schröter explained the total cost of ownership is lower. “Established

coal operators know this, but the new guys always buy on price,”

Schröter said. “Then after three or four rebuilds, they wished they

had purchased an Eickhoff machine. Some of our Chinese custom-

ers have 30 or 40 shearer loaders in their fleets.” Eickhoff maintains

a large facility in Tianjin where they are overhauling 15 to 20 shear-

er loaders per year.

Longwall shearer loaders are an important product line for Eick-

hoff and so are continuous miners. Last year, Best of Germany report-

ed on the company’s progress with continuous miners in South Africa.

This year, Eickhoff is reporting it recently sold its first continuous min-

er into India, which has a growing underground coal segment. Sing-

areni Collieries is reopening the PVK-5 mine and it recently signed a

10-year contract with Gainwell Commosales Pvt Ltd. to operate the

mine. Gainwell placed the order for the Eickhoff continuous miner.

“This is exciting news for Eickhoff as underground coal in India

has great potential,” said Uli Lange, deputy director sales for Eick-

hoff. “Gainwell is not only an important equipment distributor, it’s

also a successful mining contractor and now our partner in India.

The tendering process with state-owned coal companies in India is

often challenging and often includes contract mining. In this case,

the hiring model, the equipment will be purchased by the operator.”

Formerly known as Tractors India Pvt Ltd., Gainwell is one of

the two Caterpillar dealerships in India. Eickhoff is now Gainwell’s

exclusive supplier for continuous miners. Readers might recall that

Sophisticated Systems Improve Safety

and Productivity Underground

Eickhoff delivered its first continuous miner to India.


Cat abandoned the room-and-pillar segment for coal operators a few years ago. Gainwell uses other suppliers for shuttle cars, roof bolters and feeder-breakers.

The machine that will be installed at the PVK-5 mine will be a CM2H-45, Lange explained, which means it was originally designed for a coal cutting height of 4.5 m. “This is Eickhoff’s first continuous miner in India and there are currently 14 continuous miners operat-ing in the country,” Lange said. “The potential project list is huge.”

Working in cooperation with Gainwell, Eickhoff will make sure this project kicks off successfully, Lange explained. “This involves the training of Gainwell’s personnel,” Lange said. “There will be in-tensive training in Germany and India to reinforce the experience of Gainwell’s international team regarding Eickhoff technology.”

PVK-5 is a half-developed incline mine. It was placed on care and maintenance and Singareni is now planning to restart it toward the end of this year. At one time it was a conventional mine using drilling-and-blasting techniques. Gainwell will have to widen the roads and remove a lot of the remaining coal in the process.

They will be mining from two seams, the King and Queen seams. “We were in the King seam and we saw the areas where the previous operators took 2.5 m of the 5 m seam height,” Lange said. “Gainwell will remove that bottom coal and then advance into an upper seam section. Once they mine and depillar that area, they will move back into the lower seam ultimately with depillaring operations there, too.”

Coal India Ltd. recently achieved a national record in coal pro-duction after Gainwell deployed continuous miners at its Jhanjra Project. During December 2014, the operation set a record produc-tion of 74,505 mt/month. This was the highest recorded production from a single Indian underground mine in development until the same operation produced 78,850 mt/month during depillaring oper-ations for March 2017. The continuous miner section at the Jhanjra project produced 5,050 mt/d of coal — highest ever single day pro-duction from a continuous miner section in India. “We are onboard with a partner who knows the business,” Lange said.

The Gainwell sale could certainly lead to more Indian opportu-nities for Eickhoff. The company, however, is not only interested in selling machines. They are committed to successful coal operations with backup support from Germany.

Super-sizing Longwall HydraulicsLongwall mining operations rely on high-pressure pumps to deliver the hydraulic power needed to support and advance the face. As these mines extend the length and height of the faces, the pressures that must be maintained only increase. At the same time, autonomous operations are pushing the mining system to move the shields more quickly. This re-sponsiveness further increases the demand on hydraulic systems.

Kamat’s high-pressure pumps supply the pressure and flow that these systems now demand. The pumps have won high levels of accep-tance throughout all the major underground coal production regions because of their dependability, availability and ease of maintenance.

Business has been brisk for Kamat. Explaining that Kamat also sells supply pumps to parallel industries, such as fracking and steel descaling, Dr. Andreas Wahl, managing director for Kamat, said that the mining business contributed considerably to the company’s suc-cess last year. “We saw activity pick up in the U.S. and Australia, and China came back in a big way,” Wahl said. “The demand from China is inconsistent. We saw Chinese demand for pumps grow last year and all signs are indicating that Chinese demand could be good again in 2019, but no one knows what will happen after 2019.”

Similar to other mining suppliers, Wahl wonders what will hap-pen with global trade tensions. Some countries are encouraging the

mines to buy domestically, but they cannot replicate German crafts-manship, he explained.

Kamat sees the longwall mining business moving toward bigger pumps with higher power inputs. The standard pump for the mining business 20 years ago was a 250-kW system. Then the mines ad-vanced to 350 kW and today Kamat is selling 500-kW pumps to the mines. They have an 800-kW pump, but no mines are using that yet.

“This transition has a clear advantage for the end user because the entire system is less complex with less pumps and parts and it runs parallel to a general power input increase for the hydraulic sys-tems we are building,” Wahl said. “The systems are getting bigger and bigger, especially in Australia, China and the U.S.”

In combination with these larger pumps, Kamat is incorporating more variable frequency drive (VFD) technology. “With our specially developed frequency-converter control, our plunger pumps can be driven between 20% and 100% rotation speed,” Wahl said. “We have designed the gearing and other components to withstand op-erations at low rotation speeds.”

The standard Kamat system for longwall mining applications has a 2-MW power input with four base frames with pumps and valves and two tanks. “With the dust suppression component, we can do the same job with three 400 kW as four 250 kW on the base frames. With the bigger pumps, we are moving more liquid per pump so the system have to be engineered accordingly.”

An unloader valve is used to dump pressure off the face to com-pensate for traditional drive systems. While the unloader valve is still present, the VFDs dramatically improve system performance. “We were the first to use VFDs with the emulsion pumps in Germany in 2002,” Wahl said. “With the VFDs, the speed of pumps can be adjusted to the demand from the face. The system still uses the master and slave pump configuration. When the master reaches maximum speed, the slave pumps are brought online gradually to meet the pressure require-ments of the face. From an engineering perspective, this is state-of-the-art, much less wear, it’s a smooth, intelligent and elegant system.”

The VFDs allow a very wide range of speed adjustment from 100% down to 20% of nominal speed. One pump can pump 800 liters per minute (l/min) down to 160 l/min. When the longwall face needs 120%, the Kamat system allows one pump to run at full capacity while another runs at 20%. Other systems use two pumps running at 60%, which means they need to use two VFDs, which increases costs significantly.”

A VFD for the 1.1-KVA system will cost approximately $150,000. At 3.3 KVA, the price climbs to nearly $500,000. That explains why

Kamat’s K50000M-5G shown with motor mounted to a base frame is very popular with longwall mine operators.


these systems are so popular in China and the U.S., and not so

much in Australia. Australian coal operators use a 3.3-KVA power

supply, which makes the use of VFDs cost prohibitive.

System designs differ by region. “The classic U.S. system is a

platform with pumps and tanks, but the Australian systems have

screens monitoring everything,” Wahl said. “Obviously, they could

get by without it, but the Australian coal operators love it, so they

have it. In the U.S., it’s a much simpler system and they say put as

many pumps as you can on the platform. In China and Russia, it

looks more like a train, individual units chained together.”

As far as service and support, Kamat partners with regional

firms, such as Morgantown Machine & Hydraulics, a subsidiary of

Swanson Industries in the U.S., and Longwall Hydraulics in Aus-

tralia. “Swanson has a great workshop and they can perform all

sorts of services including major surgery on the pumps,” Wahl said.

“In general, our customers are able to do the standard service at

the pumps even in China. These pumps are very easy to service.

They don’t need to remove the head. They can change the valves,

the plunger, the packing and seals with the pump in place. For a

halfway good fitter, it’s a 1-hour job to replace valves and pistons.”

The pumps require some standard service. “The pistons last a

long time, but the seals start to leak after so many hours depending

on operating conditions and the quality of the fluids,” Wahl said.

“When the mines move the longwall, they perform more in-depth

service. That’s when they bring the whole platform into Swanson’s

shop. Swanson would replace a crankshaft and that’s something we

wouldn’t expect the miners to do.”

Seeing the role that Kamat has played in the steady improvement

in longwall operations, Wahl believes longwall operators will continue

the transition to bigger pumps and the use of VFD technology.

Underground Utility VehiclesEvery successful underground mining operation is supported by a host

of utility vehicles. Located in Emsbüren, Germany, Hermann Paus

Maschinenfabrik GmbH has been supplying utility support equipment

for more than 50 years now. The company’s MinCa series features two

basic models, the MinCa 18 and the MinCa 5.1. The vehicles are ex-

tremely versatile and can be equipped for almost any application

underground, using an interchangeable cassette system. The most

common cassette is the personnel carrier. Other cassettes have been

designed for service, diesel and lube trucks, water truck, explosives

transportation and many others applications. The payload of MinCa 18

is almost 4 metric tons, which allows for heavy loads like the Mine Res-

cue Vehicle (MRV) cassette, that Paus developed jointly with Draeger.

The engine is located at the rear of the MinCa 5.1, which im-

proves visibility for the driver and also allows for numerous engine

concepts inside the engine compartment, including several diesel

engines of different exhaust stages from Tier 2 to Tier 5 as well as

battery electric drives.

Both models are unmatched regarding their strong, helical

spring-suspended axles and chassis, offering a unique comfort for

driver and passengers.

“MinCa has always been extremely safe,” said Franz-Josef Paus.

“From the beginning, we offered both ROPS and FOPS for driver and

passenger-cassette. Braking is ensured by strong, wet disc brakes,

including a posi-stop park brake. All passengers may have single

seats with three-point belts, and of course both driver’s cabin as well

as passenger cabins can be equipped with full A/C and heating.”

Maintenance availability has always been a top priority for

PAUS on all models. All service points, such as filters and gauges

are easily accessible and visible, the chassis includes a number of

openings to reach to all components.

For some years now, PAUS has been developing battery-electric

vehicles (BEVs). The first MinCa 5.1 E model was shown on bauma

2016. “This unit has undergone a lot of testing, currently the new

generation with enhanced-battery technology is under way and will

be shown on this year’s bauma,” Paus said. “We believe BEVs will

take their share in underground mining, but not necessarily replace

all diesel vehicles. Different parameters determine the ideal vehicle,

such as mine infrastructure, layout, processes and, of course, type

of vehicle or job to be performed.”

ForSee supplies the batteries and charging systems for the

PAUS equipment. With the MinCa, there is no need to change the

battery. The onboard capacity will be enough to power the machine

for an 8-hour shift. “The MinCa 5.1 E is offered as standard with

50 kWh placed in the back, an optional 50 kWh in the front is also

available,” Paus said.

Looking toward the future, PAUS sees the underground mining

focusing more on two worlds, battery-powered equipment and auto-

nomous operations. This transition will enhance the safety for min-

ers, allow access difficult-to-reach areas and keep difficult mining

environments profitable. PAUS will continue to cover both worlds.

Automation, Communication and Energy DistributionFor many years, Becker Mining Systems AG has continuously de-

veloped the best available solutions for its customers within the

mining industry. The company continues to provide solutions in the

areas of automation, communication, energy distribution, haulage

and infrastructure. With multiple product releases in 2019, Becker

Mining Systems will break new ground in automation and energy

distribution, preparing mines for an ever-increasing amount of

data. All of its products are becoming smarter, integrating with its

software solutions MineView and smartflow, allowing mining op-

erations to achieve more from their data. Through MineView and

smartflow, mining operations have a powerful tool for monitoring

and controlling assets underground. These solutions offer AI capa-

bilities to improve safety and productivity on-site.

For underground haulage purposes, the company develops and

manufactures market-leading rail technologies. The Minetrans mono-

rail and floor-mounted trains present a clever modular kit, and are well-

advanced solutions. These track-bound solutions also come electrically

powered, and Becker has continuously improved these well-established

solutions by integrating new and updated technologies.

Having subsidiaries and service centers in all major mining

regions enables Becker Mining Systems to provide prompt and

comprehensive on-site assistance and emergency services. Product The Paus MinCa 5.1 range is a tried-and-tested concept for transporting

personnel and material.

CHINESERECORDSL 1000

RUSSIAN RECORDSL 900

CONGRATULATIONS

TO OUR GLOBAL CUSTOMERS

FOR ANOTHER SERIES

OF PRODUCTION RECORDS.

We continually demonstrate why longwall operators rely on us.

Experience has no Substitute · Eickhoff since 1864

CONTINUING

THE WINNING STREAK!

www.eickhoff-international.com

EUROPEAN RECORDSL 300

AUSTRALIAN RECORDSL 750

https://www.eickhoff-bochum.de/en/eickhoff_mining_technology


training courses and customer workshops are also a regular occur-

rence at its branches. Not only do they provide user assistance, but

they also share knowledge with, and learn from, mine operators,

working together to determine future developments.

With more than 1,500 employees worldwide, Becker Mining Sys-

tems has a common goal of constantly improving products, adopt-

ing the leadership in innovation, and delivering a superior service.

Shaft Sinking and Hoisting SystemsIn 2017, Best of Germany reported that Mosaic was partnering with

SIEMAG TECBERG to supply and install large, modern shaft-hoisting

equipment for its new K3 mine site located in Saskatchewan, Canada.

As of December 18, 2018, Mosaic commissioned the production hoist

and sent the first bucket of potash on the overland conveyor to the Es-

terhazy K2 mill. The hoist will move millions of tons of potash per year.

The K3 hoist tower contains two advanced technology SIEMAG

TECBERG hoists with supporting rope sheave assemblies. A six-

rope, 6-m Koepe production winder handles a 55-metric ton (mt)

payload using a twin drive 11-MW (15,000 hp total horse power),

said Michael Krenzer, senior project manager of SIEMAG TECBERG.

At a depth of approximately 1,100 m, it is a world leader as far as

hoisting and heavy-duty technology.

Under current market conditions, Mosaic said the project is ex-

pected to generate a rate of return well in excess of its cost of cap-

ital, while significantly lowering the risks and costs by eliminating

brine management.

Seeing the success that Canadians experienced with different

potash projects, Sirius Minerals founder of York Potash Ltd. decided

to implement similar strategies to develop its Woodsmith mine site,

located in Yorkshire, England. For the construction of the four shafts

required, York contracted with DMC Mining Services UK Ltd. and DMC

Mining Services Ltd., both subsidiaries of KGHM. The project includes

two deep shafts (a production shaft and a service shaft) that will ac-

cess a polyhalite seam and two smaller shafts to support its Mineral

Transport System (MTS). DMC decided to partner with SIEMAG TEC-

BERG for the hoisting equipment and Herrenknecht for shaft-sinking

equipment for the 1,600-m main shafts and tunnel development.

Once the initial development work is complete, four SBR-Winch-

es from SIEMAG TECBERG will be used for each Herrenknecht Shaft

Boring Roadheader (SBR) to bore the main shafts. An adaptation of

tunnel boring machine (TBM) technology married to vertical cutting

technology, the SBR delivers higher sinking rates compared to con-

ventional drill-and-blast methods, since excavation and shaft lining

can take place at the same time. The absence of explosives plus au-

tomated excavation also means greater safety levels, as no personnel

are required to work in the excavation chamber. The same technique

was used by DMC to excavate two deep shafts in Saskatchewan.

The SBR is equipped with a telescopic boom and a rotating

cutting drum, which excavates the entire shaft cross-section in a

single cycle. As the SBR descends on ropes and winches installed

on the surface, a permanent lining is inserted in sections from an

upper working deck. Altogether the SBR will require eight-stage

winches. The SBR is driven in the shaft by four synchronously oper-

ated SBR winches. Each SBR winch can also be driven individually

to balance the rope load. The ropes are triple-sheaved to minimize

the resultant maximum operating load. The 367.5-mt SBR is sus-

pended in the shaft on a total of 12 rope strands. The individual SBR

winch for its part has a service weight of roughly 67 mt providing a

maximum rope tensile strength of 525 kN. The coiled rope package

weighs a further 68 mt with a rope capacity amounting to 5,000 m.

Above the SBR, there is a working platform for shaft develop-

ment. Two utility winches will be installed directly on shaft beams

above the two shafts. A sinking hoist unit is to be supplied for trans-

porting personnel in the rope-guided kibble, mucking operations

and material transport.

In addition to the two deep shafts, a third shaft for a TBM will be

sunk at Woodsmith to the 360-m level for the MTS tunnel. The MTS

will link the Woodsmith mine directly with the Teesside harbor at Mid-

dlesbrough. The tunnel is to be driven from three points of attack with

several TBMs. One point is the Wilton portal located near the harbor and

the other two points of attack will start from MTS shafts at Woodsmith

and Lockwood Beck. The Woodsmith TBM will tunnel toward the north

and eventually meet the other TBM traveling south from Lockwood Beck.

“We are very proud to be part of that major project and pleased

that we can show the value and many advantages of group-wide

cooperation with networked structures, interlinked production pro-

cesses at various locations, state-of-the-art technologies and the

provision of sustainable project schedules and, last but not least,

can make a decisive contribution to the success of the project,”

said Michael Flender, project manager at SIEMAG TECBERG. “The

deliveries mainly stem from the SIEMAG TECBERG headquarters in

Haiger. These are rounded off by deliveries and services from sub-

sidiaries Winder Controls Europe Ltd., United Kingdom, and SIEMAG

TECBERG Inc. USA. It is advantageous that our group potentials can

be used and utilized over the entire project period.”

For the Woodsmith project, SIEMAG TECBERG was commissioned

to provide a total of eight hoisting machines, 16-stage winches and

The first 1,800-mt TBM arrives at the Wilton portal on February 18.

SIEMAG TECBERG will supply all hoisting machines, stage winches and rope

sheaves needed for sinking the MTS shafts.

MINING ▪ MATERIALS HANDLING ▪ ENERGY

SHAFT HOISTING SYSTEMS FOR UNDERGROUND MINES

SHAFT HOISTING SOLUTIONS FOR CONTAMINATED MATERIALS

MATERIALS HANDLING FOR CONVEYING HEAVY LOADS

TECHNOLOGIES FOR IMPROVED ENERGY APPLICATIONS

VENTILATION AND COOLING

www.siemag-tecberg-group.com

https://www.siemag-tecberg-group.com/


53 rope sheaves along with the corresponding automation and drive

technology, braking systems with ultra-high safety standards as

well as supervisory and coordination control units for the hoisting

systems installed in the shaft.

SIEMAG TECBERG will supply all hoisting machines, stage winch-

es and rope sheaves needed for sinking the MTS shafts and for the

subsequent tunneling phase involving mucking operations and ma-

terial transport. They include four-stage winches, two double-drum

hoisting machines, two single-drum heavy-duty hoisting machines

and two single-drum hoisting machines as permanent auxiliary

hoists. During the sinking phase for an MTS shaft, two synchronously

operated stage winches are used to operate a multideck-shaft working

platform in triple down-rope confi guration for the shaft-sinking phase.

The MTS shafts will be sunk by conventional means (drill-and-

blast). When the tunneling phase begins, the stage winches will be

recommissioned in a double-down rope confi guration to lower TBM

parts that could weigh as much as 110 mt to the MTS tunnel level.

The double-drum hoisting machine is used as kibble hoist to transport

material and muck while sinking the shaft. For tunnel boring opera-

tions, this double-drum will be used for muck skipping after recom-

missioning. The single-drum TBM cage hoist will be used for heavy-

duty transport of materials, such as tunnel lining segments, rail seg-

ments, construction material and other miscellaneous items. After

the tunneling phase is completed, this hoist will be used to transport

conveyor components to the MTS tunnel system. For emergency egress

and the transportation of personnel to the shaft working platform or to

the MTS tunnel level is undertaken by the auxiliary hoists.

After the MTS shafts are excavated, the TBMs are lowered down

the shaft in segments and reassembled underground. The fi rst 1,800-

mt TBM arrived at the Wilton portal on February 18. The two other

machines will be launched in 2020 to complete the fi nal 15 miles of

the 6-m-diameter MTS-tunnel via the MTS shafts. Workers will oper-

ate the TBMs 24 hours a day, 7 days a week, lining the tunnel with

concrete segments as it goes. Sirius expect to reach the polyhalite

seam in 2021 and to be producing 10 million mt/y of fertilizer by 2024.

Mechanized Tunneling in MiningWith 40 years of mechanized tunneling expertise, Herrenknecht de-

velops innovative machine concepts for the mining market, setting

new benchmarks in terms of effi ciency and safety.

Whether for vertical access or production shafts, sloping access

ramps, ventilation shafts or transport routes, Herrenknecht offers a

wide range of drilling and boring equipment for the mining sector.

During the construction of underground infrastructure, reliability,

safety and effi ciency are pivotal. Herrenknecht’s innovative mining

machines are based on proven principles. They are optimally suited

for safe, speedy and effi cient mechanized construction of shafts,

galleries and horizontal drives. These technologies can be used for

both small and large diameters and penetrate into any geology and

depths of up to 2,000 meters (m). Project-specifi c designs take con-

tractor wishes into account. For muck removal, pneumatic, hydrau-

lic or mechanical methods can be used. The excavated material can

also be removed through a lower level via a pilot hole.

The Herrenknecht mining portfolio includes a variety of mech-

anized shaft-boring technologies: Shaft Boring Roadheader (SBR),

Shaft Boring Cutterhead (SBC), Extension Shaft Boring Machine

(SBE), Vertical Shaft Sinking Machine (VSM), Shaft Drilling Jumbo

(SDJ) and Shaft Boring Machine (SBM). Each has different advan-

tages depending on the job-site requirements and general situa-

tional conditions. Thanks to simultaneously executable workfl ows,

high sinking speeds are possible. At the same time, these mecha-

nized methods improve work safety in mines considerably.

Hermann Paus Maschinenfabrik GmbH

Tel.: +49 (0) 5903 707-0

E-Mail: [email protected]

www.paus.de

Paus Scalers are specially designed for use in mining and tunnelling.

50 years of experience are available for your individual and efficient solution.

Showing their advantages even in challenging enviroments.

You can count on them.

Visit us on

BAUMA 2019

Open Air Area

FM 713/9

UtilizationAdvantage


https://www.paus.de/


In addition to large shaft-sinking systems, Herrenknecht has

mobile boring technology in its portfolio. A compact design is

combined with innovative solutions and thus offers a high degree

of flexibility. The Boxhole Boring Machine (BBM), for example, is

based on the principle of proven, horizontal pipe-jacking technol-

ogy and creates vertical and inclined shafts with small diameters

in stable hard rock. BBMs as well as Boxhole Backreaming (BBR),

Reef Boring Machines (RBM) and Raise Boring Rigs (RBR) work ef-

ficiently and reliably even in the tightest of spaces and the hardest

of rock — remote controlled, too, if the situation requires it. Their

modular design makes them easy to transport and quickly mobiliz-

able. Each machine is equipped for the specific project, including,

for example, the individual assembly of the boring machine with

the appropriate cutting tools.

In the mechanized creation of underground mining infrastruc-

tures, Herrenknecht sets the highest standards of health protection,

work safety and quality. As a technical pioneer, the company will

continue to develop new technologies together with contractors and

clients to make the construction of underground infrastructure in

mines even safer and more economically efficient.

With experience from more than 4,100 projects, Herrenknecht is

a technology and market leader in the area of mechanized tunneling

technology. It is the only company to deliver cutting-edge tunnel bor-

ing machines for all ground conditions and in all diameters — from

0.10 m to 19 m.

BHP Billiton’s Jansen potash project in Saskatchewan is an ex-

ample of using the technology to sink two 1,000-m deep shafts.

DMC Mining Services used two SBRs to sink the two shafts that

measured 8 m and 11 m in diameter. Shaft sinking was completed

at the end of 2018. The rock was excavated using the partial-face

method, with a cutting drum located on a telescopic boom, adapted

from VSM technology for SSMs, and conveyed through the SBR via

an innovative pneumatic system.

The roadheader is remote-controlled from the deck on the

shaft-sinking platform, allowing safe working conditions. Mecha-

nized shaft sinking aims to achieve higher efficiency, which is im-

portant for the cost-effective extraction of deep deposits.

One of the world’s most powerful raise boring rig, the RBR900VF,

is in operation at BHP Billiton’s Olympic Dam mine in South Austra-

lia. The RBR is employed for the construction of 730-m-deep ven-

tilation shafts in hard rock. Thanks to its design, the remote-con-

A shaft-sinking platform equipped with a Herrenknecht SBR is lowered in the

shaft at BHP’s Jansen project in Saskatchewan, Canada.

ARE YOU READYTO EXPLORE NEWTERRAIN?

Bauma 2019

Hall C3 | Booth 447, Booth 547

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BAUMA 2019


trolled system with the newly developed pipe feeder ensures both

efficient workflows as well as significantly greater work safety for

the personnel during installation and removal of the drill string.

Australian mining contractor Mcmahon reported, “the design

of the new raise drill has eliminated most of the manual lifting,

pushing and maneuvering efforts required by operators. This is a

major step forward that will not only boost safety, but also increase

productivity.” The machine is designed for long raises up to 2,000

m and large reaming diameters for ventilation and haulage shafts.

The robust and powerful rig with its highly efficient variable-fre-

quency drive ensures reliable operation in various conditions.

Where mechanized shaft-sinking methods cannot be used, the

Shaft-drilling Jumbo is an option. In this procedure, blast patterns

with two to five rigs can be created — either for blind shafts or

shaft enlargement. The shaft is extended with each blast and the

jumbo is repositioned.

The BBM is an example of how the technology transfer from

tunnel construction to mining operations can take place. The BBM

is based on the proven pipe-jacking method and is used to drill

vertical and inclined shafts with diameters of up to 1.5 m.

The latest top performer in Australia is a second-generation

BBM 1100 in Glencore Xstrata’s Lady Loretta mine with a contract

of more than 500 m and 26 slot holes. At up to 3 m/h and up to 16

m/shift, within just four weeks, 11 slot holes were created with total

output of more than 200 m. Three BBMs from Herrenknecht have

successfully completed upward of 130 holes with a total output of

more than 2,500 meters at different underground mines in Austra-

lia. The drilling diameter is 1.1 m at maximum drilling lengths of up

to 30 m. The remote-controlled BBM technology convinced our cus-

tomers with high occupational health and safety, high mobility and

a large spectrum of application ranges, such as ventilation shafts

and slot holes for draw points (ore extraction points).

In 2013, Herrenknecht supplied two BBM1500 for the drilling of

ventilation shafts in the world’s largest underground copper mine,

El Teniente in the Chilean Andes at 2,000 m above sea level.

The BBM1500 is a further development of the BBM1100 with a

larger drilling diameter (1.5 m) and greater torque (115 kNm). The

BBM1500 is equipped with a navigation system in order to ensure ac-

curate positioning of the hole. If necessary, the alignment of the boring

unit in the borehole can be altered by means of hydraulic cylinders.

Under the direction and with support of the systems by service

technicians from the Chile Herrenknecht subsidiary and two Chilean

drilling companies, the two Boxhole Boring Machines have completed

more than 30 slot holes and shafts with a total output of more than

1,200 m in the first 12 months. The maximum distance excavated was

60 m. Best performances of up to 2.7 m/hr and 17 m/d were achieved.

A second-generation Herrenknecht BBM 1100 creates slot holes at Glencore

Xstrata’s Lady Loretta mine in Australia.

Know-How

Performance

Reliability

Phone +49 6897 857-0

Fax +49 6897 857-188

Becker Mining Systems AG

Walter-Becker-Straße 1

66299 Friedrichsthal

Germany

[email protected]

www.becker-mining.com


https://www.becker-mining.com/


Extracting the minerals from the deposit is only half the task. Once that rock or coal is excavated, it must be moved somewhere quickly and cost effectively. Truck haulage is an option for relatively short distances. For the long hauls, however, most mines turn to conveyor systems.

Conveyors systems can be a blessing and a curse. A well-engi-neered system can move massive amounts of material. When they are down though, the entire operation is usually down. The key to effective use of conveyors is high availability. Poorly engineered systems and those that are not well-maintained will suffer from excessive downtime.

Not too long ago, conveyors only traveled in a straight line from point A to B. Today, overland conveyors cover tens of kilometers and they easily handle undulations and they even make turns. Today’s engineers are using sophisticated modeling systems to develop and build these systems and to help maintain them.

Digital Twin Identifies Issues EarlyHeadquartered in Crailsheim, Germany, Voith Turbo specializes in intelligent drive solutions, systems and comprehensive services. The company recently introduced two new programs, ERIC and ALEX, as part of its BeltGenius platform. ERIC (Efficiency and Reliability Intel-ligent Control) analyzes a range of data to determine how efficiently conveyor systems are operating. ALEX (Alignment Expert) records the alignment of idlers in a conveyor system and offers expert advice.

Explaining the BeltGenius vision, Stefan Hutzenlaub, team lead-er-application engineering for Voith Turbo, uses a house analogy, where ERIC and ALEX serve as the foundation. “Voith Turbo intends to add a lot more rooms to this house,” Hutzenlaub said. “Looking at the total cost of ownership or TCO to operate belt conveyors, Voith Turbo estimates that figure to be about $8 billion per year. By improv-ing this TCO, where we make cost improvements related to downtime, spare parts, energy efficiency, etc., we can address these issues and reduce the amount of money necessary to transport materials.”

“BeltGenius will provide mine operators with more insight into conveyor systems,” Hutzenlaub said. “If they know of an impending failure, they can take action and schedule preventive maintenance to avoid unexpected downtime. This is the overall vision.”

BeltGenius ERIC is a software solution that allows mine opera-tors to see the efficiency of their conveyor belt systems at any time. The gathered data provide them with numerous starting points to ensure the optimum use of their system, reducing their operating costs. Using standardized values, ERIC makes it easy to compare individual conveyors.

The system continuously receives data from the conveyor, in-cluding belt speed, belt tension, effective motor power for all drive motors, and temperature. These parameters are then transmitted to a server at Voith that contains a digital twin of the system, in which all relevant information about the conveyor are stored, such as belt length, belt width, the diameter of the carrying rollers, drive pulleys, return pulleys, the configuration of the transfer stations, the topography, and the trough angles. Using this information, ERIC determines a normalized efficiency value referenced to the energy

consumption for horizontal material transport, known as the Energy Performance Indicator (EnPI). This indicator allows the operator to see at a glance just how efficiently a conveyor is currently operating.

ERIC’s digital twin currently offers mine operators four dash-boards to visualize the data, Hutzenlaub explained, and Voith can provide an additional dashboard where they can outline different sections of the belt conveyor.

The digital twin compares the installed power to the actual en-ergy being used. This allows the operator to identify power reserves. In this way, the existing capacities of the belt conveyor system can be put to optimum use without jeopardizing the safety of the system. In the event of any significant deviation in the EnPI, BeltGenius ERIC sends a direct message to the operator. The operator, together with Voith, can then take action to prevent potential damage.

While ERIC is more of a Cloud-based software tool, ALEX is a more of a hands-on, sensor-based diagnostic tool with expert ad-vice. “With ALEX, we mount 40-cm sensor chains to each side of the conveyor and run the conveyor empty for three or four revolutions,” Hutzenlaub said. “We then disassemble the sensor chain and recov-er the SD cards, which contain the raw data for the alignment. Us-ing that information, Voith can provide a detailed report explaining where to align the conveyor both horizontally and vertically.”

The analysis data are listed in a well-organized log that contains specific work instructions. These data include, among other things, information about which idlers are critical, as well as how big an ad-justment must be made, in which direction, and how far. The result of the alignment work will be verified by conducting a second mea-surement run. The operator then receives the current values of the system along with a direct comparison, including an evaluation of

Smart Approaches to

Material HandlingUsing engineering expertise and technology

to move more materials

BeltGenius ERIC from Voith identifies inefficient system sections or belt segments and reduces energy and operating costs.


the potentially achievable improvements. BeltGenius ALEX has been

developed for all conveyor systems with belts thicker than 30 mm.

Depending on the conveyor length and speed, the data collection

process might take between 15 and 30 minutes. The system analyzes

the vertical and horizontal position of each idler. “This is the basis for

belt skewing,” Hutzenlaub said. “We know the real position of the idler

and we can calculate what will happen when the belt is fully or partially

loaded. The weight of the load impacts the steering forces. We provide a

report that allows the mine to run its conveyor at the highest efficiency.”

The potential savings from ALEX has already been confirmed

in an initial pilot run. There were significantly fewer unscheduled

downtimes thanks to the sensor-based, high-precision measuring

on the conveyor belt. At the same time, the energy demand for hor-

izontal material transport fell by more than 10%. Following align-

ment optimization, wear on the carrying idlers also decreased con-

siderably, extending their lifetime by one-fifth in this case.

Trough Wild Nature and Populated RegionsSichuan Yadong Cement Co. Ltd. in Pengzhou, China, has been rely-

ing on a 12.5-km overland conveyor from BEUMER Group to convey

limestone from their quarry to their silo. When constructed in 2009,

it was the longest belt conveying system in BEUMER history (BEUM-

ER installed a longer system in 2016). The troughed belt conveyor

runs through hilly terrain and nature reserves, over streams and un-

stable ground. The second project includes two additional overland

conveyors, with an overall length of 13.7 km, transporting limestone

to the cement plant. Unlike the first project, the task here was to

build the conveyor across inhabited areas. Noise emission limita-

tions set forth by the government also needed to be considered.

A traditional Chinese proverb says that the roads in Sichuan

are hard, harder than climbing to heaven. One of the cement man-

ufacturers in the region is Sichuan Yadong Cement Co. Ltd. located

near Chengdu. The company is a member of the Asia Cement Group,

headquartered in Taipeh, Taiwan.

In 2004, the Asia Cement Group decided to build a new cement

plant in Sichuan. During the development phase, the company re-

ceived approval from the Chinese government to use an abandoned

railway to transport the limestone. Halfway through finishing the

plant, however, the government decided to build a new dam. The

area intended for the transport was to be flooded, which would have

changed the project conditions considerably: roads would be flooded

and the trucks would have to take significant detours. Asia Cement

Group was also planning on building two additional kiln lines at this

location. It was determined, as a time and cost-efficient alternative,

to install a troughed belt conveyor able to navigate horizontal and ver-

tical curves. For this, the company turned to BEUMER Group. For many

years now, Asia Cement has been relying on the system supplier’s ex-

pertise and are currently operating several of its bucket elevators.

BEUMER Group took over the mechanical and electrical engi-

neering and supplied the core components for the overland con-

veyor and monitored and commissioned its installation. The advan-

tage: The Chinese subsidiary BEUMER Machinery Shanghai can be

reached easily and deployed quickly to site. “Our colleagues were

able to work closely with the customer. They know the specific local

customs, speak the language and are familiar with the particular

market and customer requirements,” said Dr. Andreas Echelmeyer,

director of conveying and loading systems at BEUMER Group.

In May 2006, Asia Cement Group awarded the contract for the

12.5-km-long system. The overland conveyor can reach a mass flow

of 1,500 metric tons per hour (mt/h) and a conveying speed of 4

m/s. “Compared to other conveying solutions, the open troughed belt

conveyors are suitable for higher throughputs,” Echelmeyer said.

“Horizontal as well as vertical curve radii are possible.” They can be

adapted to the specific task and topography. Using BEUMER calcu-

lation programs, they can calculate the static and dynamic tractive

forces of the belt during the development phase of the system. This

is a prerequisite for the safe dimensioning of horizontal curves. The

type of drive technology and conveyor belts needed are based on

these calculations. This ensures longevity of the entire system.

CIM EXPO 2019 in Montreal, Canada

Booth #1122

BeltGenius ALEX from Voith uses a sensor chain to detect inaccurate

alignment of belt conveyors and help generate solution suggestions.

The original 12.5-km conveyor spans nature reserves and rolling hills.


The rolling hills are covered with dense bamboo forest, parts

of which are listed as nature reserve. For this reason, the govern-

ment did not approve a service route nor deforestation. The ground

also presented a major challenge for the BEUMER Group engineers.

“The ground is unstable due to previous coal mining. In other areas,

the ground consists mostly of granite that could only be partially

removed,” Echelmeyer said. Another section of 1.5 km had to be

guided across a river. These framework conditions contributed to

the fact that 90% of the system was installed manually on site. As

it was impossible for trucks to transport the components, they were

carried by mules, one part at a time, to the place of installation.

The route of the overland conveyor was coordinated between

BEUMER Group and the cement manufacturer. The system suppli-

er calculated the tractive forces of the belt considering the eight

horizontal curves with radii of 1,000 m to 5,000 m. The routing was

checked for its feasibility on-site. The complete route was checked

by employees on foot, passing through rough terrain, in order to re-

liably check the predefined positions for the 460 supports for their

suitability directly on-site. Whenever technically possible, the rout-

ing of the conveyor was adapted to the topography. Height differ-

ences of up to 100 m had to be overcome within short distances,

so several sections were equipped with bridges of up to 55 m. One

section was realized with a 130-m-long tunnel.

In close cooperation with the customer, BEUMER Group designed

the overland conveyor and the bridges. The system supplier devel-

oped, built and supplied the core components for the drive and take-

up station as well as the belt of an overall length of 25 km, the idlers

and the drive technology. Since February 2009, the overland conveyor

has been transporting bulk material from the quarry to the bulk load-

ing system. Since commissioning of the first section, the mass flow of

the conveyor was increased in two steps. Today, the system conveys a

mass flow of 2,200 mt/h at a conveying speed of 4.5 m/s.

In July 2013, Asia Cement contracted BEUMER Group again for an

additional, efficient overland conveyor to replace the trucks transport-

ing the limestone from the bulk loading system to the cement plant.

A mass flow of 2,200 mt/h of limestone per hour was necessary to

meet the plant’s requirements. For this project, the first conveyor was

to be customized to these requirements. “We were planning a second

troughed-belt conveyor with an overall length of 13.7 km,” Echelmeyer

said. It would be the longest system in the history of BEUMER.

Projects of that size are often unpredictable, so flexibility was need-

ed from the engineers. During the planning phase, the cement manu-

facturer acquired another plant in Lanfeng, approximately 10 km away.

“Now we had to design the system so that both plants could be supplied

with limestone,” Echelmeyer said. The team had to divide the overland

conveyor in two parts. After 5.4 km, an additional conveyor can be added

to be fed to Lanfeng in the future. In February 2015, the system supplier

started with the installation of the conveyor frame.

Both overland conveyors have four horizontal curves with radii of

1,200 m, 1,500 m and 1,800 m. “We provided the engineering and the

individual parts such as pulleys, motors, drive and control technolo-

gy, and the entire automation,” Echelmeyer said. The installation was

monitored by a BEUMER Group supervisor and the wiring of the system

was supported by a BEUMER electrical engineer. The system supplier

was also in charge of the commissioning in May 2016. The troughed

belt conveyor is now supplying three kiln lines, a fourth line is planned.

For this system, the Chinese government has set out exact reg-

ulations on the noise emission levels so the residents would not be

impacted. “We had to minimize the noise to an extremely low level,”

Echelmeyer said. The system supplier took several constructive mea-

sures to reduce the noise emissions. “We used noise-reducing idlers

and customized protective covers on the drive stations,” Echelmeyer

said. In collaboration with the operator, BEUMER Group optimized the

conveyor frame and the completely enclosed conveyor bridge.

BREATHE THE NEXT GENERATIONThe New CFT Dry Deduster Type CFD

Optimised design Lower operating costs

New safety features and smart technology Sustainability for low environmental impact

Member Companies of the CFH Group

Sub-Exhibitors:

www.cft-gmbh.de

VISIT US!

Hall C3 no. 235

Courtyard Booth no. 23C.14

Completed in 2016, this troughed conveyor supplies three kiln lines.

https://cft-gmbh.de/


Bearing specialist Schaeffler recently introduced the sealed

241/1250 spherical roller bearing for high-pressure grinding roll

(HPGR) applications. Designed to offer significant cost savings and

boost efficiency, the ultra-large 241/1250 bearing features an out-

side diameter of nearly 2 meters (m) and was specifically designed

for the highest-capacity HPGRs. Previously only available in an open

configuration (without seals), Schaeffler’s sealed version of this

massive roll-support bearing is designed to prevent the crushing

materials from contaminating its internal components.

In the past, miners have typically been forced to inject high

quantities of grease into the bearings to prevent contamination.

While necessary, this practice wastes resources and significantly in-

creases a mine’s preventive maintenance expenditures. By introduc-

ing a sealed bearing for this challenging application, Schaeffler’s

innovation aimed to also increase mining productivity.

The bearing’s sheer mass — as evidenced by a total weight of

approximately 8 metric tons (mt), including rolling elements that

weigh 60 kg each — presented an engineering challenge that very

few companies are able to master, even before the complex seal-

ing arrangement is factored in. The outside diameter of the molded

seal, which features design elements that were first developed for

marine applications, measures approximately 1.4 m.

The state-of-the-art sealing properties are provided by metal

shields installed on both of the bearing’s side faces, each of which

features an optimized polymer seal that prevents the ingress of

crushing material.

Since the introduction in 2017, the portfolio of the sealed ver-

sion for large-size spherical roller bearings has been continuously

enlarged and is now successfully established in the market with a

huge range of available sizes.

Conveyor EquipmentHeadquartered in Hilden, Germany, the ZILLLER Group owns three

companies that specialize in conveyor maintenance: NILOS supplies

belts, industrial rubber, and all the materials needed for hot or cold

vulcanizing; WAGENER Schwelm GmbH & Co. specializes in vulca-

nizing presses for splicing and repairing conveyor belts; and Coal

Control, which has developed a system that detects longitudinal rips

in belt conveyors as well as automation technology of all kinds.

One special product, the Rotocut from Wagener Schwelm was

designed to improve safety of workers by reducing the noise and

dust when a belt must be cut for repair purposes. Available in two

different sizes, the smaller Rotocut RCM20 can cut belt thickness

up to 20 mm and a Ø steel cord up to 7.5 mm (ST2500). It’s manu-

ally driven, with a carrying side of 9 mm max., running side 5 mm

max. and a weight of 45 kg, which makes it a mobile tool to use on

site. A 65-kg version of the RCE20 has an electric drive. The larger

Rotocut RCE 40 is able to cut belts belt with thickness up to 40 mm

and Ø steel cord up to 11 mm (ST5400) with a cutting speed of up

to 1.10 m/min safely. The weight of this big machine is 165 kg.

Through the NILOS campus, the company also offers courses

to train technicians to become a certified specialist for vulcanizing

conveyor belt.

Positive Displacement PumpsThe Pniówek coal processing plant in Poland operates nine chamber filter presses with 570 m3 of filtration area each. Before moderniza-tion, two centrifugal pumps were used two feed the press and they

were consuming 560,000 kWh/year of energy. Added to this were repair costs of approximately 27,000 EUR annually. The plant operator knew there had to be a better way. PRO-

INDUSTRY Sp. z o.o. Sp.k launched a project to modernize this sys-

tem at the beginning of 2013. An ABEL positive displacement pump was added to the filter press in parallel with the existing centrifu-gal pump. This arrangement sought to improve overall efficiency by

allowing the centrifugal pump to work within its optimal flow and pressure curve while shifting the higher-pressure duty to the ABEL PD pump. The ABEL HMD-G-50-0500 was selected for its abra-sion-resistant piston-diaphragm design and its energy efficiency.

It pumps 50 m3/h at a pressure of 15 bar.

Sealed Spherical Roller Bearings

for HPGRs

The ultra-large 241/1250 sealed bearing was designed specifically for HPGR applications.

The Rotocut RCM20 can cut belt thickness up to 20 mm and a Ø steel cord up to 7.5 mm (ST2500).


Installation of the ABEL pump exceeded the expectation of the

plant operator — shortening the filtration cycle by approximately 30

minutes, extending maintenance intervals of the centrifugal pumps,

reducing consumption of stuffing box water causing dilution of the

feed, significantly reducing noise in the pump station and most im-

portantly, extraordinarily reducing energy consumption. In addition,

the flocculated structure of the filtered material was no longer dis-

mantled and a shorter filtration cycle allowed the plant to remove

one centrifugal pump from operation saving money.

Since startup in February 2013, the ABEL pump has operated

reliably. Except for a routine scheduled oil change, the pump did

not require any service or parts replacement, performing beyond the

expectations of authorities.

The total annual energy consumption has been reduced to ap-

proximately 27,000 EUR/year. In addition, repair costs have been

significantly reduced by roughly 7,000 EUR/year, due to the sub-

stantially less demand on the remaining centrifugal pump. In total,

costs were lowered by around 47,000 EUR/year.

Moving the Big Things Based in Witten, Germany, ZF Industrieantriebe Witten GmbH has an

unequalled, wide range of gearboxes for mining applications and large

construction machines. Their drive, swing, winch and pump distribution

gearboxes are extremely compact and combine precise machine control

with highest power transmission. The ZF experts know exactly what is

really needed to get the optimum performance from the machine.

For stationary equipment, the next generation of gearboxes is

smart. The new generation of ZF industrial drives is based on a new-

ly created modular system. The latest portfolio comes up with an

extremely compact and flexible design (increased power density of

up to 40% per gearbox) with the advantage of reduced weight and

size or elongation of working lifetime.

The connectivity inside the industrial environment is one of the

ZF Group’s current advantages: the cloud-based Performance Man-

agement System ZF ProVID enables a permanent Condition Monitor-

ing of the complete drive systems.

As a result, potential damage to gears and systems can be de-

tected at an early stage, downtimes can be reduced by preventive

maintenance measures, and thus significantly increasing the avail-

ability of the complete system and reduce the total cost of ownership

(TCO). The first systems have been installed in ropeway applications

and this know-how is incorporated into the extension of the system

to other industrial applications now.

Keeping It CoolAs mining and tunneling projects become more and more complex,

the problems associated with climate control also become more of a

challenge. Known as the experts for dust collection and ventilation

in the mining and tunneling industries, for some time now CFT has

also provides air-cooling solutions. The basis for this offering is the

close cooperation with WAT Wärme-Austausch-Technik GmbH, like

CFT, is also part of the CFH Group.

CFT’s product portfolio ranges from de-dusting systems for

surface and underground operations through ventilation systems to

mine air heating and cooling systems. Together, CFT and WAT have

recently implemented international cooling projects which include

both localized units up to 3 MW cooling capacity as well as main

centralized systems each with a total capacity exceeding 30 MW.

An ABEL HMD-G-50-0500 positive displacement pump improves filter press

performance at a coal processing plant in Poland.

CFT installed a ventilation system with integrated heating and cooling for the Slavkali shaft sinking project in Belarus.


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ABB Automation GmbH

Geschäftsbereich Open Pit Mining

Hänchener Str. 14

03050 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

allmineral Aufbereitungstechnik

GmbH & Co. KG

Willstätterstr. 15

40549 Düsseldorf

Web: www.allmineral.com

ANDRITZ KMPT GmbH

Industriestrasse 1-3

85256 Vierkirchen

Web: www.andritz.com/separation

ANDRITZ Ritz GmbH

Güglingstr. 50

73529 Schwäbisch Gmünd

Web: www.andritz.com

ANDRITZ SEPARATION GmbH

Edmund-Rumpler-Str. 6A

51149 Köln

Web: www.andritz.com/separation

apc analytics GmbH

Daimlerstrasse 17

61449 Steinbach / Ts.

Web: www.apc-analytics.com

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-

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

Oberste Elpersweide 4

36304 Alsfeld

Web: www.bellequipment.com

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

Bochumer Eisenhütte GmbH & Co.KG

Klosterstrasse 46

44787 Bochum

Web: www.be-th.de

http://www.abb.com/mining

https://www.abel.de/

https://www.aemdessau.de/

https://www.allmineral.com/


https://www.andritz.com/


http://www.apc-analytics.com

https://www.aumund.com/

http://www.aviteq.de

https://www.bartec.de/de/produkte/elektrotechnik-fuer-den-bergbau/

http://www.bauer.de

https://www.becker-mining.com/

http://www.bellequipment.com

https://www.beumergroup.com/

https://www.bhs-sonthofen.de/

https://www.be-th.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 TechnicBeisenstr. 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

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

Doppstadt Calbe GmbHBarbyer Chaussee 3

39240 Calbe (Saale)

Web: www.doppstadt-gurttrommel.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

Maschinenfabrik Gustav EirichGmbH & Co KGWalldürner Str. 50

74736 Hardheim

Web: www.eirich.com

EnviroChemie GmbHIn den Leppsteinswiesen 9

64380 Rossdorf

Web: www.envirochemie.com

http://www.boschrexroth.com

http://www.braeutigam-group.com

https://www.cat.com/mining

http://www.mining.cat.com

https://cft-gmbh.de/

https://www.civ-burg.de/

http://www.coal-control.com

http://www.deutz.com

https://www.dmt-group.com/

http://www.doepke-gmbh.de

http://www.doppstadt-gurttrommel.de

http://www.draeger.com

http://www.duechting.com

https://durmat.com/

http://www.eep.de

https://www.eickhoff-bochum.de/en/eickhoff_mining_technology

https://www.eirich.com/

https://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 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

Fagus 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

HADEF HEINRICH DE FRIES GmbH

Hebezeuge • Winden • KraneHebezeugfabrikGauss Str. 2040235 DüsseldorfWeb: www.hadef.de

Hammelmann GmbH

Carl-Zeiss-Straße 6-859302 OeldeWeb: www.hammelmann.com

Hauhinco Maschinenfabrik

GmbH & Co. KG

Beisenbruchstr. 1045549 SprockhövelWeb: www.hauhinco.de

HAVER NIAGARA GmbH

Robert-Bosch-Str. 648153 MünsterWeb: www.haverniagara.com

HAWE Hydraulik SE

Streitfeldstr. 2581673 MünchenWeb: www.hawe.de

HAZEMAG & EPR GmbH

Brokweg 7548249 DülmenWeb: www.hazemag.com

https://www.simulationx.com

http://www.fam.de

http://www.feluwa.com

https://www.filtrationgroup.com/

http://www.fLsmidth.com

http://www.westfalia-separator.com

https://www.nord.com//

http://www.ghh-fahrzeuge.de

https://www.fagus-grecon.com/

https://www.gta.eu/

http://www.helogistik.de

http://www.hadef.de

http://www.hammelmann.com

https://www.hauhinco.de/

https://www.haverniagara.com/

http://www.hawe.de

http://www.hazemag.com


HELLA Fahrzeugteile Austria GmbHHandelskai 94 - 96

01200 Wien

Web: www.hella.com

hema electronic GmbHRöntgenstraße 31

73431 Aalen

Web: www.hema.de

Herrenknecht MiningSchlehenweg 2

77963 Schwanau

Web: www.herrenknecht.com

HYDAC INTERNATIONAL GmbHIndustriegebiet

66280 Sulzbach/Saar

Web: www.hydac.com

Ingeteam GmbHGrand Bateau - Zollhof 6

40221 Düsseldorf

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 GmbHForststr. 29

40597 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 SE & Co. KGaAJohann-Klein-Str. 9

67227 Frankenthal

Web: www.ksb.com

Liebherr-Mining Equipment SAS49 rue Frédéric Hartmann

68025 Colmar, France

Web: www.liebherr.com

LOESCHE GmbHHansaallee 243

40549 Düsseldorf

Web: www.loesche.com

marco Systemanalyse und Entwicklung GmbHHans-Böckler-Str. 2

85221 Dachau

Web: www.marco.de

MATO GmbH & Co. KGBenzstr. 16 - 24

63165 Mühlheim

Web: www.mato.de

https://www.hella.com/

http://www.hema.de

http://www.herrenknecht.com

http://www.hydac.com

https://www.ingeteam.com/

https://www.joest.com/

http://www.kamat.de

https://www.kleemann.info/

https://www.komatsu-mining.de/

http://www.koeppern.com

https://www.krummenauer.de/

https://www.ksb.com/

https://www.liebherr.com/

https://www.loesche.com/

https://www.marco.de/

http://www.mato.de


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.dee

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

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

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.putzmeister.com

RWE Technology International GmbH

Stüttgenweg 2

50935 Köln

Web: www.rweti.com

SAMSON AG

MESS- UND REGELTECHNIK

Weismüllerstr. 3

60314 Frankfurt

Web: www.samson.de

Sandvik Mining and Construction

Crushing Technology GmbH

Friedrich-Ebert-Str. 75

51429 Bergisch Gladbach

Web: www.sandvik.com

SCHADE Lagertechnik GmbH

Bruchstraße 1

45883 Gelsenkirchen

Web: www.schade-lagertechnik.com

Schäfer Pumpen & Hydraulik GmbH

Kaiserswerther Str. 74

40878 Ratingen

Web: www.schaefer-ph.com

https://www.mesutronic.de/

http://www.mtu-online.com

https://www.jdngroup.com/

https://www.nilos.com/

https://www.oddesse.de/

http://www.pfIsterwaagen.de

https://www.pfreundt.de/

https://www.plarad.de/

http://www.prakla.de

https://www.pumpentechnik-erkrath.de/

https://www.putzmeister.com/

https://www.group.rwe/en/the-group/organisational-structure/rwe-ti

https://www.samson.de/

http://www.sandvik.com

https://www.aumund.de/en/schade

https://www.schaefer-ph.de/


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

Pallaswiesenstr. 100

64293 Darmstadt

Web: www.schenckprocess.com

Schopf Maschinenbau GmbH

Parkstr. 19 - 21

73760 Ostfildern

Web: www.schopf-mining.com

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

SKF Lubrication Systems

Germany GmbH

Neuenhausplatz 73

40699 Erkrath

Web: www.skf.com

SMT Scharf GmbH

Römerstr. 104

59075 Hamm

Web: www.smtscharf.com

STEINERT GmbH

Widdersdorfer Str. 329 - 331

50933 Köln

Web: www.steinert.de

Stromag GmbH

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

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

http://www.schalke.eu

https://www.schenckprocess.com/

http://www.schopf-mining.com

https://www.schulte-strathaus.de/

https://seka.gmbh/

https://www.siemag-tecberg.com/

https://www.siemens.com/mining

https://www.skf.com/

http://www.smtscharf.com

https://steinertglobal.com/de/

https://www.stromag.com/

https://www.takraf.tenova.com

http://www.thomas.magnete.com

https://solutions.blair.com/

https://www.tlt-turbo.com/

https://www.tml-technik.com/

https://www.schaeffer-lader.de/rohstoffgewinnung_verarbeitung

https://www.schaeffer-lader.de/rohstoffgewinnung_verarbeitung


Tüschen & Zimmermann

GmbH & Co. KG

Winterberger Str. 8257368 LennestadtWeb: www.tueschen-zimmermann.de

URACA GmbH & Co. KG

Sirchinger Str. 1572574 Bad UrachWeb: www.uraca.de

VAUTID GmbH

Brunnwiesenstr. 573760 OstfildernWeb: www.vautid.com

VELCO Gesellschaft für Förder-

Spritz- und Siloanlagen mbH

Haberstr. 4042551 VelbertWeb: www.velco.de

Voith Group

Voith GmbH & Co. KGaA

St. Poeltener Str. 4389522 HeidenheimWeb: www.voith.com

VULKAN Kupplungs- und Getriebebau

Bernhard Hackforth GmbH & Co. KG

Heerstr. 6644634 HerneWeb: www.vulkan.com

WILO SE

Nortkirchenstr. 10044263 DortmundWeb: www.wilo.com

WIRTGEN GmbH

Reinhard-Wirtgen-Str. 253578 WindhagenWeb: www.wirtgen.de

ZF Industrieantriebe GmbH

Mannesmannstr. 2958455 WittenWeb: www.zf.com

ABB Automation GmbH...................................................... VDMA 23

ABEL GmbH ....................................................................... VDMA 34

allmineral Aufbereitungstechnik GmbH............................... VDMA 3

Andritz AG ......................................................................... VDMA 12

Becker Mining Systems GmbH........................................... VDMA 32

Beumer Group GmbH & Co KG ............................................. VDMA 5

CFT GmbH ......................................................................... VDMA 35

Eickhoff Bergbautechnik GmbH......................................... VDMA 27

Hermann Paus Maschinenfabrik GmbH............................. VDMA 30

Herrenknecht AG................................................................ VDMA 31

JÖST GmbH + Co. KG......................................................... VDMA 11

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

Liebherr Holding GmbH ..................................................... VDMA 17

Maschinenfabrik Koeppern GmbH & Co KG........................ VDMA 13

RUD Ketten Rieger & Dietz GmbH u. Co KG........................ VDMA 22

RWE Technology International GmbH................................. VDMA 21

Siemag Tecberg GmbH ...................................................... VDMA 29

Siemens AG International.................................................... VDMA 7

Steinert Elektromagnetbau GmbH..................................... VDMA 12

TAKRAF GmbH .................................................................. VDMA IFC

UGOL ROSSII & Mining 2019 - Messe Düsseldorf GmbH...VDMA IBC

Wirtgen GmbH................................................................... VDMA 19

ADVERTISING INDEX

http://www.tueschen-zimmermann.de

https://www.uraca.de/

https://vautidgroup.com/

https://www.velco.de/

http://www.voith.com

http://www.vulkan.com

http://www.wilo.com

https://www.wirtgen.de/

https://www.zf.com/

www.ugol-mining.com

26th International Trade Fair for Coal Mining Technology,

Preparation and Materials Handling

NEDRA ROSSII 5th International Trade Fair for Exploitation, Processing and

Refining of Metals and Industrial Minerals

SAFETY & HEALTH 10th International Trade Fair for Occupational Health and Safety

in the Mining Industry

Novokuznetsk, Russia

4 – 7 JUNE 2019Be part of it!

Messe Düsseldorf GmbH

P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany

Phone +49 211 4560-7705 _ Fax +49 211 4560-7740

www.messe-duesseldorf.de

https://www.ugol-rossii.com/

https://www.messe-duesseldorf.de/

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.

Documents

EST OF ERMANY Mining Equipment 2019 · TAKRAF, incorporating DELKOR and Tenova Advanced Technologies, is an integrated equipment and solutions provider to the global mining, bulk