02 2011
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02 2011 EDUCATION Basics of Geo-Mechanics and Hydrology Part III - Basics of Hydromechanics
Tudeshki, H.
Institute of Mining | TU Clausthal | Germany
TRANSFER OF TECHNOLOGY Wismut – Uranium ore mining and remediation of legacies in Saxony and Thuringia
Rieger, U. ; Mann, S. ; Richter, R.
celler brunnenbau in Madagascar – Exploration of a Bitumen Deposit
Ganzer, Ch.
Use of directional drilling for underground exploration drilling - Potash Mine in Sigmundshall
Jautze, T. ; Holländer, R.
Wheel loaders as a basis for blasting vehicles, armature drill carriages and roof bolting rigs, as well as auxiliary vehicles
BMWi | Wismut GmbH | Germany
celler brunnenbau GmbH & Co KG | Celle | Germany
Thyssen Schachtbau GmbH | K+S Kali GmbH | Germany
Paus, F.-J. ; Kaufmann, M. ; Rautenstrauch, W.
Paus Maschinenfabrik GmbH | Mössinger+Wolter Maschinenbau GmbH | Germany
JUNGFRAU – TOP OF EUROPE: World-famous names in tourism and technology united at 3.454 m
Sandvik Mining and Construction
High pressure filtration laboratory and plant testwork: Tube Press
Metso Minerals Deutschland
Essen | Germany
Mannheim | Germany
NEWS & REPORTS allmineral - successfull in Down Under: Three contracts from Rio Tinto , Australia
allmineral Aufbereitungstechnik
ContiTech Takes Over Chinese Conveyor Belt Maker on June 1, 2011
ContiTech AG
Cat ® M Series 2 Motor Graders Deliver Customer Value with More Power From Cleaner Engines, Added Operator Comfort and Productivity Gains
CATERPILLAR Inc.
New Cat ®-621H, 623H and 627H Wheel Tractor - Feature New Designs and Technology for High Productivity and Operator Comfort
CATERPILLAR Inc.
Caterpillar Puts The Operator First With Three New B Series Articulated Trucks
CATERPILLAR Inc.
Duisburg | Germany
Hannover | Germany
Europe
Europe
Europe
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Sandvik Metso MTC
Hazemag & EPR GmbH Allmineral GmbH
02 2011 EDUCATION NEWS & REPORTS HAVER & BOECKER reaching new dimensions with the NIAGARA T-CLASS®
HAVER & BOECKER Screening Group
New Names make it easier to distinguish between different drill rigs
Atlas Copco Deutschland
Atlas Copco wins large orders in Saudi Arabia
Atlas Copco Deutschland
Kleemann Mobicat MC 110 Z: First Kleemann for Pinden
Kleemann GmbH
Münster | Germany
Surface Drilling Equipment | Essen | Germany
Essen | Germany
Göppingen | Germany
Volvo CE: David Smith Contractors Ltd opt or more Volvo crawler excavators Volvo CE: Arnold Plant Hire take two Volvo L50F loading shovels Telestack install 2 x Mobile Shiploaders and 2 x mobile truck unloading units for loading coal in Port of Vostochny, Russia
Volvo CE Europe GmbH Ismaning | Germany
Volvo CE Europe GmbH Ismaning | Germany
Telestack Limited Omagh | Northern Ireland
Powerscreen Terex GB Limited
From Florida to the Dominican Republic with Powerscreen! Customer Service in Focus: HCM President opens HCME’s new European Parts Depot
Hitachi Construction Machinery Amsterdam | Netherlands
E.ON setzt auf Grossdumper von Bell: Sparen im großen Still!
Bell Equipment Deutschland GmbH
Komatsu Europe International Launches New HM300-3 Articulated Truck Komatsu Europe Launches D65-17 Dozer
Komatsu Europe International N.V.
Alsfeld| Germany
PREVIEW STEINEXPO 2011
EVENTS The AMS-Event calender 2011
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Sandvik Metso MTC
Hazemag & EPR GmbH Allmineral GmbH
PREFACE
ConCept rs, e d , a e r Dear and Gentlemen Ladies on the occasion of numerous conversations with representatives of the mining and processing industry we have decided to adapt the concept of our magazine AMS-Online up to the level of the today‘s industrial requirement. As part of this issue, we would like to introduce you about the new concept of our magazine. In the following lines we will explain in a brief overview the new features and show you the associated benefits. Using some pictures, we will give you the first impressions of the new magazine character.
Innovations enclose: • Beside the quarterly publication of the AMS-Online issue, daily and weekly continuous publication of professional contributions and news • Interactive AMS-Online issues for direct online view • Representation of the authors also on the online-portal • Integration of Social Media Marketing Services • Possibilities for interactions with the readership • Key-word-search for articles
The final update from our approach concept to our new concept take palce during the frist days of july. In addition to the annoucing the new features in the AMSOnline issue, we will inform our readership about the successful upadte beyond our newsletter. If you should have questions to the new concept, we are available for your question with pleasure. Please contact us by telephone or by email. We are excited about the future and hope to continue our successful cooperation.
• New concept of advertisement in AMS Online • Browser-optimised layout adaptation • Job-board for mining and processing industry • Publication of special issues • and more ...
... your AMS-Online editorial team ... Christian Thometzek
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PREFACE
ConCept Since its first publication in 2008, our professional journal “AMS-Online� has offered updated information from mining and processing industries to a broad, continuously growing and interested readership. The AMS issues are published in German and English languages and can be accessed free of charge in highresolution print quality on our portal (www.advanced-mining.com). Due to the informative character of AMS and its portal, which can be characterized as a contact hub between the machine and mining industry, respective research institutions and various experts, we have managed to create a forum for intensive exchange of information and establishing of ties. The high number of page views and readers from over 90 countries of the world encourage us to continue our work.
The New AMS-Online Concept 2011 Based on our discussions with clients during the past year, as well as international contacts made at various events, we have decided to update our proven technique and to optimize our already successful AMS-Online concept.
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PREFACE
After the update, the basic concept, as well as the informative character of our magazine will be maintained and improved. Furthermore we will continue to report on the mining sector in the familiar categories “Further Education”, “Transfer of Technology” and “News & Reports”. The possibility of portraying of businesses within the framework of Premium Profiles will also remain. The changes are mainly in the field of technical conversion of future publications.
ConCept
News After consultations with our readers and partners in the industry, we decided to expand the AMS concept by reporting on “Daily News”. Interesting news from industry will be directly published on a daily and/or weekly basis. At the same time we will continue the proven concept of quarterly publishing. A comprehensive AMS-Online issue will be published at the end of each quarter, so to speak a “best of”, containing all published news, as well as a comprehensive further education subject and selected up-to-date professional articles/job reports. As before, each AMS issue is archived as a PDF document and can be downloaded any time after publication. From now on our partners in the industry will have the opportunity to announce vacancies or to obtain information about potential employees through review of applications for posts.
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PREFACE
Advantage
ConCept
The advantage of this continuous publication is a quicker access to information, which increases the online character of the magazine. In future our readers will have the opportunity for full text searches of individual articles and authors in our issues, through various search engines. Furthermore it will be possible to find particular contents in the published articles. Due to the individual publication of articles new key words are established and lead to the fact that search engine results are better screened and the success rate of searches in the internet is increased.
Social Media Marketing In addition to announcing publications through our newsletter we will also integrate social networks and micro-blogging services into our new concept. Apart form an intense networking, the advantage is that the link power of our portal is significantly increased. Each published article will be announced through social networks and micro-blogging services, in order to ensure high accessibility.
Layout In order to create an informative, well-arranged, search-engine and browser optimized website that engages the reader and enables interactions like commenting, assessing and recommending, we will also update the layout of our portal. Furthermore we will list authors on our portal, in addition to introduction of our premium costumers and the newly published article.
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PREFACE
ConCept
Impressions: • The new home page of your AMS-Online portal (on top) • The new clear-designed archive, for individual publication and the AMSOnline issues (on the right side)
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PREFACE
ConCept
Impressions: • The new desgined layout of the online publication (on top) • The interactive online view of the AMS-Online issues (on the right side)
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TRANSFER OF TECHNOLOGY
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EDUCATION
Basics of Geo-Mechanics and Hydrology Part III - Basics of Hydromechanics von Univ.-Prof. Dr.-Ing. habil. H. Tudeshkil Institut für Bergbau | TU Clausthal | Deutschland
E
ine notwendige Voraussetzung zur Planung von Bergwerken bildet die genaue Kenntnis über die physikalischen und mechanischen Eigenschaften des Untergrundes. Im ersten Abschnitt im AMS-Online Heft 04/2010 wurden einige elementare Eigenschaften des Untergrundes, speziell für Lockergesteine vorgestellt. Im Anschluss daran wurden zu Beginn des Jahres im AMS-Online Heft 01/2011 auf die Kennwerte bezüglich Durchlässigkeit und Festigkeit des Lockergesteins eingegangen. Der Teil III widmet sich nun den hydromechanischen Grundlagen. Im Rahmen dieses Beitrages wird vorrangig auf die Bedeutung des Wassers eingegangen.
Introduction to Hydrology The water on our earth is in a constantly changing circulation system. The following figure 1 shows a simplified diagram of the water balance of the earth.
The figures displayed in the picture indicate the annual water transport in 100 km³. While the blue figures display actually observed values, the red figures were taken from a model calculation of the Max-Planck-Institute of Meteorology in Hamburg.
Fig. 1: Earth Water Balance [15]
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EDUCATION The basic equation of hydrology gives an overview over the water balance of the earth, and contains the main components of the water balance of the earth:
P = E + R + ∆S with
P: E: R: ∆S:
Term 1
Water has several physical characteristics. As such, water reduces its density and expands when it freezes. All other material contracts during hardening in case of a reduction of temperature and as such becomes denser than its fluid. This is the reason that hardened iron sinks in its melt, whereas ice floats on water.
Precipitation Evaporation Runoff Change in water supply
Table 1 gives an overview over the size and composition of water reservoirs of the earth. The lion’s share of the water resources lies in the oceans and is in form of salt water. Fig. 3: Dipole water molecule [16] Tab. 1: Water reservoirs of the earth
Water volume 103 km3
Percentage %
1.350.400
97,580
Ice and snow
26.000
1,870
Ground water
7.000
0,510
Soil moisture
150
0,010
Surface water
127
0,009
Salt lake
105
0,007
Water in biomass
50
0,004
Atmosphere
13
0,001
Part of hydrosphere Ocean
Characteristics of Water As generally known, water is found on earth in three aggregate states, fluid, solid and gaseous. Chemically, water consists of two parts hydrogen and one part oxygen.
The specific characteristics of water are mainly based on the molecular structure of the H2O water molecule. The oxygen atom displays strong electronegative characteristics, which is due to its six outer electrons and the fact that atoms strive for a full outer shell with eight electrons. The strongly electronegative oxygen atom attracts the hydrogen electrons. Therefore an unequal charge distribution and a polar molecule come into existence. This is called a dipole. Figure 3 shows the generation of such a dipolar water molecule. Due to the lack of electrons the hydrogen atoms have a partially positive, and the oxygen molecule has a partially negative charge. Water molecules develop hydrogen bridges among each other. This occurs because of electrostatic forces between partially positively charged hydrogen atoms and the partially negatively charged oxygen atom and leads to a tetrahedron arrangement. The specific physical and chemical characteristics of water are based on the mentioned dipole character of the water molecules. The following figure 4 shows a general phase diagram, which can be applied to most substances. The melting curve, which is tilted to the right, shows a characteristic course. At constant temperature (marked by the red line in the diagram), and with increase of pressure, a fluid turns to a solid. In this connection water shows an anomaly, as the melting curve tilts to the left (figure 5).
Fig. 2: Wassermolekül [16]
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EDUCATION
Fig. 4: General phase diagram
Fig. 5: Phase diagram of water
At a constant temperature (marked as red line in the diagram), an increase in pressure leads to a reduction of the freezing point. It is only because of this phenomenon, that it is possible to skate on ice. The high pressure incurring from the weight of the skater liquefies the ice. This water film makes gliding possible. As an example it would not be possible to ice skate on CO2-ice (dry ice). The reason for these characteristics of water is also due to the formation of hydrogen bonds. The unusual cohesion of water (high surface tension) is also related to the formation of hydrogen bonds. The capillarity, i.e. ascension of water in narrow tubes, is related to the surface tension. In full wetting, the capillary head h of water in a capillary tube is calculated according to the following formula:
σ h = 2 ⋅ ⋅ R ⋅ g ρ with
σ: ρ: R: g:
Term 2
capillarity [N/cm] density [g/cm³] capillary radius [cm] gravitational acceleration [m/s²]
The thermal conductivity of water is very low, and a high energy input is needed to warm water. 2,257 kJ are required for vaporization of 1 kg of water. This heat is again released during condensation of water (heat of condensation). Water is a very good heat store, i.e. it releases its heat energy very slowly. This explains the differences in temperature fluctuations between a balanced oceanic
Issue 02 | 2011
climate and a continental climate, which is characterized by major temperature fluctuations. Furthermore, this characteristic in the reason for the see-land-wind system of the earth.
Water in Soil Under normal conditions all soil contains water. The pores of soil are very often filled with water, while solid rocks mainly contain water in clefts. In case water cannot be removed from an earth sample, even after a drying of 105 °C, it is not categorized as ground water, but as crystal water of soil particles. Figure 6 shows a rough overview over the division of the earth zones into percolation zone, capillary zone and ground water zone. Water can occur in various manifestations in soil. According to DIN 4049, ground water is defined as “underground water, which cohesively fills the cavities of the earth crust, and the movements of which are solely determined by gravity and the friction forces caused by the movements itself“ [14]. The ground water horizon can develop a free ground water level or a potentiometric surface. A so-called potentiometric surface can appear in a ground water body, which has been developed in an aquifer and is covered by an aquiclude, and the course of the groundwater level can be described by so-called hydrographs. In soil aquifers, the fluctuations of the ground water level are very low, whereas they can be high in fractured and karst aquifers. The following figure 7 shows an example of a ground water hydrograph during the time frame of 1978 until September 1987.
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EDUCATION Fig. 6: Division of earth zones
Water on partially impermeable layers, that is limited in amount and location, is called strata water. Part of the water in soil is present as adsorption water. Adsorption describes the tendency of fluid components to accumulate on solid surface. In this case the adsorption forces occur between the solid phase soil matrix and the water molecules.
In case water is only present for part of the year, e.g. during spring, it is called percolating water. Ground water or percolating water layers are usually developed above a layer with low permeability, a so-called aquiclude. Ground water is generated in relatively permeable soil or fissured rocks (aquifer) through the accumulation of percolating water.
The so-called capillary water is kept in the capillaries of earth by adhesion and cohesion forces. Herby the capillary water rises the higher, the smaller the pore diameter of the soil is. Figure 8 shows the occurrence of adsorption and capillary water.
Fig. 7: Ground water hydrograph [22]
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EDUCATION Fig. 8: Bonding forms of ground water
Part of the ground water, which is kept in the soil pores, against gravity, is called attached ground water. Attached ground water can occur either as adsorption water at the surface of solid soil particles, or as capillary water in soil pores, and is a generic term for adsorption and capillary water. In sand, the portion of attached ground water can be up to 10%, in silt up to 35% and in clay even up to 45%. Figure 9 shows the course of the gravity attractive forces between grain surface and water molecules, subject to distance. Free water occurs from a distance of 5•10-5 mm upwards. In this case the attraction forces are very low, and the water is mobile. In case of smaller distances to
Fig. 9: Size of molecular forces near the grain surface
the grain surface, the occurring forces rise exponentially. Due to molecular forces, bound and absorbed pore water can usually not be mobilized through hydrodynamic forces. Only free pore water can flow. Figure 10 again gives an overview over the distribution and movement of ground water.
Fig. 10: Distribution of precipitation and ground water [17]
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EDUCATION Fig. 11: Groundwater storey [18]
Another important term in hydrogeology is the multi-aquifer formulation (groundwater storey). Groundwater storeys consist of the alternation between aquifers and rock bodies. Aquifers absorb and transfer ground water and ground water can circulate in them. Aquifers have a high permeability. Based on the consistence of rocks, pore – fractured and karst aquifers can be differentiated. Aquicludes are layers with a low permeability that retain percolating water. A major criterion of aquicludes is the fact, that the water flowing from above flows off quicker to the side than downwards. The following figure 11 shows an example for the arrangement of aquifers and aquicludes.
The aquifers that can be found in nature can be divided into various types. One important aspect is the differentiation between confined and unconfined aquifers. Unconfined aquifers are characterized by a free (unconfined) ground water surface, where air and water pressure are in balance. In such an aquifer, the stand pipe water level in a well corresponds to the water level in the aquifer. In case water is extracted from a borehole in free ground water, and if there is no regeneration of ground water, the aquifer will be emptied. It creates a relatively steep fall of the ground water level (Absenktrichter). An aquifer that lies between two aquicludes, is called a confined aquifer (artesian aquifer). In a confined aquifer this lies in a well above the upper aquiclude. In such an artesian aquifer the stand pipe level even lies above the earth surface, and the water leaves the well (artesian well, figure 13 and 14). Fig. 12: Demonstration of a ABSENKTRICHTER
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EDUCATION Fig. 13: Principle of an artesian well [19]
Aquifers can further be classified according to their strength and the type of flow-through cavities. Hereby the following distinction can be made: • Pore aquifers, • Fractured aquiferes and • Karst aquifers.
Pore aquifers are mainly found in soil. The pores, which have a portion of approximately 30%, are filled with water.
An artesian well is a well that only flows through the pressure of ground water. Natural artesian wells can often be found in oases in deserts. Artesian wells always lie below their immediate surroundings. If the water-bearing stratum shows a trough structure and the stratum is drilled, the water is pressed to the surface by itself through the existing pressure in the confined aquifer. According to the principle of communicating pipes, the water from the confined layer can maximally rise up to the highest point of the ground water level in the water-bearing stratum.
The flow-through cavity, through which the ground water can move, is composed of these pores. Fractured aquifers can be found in hard rocks. Cleft ground water is groundwater in hard rocks, in which cavities are due to clefts and other slits. Karst aquifers are developed in karstified rocks. One example for karst ground water aquifers are karst cavities in carbonated rocks. These cavities are generated by the mostly different chemical composition of carbonated rocks and the accompanying uneven solvent power of the water containing CO2. Therefore irregular cavities, which can be flown through by ground water, are generated over geological timeframes. In karst regions, there is a close connection between ground and surface water and very high fluctuations of ground water levels can occur. Figure 15 graphically depicts the three mentioned types of aquifers.
Fig. 14: Artesian well [20]
The pressure of an artesian well decreases, in case the afflux is lower than the extracted water amount, i.e. if the ground water level in the water-bearing layer sinks, due to the water extraction. The phenomenon of confined ground water is of high importance for construction and mining measures, since the movement of earth masses and the resulting changes in load can lead to floor and shear failures in mountains. In case an upward ground water flow completely cuts the shear strength, a hydraulic shear failure occurs. In this case, the flow force affecting the grains exceeds the weight of the soil grains under uplift pressure and the soil skeleton looses its cohesion.
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EDUCATION
Fig. 15: Pores, fractured and karst aquifers [22] [23]
The following figure 16 shows the occurrence of various types of aquifers, at the example of the federal state North Rhine Westphalia.
Fig. 16: Types of aquifers, example of Kaernten, Austria [21]
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EDUCATION Bibliography [1] Dörken, W.; Dehne, E. Grundbau in Teil 1 Werner Verlag, 3. Auflage, Düsseldorf, 2003
Beispielen,
[2] Schreiber, B. Mitteilungen zur Ingenieurgeologie und Hydrologie, Heft 35, Lehrstuhl für Ingenieurgeologie und Hydrogeologie der RWTH Aachen, Aachen 1990 [3] Schnell, W. Grundbau und Bodenmechanik 1 + 2 (Studienunterlagen), Institut für Grundbau und Bodenmechanik der TU Braun-schweig, 7. Auflage, 1990 [4] Arnold, I.; Schutze, D. Der Einsatz von Dichtwänden im Lausitzer Braunkohlerevier, Vortrag anlässlich des Clausthaler Kongress für Bergbau und Rohstoffe, Mining 2002, Clausthal [5]
Rheinbraun AG Informationsbroschüren
[6]
Prinz
Abriss der Ingenieurgeologie
[18] DIN 4021 DIN 4021 - Baugrund; Aufschluss durch Schürfe und Bohrungen sowie Entnahme von Proben, 1990, Berlin, Beuth-Verlag [19] Precision Graphics, imagepages/A4artwel.html
http://www.bartleby.com/61/
[20] University of Wisconsin University of Wisconsin – Stevens Point, Department of geography and geology, http://www.uwsp.edu/geo/ [21] Joanneum Research Institut für WasserRessourcenManagement, Tiefengrundwasservorkommen Kärntens [22] Schmidt, F. Schmidt, Frank, Dipl.-Geol.: Hydrogeologische Aspekte und Konsequenzen bei der Rohstoffgewinnung in Kluft- und Karstaquiferen, AI Aggregates International 1/2006, Köln
[7] Sieb- und Schlämmanalyse Institut für Geotechnik und Tunnelbau, Baufakultät, Universität Innsbruck
[23] Geologisches Landesamt Nordrhein-Westfalen Im Grunde Wasser, Hydrogeologie in Nordrhein-Westfalen, Krefeld 1999
[8] DIN 1054 DIN 1054 - Zulässige Belastung des Baugrunds, Beuth-Verlag, 1976
[24] Firma Ott Hydrometrie Informationsmaterial Firma Ott Hydrometrie, Kempten, www.ott-hydrometry.de
[9] Grundbautaschenbuch Grundbautaschenbuch, Teil 1, 5. Auflage, Verlag Ernst & Sohn, Berlin, 1996
[25] Ingenieurbüro für Energie- und Umwelttechnik Niederschlagsverteilung in Deutschland, Ingenieurbüro für Energie- und Umwelttechnik, www.schimke.de/niederschlag. htm
[10] Schultze / Muhs Schultze / Bodenuntersuchungen für Ingenieurbauten, 1967
Muhs,
[11] DIN 18124 DIN 18124 Baugrund, Untersuchung von Bodenproben - Bestimmung der Korndichte - Kapillarpyknometer, Weithalspyknometer, Beuth-Verlag [12] Computer gestütztes Lernen in den Bauingenieurwissenschaften h ttp://www.calice.igt.ethz.ch/bodenmechanik/ classification_d/classification_d.htm [13] PERO GmbH Prospektmaterial der Firma PERO GmbH, http://www.pero-gmbh.de [14] DIN 4049 DIN 4049, Teil 1 - Hydrogeologie; Grundbegriffe; 1992, Ber-lin, Beuth-Verlag [15] Deutsches Klimarechenzentrum, Klimarechenzentrum, http://www.dkrz.de
Deutsches
[16] Chemischer Aufbau des Wassermoleküls, Hauptseminar Ernährung im IGTW an der Universität Hamburg, http://ernaehrungs-city.de/aqu-lv2.htm [17] Schröder, D Schröder, Stichworten. 2. Auflage. Berlin 1992
Bodenkunde
in
[26] Baumgartner & Liebscher Baumgartner, A. Liebscher, H.-J.,: Allgemeine Hydrologie, Berlin, 1996
der
und
[27] Umweltbundesamt, Umweltbundesamt, http://www.umweltbundesamt.de/altlast/web1/berichte/ [28] Informationsportal Grundwasser-online, Informationsportal Grundwasser-online, http://www.grundwasser-online.de [29] Stadtentwicklung Berlin, Stadtentwicklung Berlin, Senatsverwaltung für Stadtentwicklung, http://www.stadtentwicklung.berlin.de/umwelt/wasser/ [30] Der Brunnen www.der-brunnen.de [31] 1998
Informationsportal
Brunnenbau,
Bieske, Erich, Bieske, Erich, Bohrbrunnen, 8. Auflage,
[32] Dörken, Dehne Dörken, Wolfram und Dehne, Erhard, Grundbau in Beispielen Teil 1, 3. Auflage, 2002
Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining College of Shahrud (Iran); following several years of work in the mining industry, he completed his mining study at the RWTH Aachen in 1989. Since 1992 he was Chief Engineer at the Institute for Surface Mining (Bergbaukunde III) of the RWTH Aachen, mainly active in the field of open cast mining and drilling technique. He did his doctor degree in 1993 and qualified as a university lecture in 1997. In 1998 the Venia Legendi was awarded to him be the RWTH Aachen for the field “Rock and Earth Open Pit Mining”. In November 2001 he was appointed as Professor for Surface Mining and International Mining at Clausthal University of Technology. He already has over 25 years of experience in the field of project planning and cost-benefit analysis within the frame of various mine planning projects. The international tasks rendered by him mount up to more than 300 international raw material-related projects. | tudeshki@tu-clausthal.de | www.bergbau.tu-clausthal.de |
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NEWS & REPORTS
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TRANSFER OF TECHNOLOGY
Wismut – Uranium ore mining and remediation of legacies in Saxony and Thuringia
by Ulrich Rieger, BMWi | Germany Dr.-Ing. Stefan Mann, Reinhard Richter Wismut GmbH | Germany
ismut GmbH was founded 20 years ago with the mission of decommissioning former W uranium mining and processing facilities in Saxony and Thuringia and rehabilitating and reclaiming contaminated plant areas. This study is intended to outline the corporate history of Wismut and progress achieved thus far in implementing the rehabilitation project.
History of Uranium and of the Wismut company In an address delivered in 1789 to the Prussian Academy of Sciences in Berlin, the German chemist Martin Heinrich Klaproth announced the discovery of Uranium. Henri Becquerel was the first to uncover its radioactive properties in 1896. Two years later, Marie Curie (a student of Becquerel’s) coined the term „radioactivity“ (from Latin radiare = emit beams) after having discovered that thoriumbearing compounds emit the same type of radiation.
During the 19th century and until the mid-20th century, uranium was used for tinting glass and ceramics. Uranium compounds were used in glass-making to tint vases and decorative objects, but also articles of daily use such as bowls, glasses etc., in a yellow-greenish colour (Anna green). After the dropping of American atomic bombs on Hiroshima and Nagasaki and the end of World War II the nuclear arms race began. As the Soviet nuclear industry had no domestic raw material supply, the Soviet occupying power undertook intense prospecting for uranium ore. In September 1945 the „Sächsische Erkundungsexpedition
Fig. 1: Wismut sites
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TRANSFER OF TECHNOLOGY (Saxony ore search department)“ was established under the overall control of the Soviet military. Its task was the search for uranium deposits in the Ore Mountains in Saxony. As mining operations by the Wismut company proceeded, prospecting and exploration were extended up to the Harz Mountains and towards Western Thuringia as well as to Eastern Saxony.
January 1, 1991. This put an end to uranium ore mining by Wismut. The Federal Republic of Germany and the USSR signed a governmental agreement on May 16, 1991, on the termination of Wismut operations. With the coming into force of the „Wismut Act“ in December 1991, the company SDAG Wismut was changed into Wismut GmbH, a company under German corporate law.
Order No. 131 of the SMA (Soviet Military Administration) in Saxony transferred German mining companies into Soviet ownership (Johanngeorgenstadt, Schneeberg, Oberschlema, Annaberg, Lauter, and Marienberg as well as the Pechtelsgrün processing facility) „to partially settle reparation claims of the USSR“.
Corporate restructuring was initiated as long ago as 1990 with the establishment of Wismut I, Mining Division (subsequently became Wismut GmbH) and Wismut II, Mechanical and Structural Steelwork Engineering, Civil Engineering, Logistics, Service, and Consulting/ Engineering Divisions and completed in 1992 by the splitting off of the later mentioned divisions which were to operate under the company name „DFA Fertigungs- und Anlagenbaugesellschaft“.
Established in 1947 as state-run nonferrous metal company (AG) Wismut, the company changed to binational Soviet-German ownership (SDAG) Wismut in 1954 and continued uranium ore mining and processing in Saxony and Thuringia until the end of 1990. In the early 1950s, Wismut occasionally had up to 130,000 employees on its payroll. By the end of uranium ore mining at the end of 1990, AG/SDAG Wismut had produced a total of 231,000 tonnes of uranium, ranking the GDR as the world‘s fourth largest uranium producer after the USSR, the United States, and Canada. With German reunification the Federal Republic of Germany assumed responsibility for the Wismut company. In October 1990, the Federal Republic of Germany and the USSR signed a transition agreement under the provisions of which SDAG Wismut ceased its operations on
Uranium mining legacies left behind in Saxony and Thuringia Beginning already in 1986, ecological activists in the GDR undertook research on the sanitary and ecological consequences of uranium mining by Wismut. In 1988, the Kirchliche Forschungsheim Wittenberg published the documentary study „Pechblende“ - Der Uranbergbau in der DDR und seine Folgen“ (Pitchblende – Uranium mining in the GDR and its consequences) by Michael Beleites. What had been a subject that was untouchable for many was for the first time unveiled to a wider public.
Fig. 2: Drosen mine site, 1991
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TRANSFER OF TECHNOLOGY Fig. 3: Beerwalde waste rock pile, 1991
At the time when uranium production was terminated, Wismut plant areas covered a total area of ca. 37 km2; this total included the areas of 7 mining sites (example – figure 2) and 2 processing units, ca. 311 million m³ of radioactive waste rock (mine dumps, example – figure 3) dumped on 1,517 ha as well as some 160 million m³ of tailings (residues of chemical processing). These legacies are located within densely populated areas of the Free States of Saxony and Thuringia. Extending right to the outskirts of the town of Ronneburg was a worked-out open pit mine with a residual depth of 150 m, a length of 2 km and a width of 1 km, and with a residual open volume of 84 million m³ (figures 4, 5). Uranium mining legacies were particularly severe at Schlema, the former radium spa which had to close its facilities already in November 1946 on Soviet orders. At this site, 40 waste rock piles containing ca. 45 million m³ had been dumped in some cases in the immediate vicinity of inhabited areas. With its height of some 41 metres, waste rock pile #250 was visible from far away and shaped the local landscape for many years (figure 6). Buildings and infrastructure of the radium spa had for the most part to be
demolished because uranium mining near ground surface had caused surface subsidence of up to 6 m. What became known as subsidence area extended over a surface of ca. 15 ha (figure 7). While residues of uranium ore mining were dumped on waste rock piles, the residues of uranium ore processing (tailings) were deposited in tailings management areas (TMA) (figure 8). These TMAs were for the most part established in gravel pits, in worked out open pit uranium mines, or by the damming of valley locations (figure 9). At the two processing sites of Crossen and Seelingstädt a total of some 160 million m³ of tailings were deposited in the TMA by 1990. Thickness of the tailings in the TMA varies from 10 to 72 m.
Fig. 4: Lichtenberg open pit mine, Ronneburg, 1991
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TRANSFER OF TECHNOLOGY Fig. 5: Ronneburg waste rock pile landscape, 1991
Fig. 7: Subsidence area at Schlema,1960
Fig. 6: Waste rock pile #250 in Schlema,1965
Fig. 8: Tailings deposition at a tailings management area (TMA)
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TRANSFER OF TECHNOLOGY Fig. 9: Helmsdorf TMA in June 1991
In addition to the legacies left behind on the surface at the time when uranium mining was terminated, the mining sites in Saxony and Thuringia also included 56 pit shafts and 1,400 km of open underground mine workings with a maximum depth of up to 1,800 m.
Bases of rehabilitation and financing The „Wismut Act“ assigns the societal task to Wismut GmbH to rehabilitate the legacies left behind by uranium mining and milling operations. The legal framework for the project is set forth in a number of laws and regulations the most prominent of which are the Federal Mining Act, the Atomic Energy Act, the Radiation Protection Ordinance, and the Federal Water Act. Furthermore, under the provisions of the German unification treaty, two former GDR regulations continue to be applied: • Ordinance on the Guarantee of Nuclear Safety and Radiation Protection (VOAS) of October 11,1984, including VOAS implementing regulation, • Directive on Guarantee of Radiation Protection for Waste Rock Piles and Tailings Ponds and the Usage of Materials Deposited Therein (HaldAO) of November 17, 1980.
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Furthermore, the assessment of impacts due to the mining and milling of uranium ores also considered relevant recommendations issued by the Commission on Radiological Protection (SSK). The paramount criterion underlying the radiological evaluation and selection of remedial options was the observance of a guidance value for additional exposure due to uranium mining of 1 mSv/a. This effective equivalent dose is the sum of all components impacting the reference person at the considered reference site. In addition to the legal framework for the conduct of the remedial operations, the creation of the financial conditions was another crucial prerequisite. With the aforementioned agreement between the Federal Republic of Germany and the Soviet Union of May 16, 1991, the federal government has also assumed the sole financial responsibility for the company Wismut GmbH. Based on a rehabilitation program, the federal government assumed a financial commitment to fund the environmental restoration project. A recent assessment of the rehabilitation programme puts cleanup costs at some 7,1 billion euros for a period running up to 2040. During 20 years of remediation activities some 5.4 billion euros have been spent.
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TRANSFER OF TECHNOLOGY Fig. 10: Personal development and financing
In 1991, SDAG Wismut had 27,800 employees on its payroll. In 1992, the newly established Wismut GmbH had ca. 6,700 employees (on January 1, 2010: ca. 1,500). More than 10,000 former employees had registered with job creation schemes and employee development and vocational training programmes in Western Saxony and Eastern Thuringia, and ca. 9,600 had found jobs in the newly established DFA which was spun off in 1992.
Focus of remedial action Mine decommissioning, remediation, and flooding In mine decommissioning, the initial cleanup measure was the removal of all substances with the potential to contaminate the incoming water. A special case of mine flooding is the KĂśnigstein mine where uranium mining had switched later to in situ leaching with dilute sulphuric acid. The mobilised contaminant potential has to be neutralised within reasonable technical and spending limits by a targeted decommissioning process involving washing and post-treatment. Partial backfilling of mine cavities and mine flooding helps prevent surface subsidence damages. In the long term protection of groundwater against further releases of contaminants, and of heavy metals is achieved particular. Figure 11 depicts the schematic evolution of mine flooding at the Schlema- Alberoda site.
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Area rehabilitation - dismantling demolition Contaminated materials generated as part of area cleanup or of dismantling and demolishing operations are selectively sorted and separately disposed of. Uncontaminated materials are being recycled. Excavated soil contaminated with radionuclides and hydrocarbons is treated in microbiological units before it is eligible for disposal in engineered cells (e.g. within tailings management areas or waste rock piles). These cells are subsequently sealed and vegetated. Figures 12/13 exemplify the rehabilitation of a former plant area. Until now, a total surface area of 1,337 ha was reclaimed involving the excavation and placement of ca. 19 million mÂł of material. To date, more than 700 ha of the reclaimed areas have been sold, primarily for agricultural and forestry reuse.
Rehabilitation of waste rock piles and open pit mine Following comprehensive radiological, geotechnical, and geochemical evaluation of the waste rock materials the appropriate planning and licensing documents were developed. When regulatory approval was received work was initiated to profile waste rock piles with a view to achieving enduring stability.
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TRANSFER OF TECHNOLOGY
Fig. 11: Schematic flooding of the Schlema- Alberoda mine
As exemplified by waste rock pile #366 (figures 14/15), Aue Operations Office, remediation progress is clearly visible at all other sites as well. Regrading of waste rock pile #366 was a prerequisite for running the feeder road from Aue to the BAB 72 motorway across that waste rock pile.
once had been at a maximum of 240 m was still ca. 150 m in 1990. By 1991, 76 million m続 of waste rock material had already been relocated into the open pit for backfilling. Starting in 1991, the residual hole of the Lichtenberg open pit was backfilled with material excavated from surrounding waste rock piles according to an approved pattern.
Uranium ore was not only mined in underground pits but to some extent also in open pit mines. The last and largest open pit mine of Wismut awaiting backfilling was located near the town of Ronneburg (figure 16). Its depth which
In addition to waste rock, radioactively contaminated materials generated as part of the cleanup during demolition and area rehabilitation (demolition debris, scrap, excavated soil) was also placed into the open pit.
Fig. 12: Processing unit #101 in Crossen near Zwickau, 1991
Fig. 13: Processing unit #101 in Crossen near Zwickau, 2009
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TRANSFER OF TECHNOLOGY Fig. 14: Waste rock pile #366 before (1991)
Fig. 15: Waste rock pile #366 after reclamation with Autobahn feeder road 2009
Fig. 16: Lichtenberg open pit mine, Ronneburg in 1991
To date, a total of ca. 132 million m³ of mine waste were placed into the open pit mine as part of the cleanup process. The mound created on top of the backfilled open pit was capped and vegetated (figure 17). A road and trail network and a system of surface water drains are being implemented. Works are slated for completion in 2014/2015. The observation point known as „Schmirchau height“ was made accessible to the public already in July 2010.
Remediation of tailings management areas Since 1991, remediation of tailings management areas (TMA) poses a formidable challenge.
Fig. 17: fill body 2010
After having examined a number of options, Wismut has identified in situ reclamation of the facilities including partial dewatering of the residues by technical means as the preferred option. Following removal and treatment of the supernatant water, this option involves the placement of an interim cover and of a final cover to be implemented at a later stage (figures 18/19).
Fig. 19: Culmitzsch tailings management area, 2010
Fig. 18: Culmitzsch tailings management area, 1991
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TRANSFER OF TECHNOLOGY The various work steps for placing the interim cover include (figure 20): • Placement of geofabric to protect exposed tailings against dusting and of geogrid to enhance the load-bearing capacity and improve load distribution, • Establishment of vertical and horizontal drains to enhance the consolidation process and expel pore waters, as well as • Placement of a mineral cover layer to serve as a working platform and surcharge load to enhance consolidation
Placement of the final cover serves the dual purpose of long-term reduction of contaminant release and of providing the basis for subsequent landscaping. The cover consists of mineral soil materials and is designed according to the storage and evaporation principle with a thickness 1.5 m to 2.0 m. Quality assurance programmes are defined for all remedial operations.
Such waters include: • Flood water, rising groundwater in mines subject to flooding and overflow water when mines are flooded, • Supernatant and pore water, the water contained in the tailings management areas of former uranium processing units, • Surface water/seepage, water infiltrated into waste rock piles and tailings management areas, respectively, and emerging at the toe of the dump or of the dam.
The total volume of waters requiring treatment at all sites is assumed to amount to ca. 750 million m³ during the entire rehabilitation period. The water treatment units are being adapted to declining feed water volumes and contaminant loads. Such decline, and eventual compliance, will also determine how long the treatment units will have to be operated. Current estimates, on a site by site basis, are in the order of 25 to 30 years.
Environmental monitoring Remedial measures are subject to emission and immission surveillance under approved basic programmes to monitor environmental radioactivity. Wismut GmbH operates a rehabilitation monitoring and a basic monitoring system in order to ensure: • surveillance of water, atmospheric, and soil pathways as well as of the biosphere, • documentation of the impact on humans and the environment during and after remedial work, Fig. 20: Schematic diagram of interim cover placement
Water treatment Waters contaminated with heavy metals generated as part of the clean-up of former uranium mining and processing have to be treated prior to their discharge to receiving streams.
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• demonstration of regulatory compliance, and • performance review.
In 2010, Wismut operated a total of 2,070 measuring points. Of that total, 600 monitored the atmospheric pathway, 370 monitored surface water, and 1,100 monitored groundwater. Under the 2010 water pathway monitoring programme, ca. 10,000 samples were taken and analysed. An additional 25,000 samples were analysed for purposes of control and surveillance of Wismut‘s water treatment plants. Figure 21 portrays the current State of remediation progress achieved by Wismut GmbH.
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TRANSFER OF TECHNOLOGY
Fig. 21: State of remediation progress
Formerly abandoned Wismut sites These legacies were assessed to determine their radiological impacts under the inventory program on behalf of the Federal Office of Radiation Protection. In Saxony, more than 1,900 of such objects (waste rock piles, pit shafts, tailings management areas - figures 22/23) were identified. Other formerly abandoned sites are located in Thuringia and Saxony-Anhalt.
With a view to remediating these formerly abandoned Wismut sites in Saxony (mining legacies no longer administered by Wismut on June 30, 1990 and are not in the responsibility of the Wismuth GmbH), the federal government and the Free State of Saxony signed an administrative agreement in September 2003. Financing is provided by both sides up to 2012 to 39 million euros each. By the end of 2010, a total of 58 million euros was spent. In its capacity as project executing organisation Wismut GmbH is tasked with the proper conduct of remedial works.
Fig. 22: Waste rock piles at Schneckenstein site, ca. 1960
Fig. 23: Waste rock piles at Schneckenstein site, 2010
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TRANSFER OF TECHNOLOGY Outlook From a present-day perspective, core rehabilitation tasks will be completed after 2022. Following that, postremedial and long-term tasks will have to be addressed. Such tasks include: • Inspection and repair of covers on waste rock piles, tailings management areas, and the fill body atop the backfilled Lichtenberg open pit, • Treatment of contaminated flood water and seepage, • Safeguarding of mine workings to be kept open in the long term, • Environmental surveillance (monitoring), • Repair of surface damages, and
Information about the authors: Regierungsdirektor Ulrich Rieger Federal Ministry of Economics and Technology, Division III B 3 Scharnhorststraße 34 – 37 10115 Berlin Dr.-Ing. Stefan Mann Managing Director Operations, Wismut GmbH Dipl.-Ing. (FH) Reinhard Richter Wismut GmbH Jagdschänkenstraße 29 09117 Chemnitz Picture credits: Wismut GmbH
• Long-term data management.
For more complete information, please log onto the BMWi website at www.bmwi.de or onto the Wismut GmbH website at www.wismut.de.
| www.bmwi.de | | www.wismut.de |
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TRANSFER OF TECHNOLOGY
celler brunnenbau in Madagascar – Exploration of a Bitumen Deposit
by Dr. Christoph Ganzer celler brunnenbau GmbH & Co KG | Germany
Water is one of the most valuable resources of our planet. Humans, agriculture and many industries depend on a steady water supply. celler brunnenbau gmbh & co. kg makes that possible worldwide. The drilling technique of the family business founded in 1975 is applied in over 30 countries. Our sustainable quality and reliability render our experts sought-after consultants and partners for well and drilling projects of any scale. By experience, the water industry, energy suppliers and the industry rely on drilling expertise from Celle. Such as the mineral oil concern TOTAL in France that entrusted its drilling operations for the exploration of its bitumen deposit in Madagascar, which was globally tendered in January 2009, to celler brunnenbau. Apart from the drilling operations, the article especially describes the inbound logistics, which are focussed on the project start with regard to deadlines. The consignment of sea and air freight to Madagascar as well as the following coordination of transports in Madagascar represented a special logistic challenge in this case. The responsible handling of resources in Madagascar is underlined by a very extensive HSE system in the entire course of the project. The article also exemplifies the measures concerning health protection, industrial safety as well as environmental protection.
Project Description Assignment
Geography
celler brunnenbau was able to establish itself against 19 competitors in April 2009 and was assigned to drill out 18,000 core drilling meters in bituminous sandstones in the wireline core barrel drilling procedure HQ3 by TOTAL E&P Madagascar. In total, approx. 130 drill holes up to a maximum depth of 450 m were planned. The aim was to keep to a time limit of twice six months, interrupted by the rainy season from November to April.
The insular state of Madagascar which has been independent from France since 1960 is the fourth biggest island on earth. It is located east of Africa in the Indian Ocean. The Strait of Mozambique separates Madagascar from the African continent. The Comoros, located in the north, as well as Mauritius and Réunion in the east are well-known neighbouring islands of Madagascar. There are approx. 21 million inhabitants. The capital Antananarivo with its approx. 1.5 million inhabitants is located centrally in the elevated plain at 1,100 m above sea level. The island’s north-south extension is approx. 1,600 km, the east-west extension is approx. 600 km. The road network of the 540,000 km² island is subdued with aprox. 50,000 km of which only approx. 5,000 km are asphalted.
Partners In January 2009, celler brunnenbau made a 5-day probing trip to Madagascar to meet up with a company that had already pre-qualified in the ongoing tendering process. A direct application was no longer possible for celler brunnenbau since the tendering process was already under way. With the intention of initiating the Joint Venture Bemolanga with this partner, celler brunnenbau was, on the one hand, able to ensure the legally compliant participation in the tender and, on the other hand, pledge the French managed local logistics company FOREX SARL. By means of the intended rental of a drill rig from the governmental mining organisation OMNIS, celler brunnenbau would recognize the national interests of the Republic of Madagascar in this prestige project at an early stage. Contracts with these partner became effective at the contract conclusion of TOTAL with celler brunnenbau on 29th April 2009.
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The project area of BEMOLANGA is located 300 km west of Antananarivo. The nearest port can be found in the city of Maintirano, 150 km west of the project area.
Deposit The deposit on the mainland consists of three sandstone layers up to a dimension of approx. 40 m, which carry bitumen and are separated from each other by layers of clay. The deposit extends over the entire west coast. The governmental mining organisation OMNIS is the leading authority for the allocation of licences for the exploration of strategic resources, including mineral oil. The area of exploration is divided into exploration blocks and
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extends over the entire west coast (see image 01). The exploration rights for exploration block no. 3102 with a size of 7,175 km² are shared by the companies MADAGASCAR OIL and TOTAL E&P MADAGASCAR, the latter being the operator. The oil reserves of oil (P50 ) with a density of approx. 8 – 13°API are indicated with 16 billion barrels of OIP (Oil in Place). For comparison: the global annual consumption amounts to approximately twice that amount. Bituminously bound oil of this density is heavy oil and requires a special mining process for its exploitation by means of open cast mining or superheated steam injection for condensation.
Image. 1: Project area 1) Proved, Probable, Possible - P90, P50, P10 (Proved, probable, possible reserves) The actual amount of reserves will never be exactly detectable, but estimates can be carried out. Thus, the expected amount of reserves is determined with the aid of 3 index numbers:
Proved reserves (P resp. P90) The smallest number: the reserves of which geologists are 90 % sure that they exist (sometimes a 95 % probability is indicated and named P95). Probable resp. proved + probable reserves (2P resp. P50) The average number (average): the number which indicates the actually existing reserves. Possible resp. proved + probable + possible reserves (3P resp. P10) The highest number: the reserves of which geologists are 10 % sure that they exist (sometimes a 5 % probability is indicated and named P5).
Preparation
2) API degree (American Petroleum Institute degree) is a conventional density unit for crude oil, commonly used in the USA. It is globally applied for the characterization and as a quality measure of crude oil. The API degree results from the relative density of the crude oil at 60 °F (15 5/9 °C) referred to water by API degree = (141,5/rrel)-131,5 . Crude oil is indicated as „light“ above 31.1 °API , „medium“ between 22.3 °API and 31.1 °API and “heavy” below 22.3 °API. The API degree is generally added to the type name.
Tasks of the partners
Technics
celler brunnenbau as a drilling contractor had the operative and financial lead management in the Joint Venture Bemolanga. It placed the project management and the drill superintendent for each drill in the corresponding shift as well as the head mechanician. The business relationship with the joint venture partner FOREX was based on a pure renting for the provision of vehicles and staff for the entire logistics as well as the cementation of the drill holes and the pulling out of the casings. For this purpose, a PRINCESS drill rig of Chinese build was used. The governmental mining organisation OMNIS was contractually committed to provide a drill rig, an exploration drill rig CS14 by Atlascopco and the operating drill team. The fact that it was of the same model as the celler brunnenbau drill rig promised to reduce the expenses for repairs and maintenance as well as the spare part inventory.
Due to the performance requirements of 18,000 drill meters in 2 x 6 months, celler brunnenbau decided to drill actively with two drills in 2 shifts around the clock 7 days a week. For this purpose, a new Atlascopco exploration drill CS14 was purchased and another one rented from OMNIS, the governmental mining organization in Madagascar. The core drilling equipment was acquired from DATC, a company from France, via a German importer. In 2010, this equipment was complemented with a core drilling equipment from Atlascopco. The special thing about the core drills was the customer’s requirement to exploit all the cores in a transparent liner. With this system, the drilled bitumen layers can be sealed against gas emission and still be visually examined. The drilling fluid system consists of 3 x 1m³ open tanks which were designed in a pilable way for transport reasons, desander for the separation of the
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TRANSFER OF TECHNOLOGY Image 2: fleet
abrasive solid fraction as well as a GRINDEX mud pump to mix the drilling fluid additives. The entire drilling equipment was available for both drill rigs.
partner companies. The inclusion of local staff under the project responsibility of cb is very obvious. The 8 cb and FOREX expatriates were in charge of 29 local staff.
The joint venture partner provided the entire fleet for the logistics. Trucks with a loading crane as well as a tank truck for the disposal of the bitumen which had been separated from the fluid. In addition, he provided trucks with a loading platform for the transport of the drill rods, the fluid tanks, the water IBCs and the liners as well as the drilling tools. Generators for the electricity supply of the pumps and lighting were designed as trailers. Later, two off-road vehicles were exchanged against small trucks for the transport of the team.
Every project, especially a project abroad, makes special demands on the staff and the operating machines. So the project planning and preparation are the key phases of an economic and operationally safe project execution. The following preparations were carried out:
Staff The number of staff and staff qualification depended on the following factors:
• Shift operation (2 x 12h) • Fly in / Fly out operation (4 weeks in, 2 weeks out) • Operating machines (climate,
culture,
task,
This resulted in a team size of 37 people on the construction site under the management of celler brunnenbau. The cb team changed at a 4/2-week rhythm, every 2 weeks only 2 people changed. This procedure avoided the loss of information due to changes. The local staff changed at a 4-week rhythm. Chart 01 shows the manpower in an overview, differentiated according to the
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• Briefing and Training at the Drill Rig – During the test week, the operating staff was trained and briefed at the drill rig. The customer made use of this test week to survey and approve the equipment. • Occupational Health Screening – All of the staff of celler brunnenbau scheduled for the operation in Madagascar were examined concerning their suitability for their assignment abroad (G35) at the Works Medical Office (BAD) in Hanover.
• Task
• Assignment conditions accomodation)
• Test of the Drilling Equipment – The entire equipment was submitted to a last test before the shipping. The team and the participating representatives of the supplying companies tested the drilling and the equipment on the grounds of a befriended mining company, which offered comparable geological formations.
• Vaccinations for Madagascar – All staff received the required vaccinations within health protection. • Intercultural Training – An understanding of the country and its people is always helpful during a stay in foreign cultural areas. The drill superintendents were in charge of Malagasy staff. So it was very important for celler brunnenbau to strengthen the staff’s intercultural competence and prepare them accordingly for their stay in Madagascar.
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TRANSFER OF TECHNOLOGY Chart 1: Project team
Function • Language Training – In connection with the intercultural training, our employees also successfully completed a 2-week English language training before their first operation. This language training was continued with a 6-week intensive course during the winter months.
Company
cb
Project Manager
1
HSE Manager
1
TotalPersonnel OMNIS FOREX 1
Logistics Manager Dril Superintendents
4
Chief Mechanician
1
1
2
2
2
2
6
• First Aider Education – TIn spite of having medical care in the camp and emergency plans for the evacuation of casualties or sick people, the drill superintendents were educated as first aiders.
Driller
4
4
8
Drill Helper
2
3
5
• PSA (Personal Safe Equipment) – Naturally, all cb employees were equipped with tropicalized workwear and protective gear.
Driver
10
10
Mechanician
1
1
Mechanician Helper
1
1
24
37
Total Personnel
7
1
6
Logistics (Mobilization) Due to the very tight time frame between the assignment and the start of drilling, the logistics streams had to be coordinated so that they took place parallelly timewise. It was the aim to start drilling on 20th July 2009 considering the equipment delivery times, the limited loading capacity of the container trucks as well as the inability to pass the Manambaho river due to flood water. The customer had built a bridge across this river in 2010 so that it was possible to manage the demobilization of the logistics vehicles directly from the project area to Antananarivo in 2010. Thus, the costs for transport via ferry could be saved. 1. Sea Transport from Hamburg to Mahajanga – On the seaway from Hamburg to Mahajanga, seven 20-foot containers with a drill rig and the equipment were shipped first (see image 03). After the intermediate handling in Dschibuti, the container ship of the French shipping company had to pass the coast of Somalia. It reached the port of Moroni on the Comoros without incidents and the load was handled onto a feeder ship to Mahajanga in Madagascar. 2. Air Freight from Hanover/Paris to Antananarivo – Due to the long delivery time of the plastic liners, a partial load was priorly sent to Antananarivo by air freight. It was then transported within the mobilization of the JVB partner under #4. This lot size was prognosticated so that the drilling operation was provided for up to the time that the second sea freight #5 would reach Madagascar with the remaining liners (6,000 pieces in six 20-foot containers).
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3. Land Transport from Antananarivo to Mahajanga – The joint venture partner had scheduled his mobilization to the port of Mahajanga so that his drill rig, a tractor and the OMNIS drill rig, which was packed in a container, arrived in Mahajanga at the same time as the first sea freight from Hamburg. 4. Sea Transport from Mahajanga to Maintirano – The entire equipment from #1, #2 and #3 was then stowed on a ferry (landing craft), transported from Mahajanga to Maintirano and unloaded there. 5. Land Transport from Maintirano to Bemolanga – In Maintirano, the containers were put into intermediate storage and driven to Bemolanga to the workshop, which was to be established there, with a local freight forwarder in several transports. 6. Land Transport from Antananarivo to Bemolanga – At the departure of the ferry #4, the convoy of off-road vehicles and vehicles suitable for mudflat set off from Antananarivo to Bemolanga. It took the trucks and off-road vehicles three days for the 500 km roadway. The road, which was asphalted at the beginning, soon turned into a bush track, which was very difficult to pass due to the rainfalls.
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TRANSFER OF TECHNOLOGY Image 3: Logistic Coordination
Image 4: Landing at low tide in Maintirano
Image 5: Mobilisation into project area (right & left below)
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TRANSFER OF TECHNOLOGY Operation Since the drill holes were close to the surface (the deepest drill hole was 242 m deep), the drilling operation was characterized by continuously repeated work steps. This was especially helpful concerning the education of the local drillers because routine develops the positive learning success by permanently repeating the work processes. • Mobilizing to the drill location • Establishing the drill location • Drilling of HW Casings • Core drilling (HQ3) • Demobilizing from the drill location • Mobilizing to the next drill location • Logging • Cementation and pulling out casings
Mobilization to the Drill Location – The drill locations were all prepared by the customer and the drilling entry points mapped. Before each drill location change, the project manager of the Joint Venture Bemolanga approved the accessibility of the drill locations and the drill location in its composition. At the crossings, the shoved roads of access were equipped with sign posts of the drill locations to be reached for better orientation.
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Establishing the Drill Location – Each drill location was established according to a positioning plan agreed with the customer and accepted by the customer’s supervisor prior to drilling start. First, the trailer-mounted drill was positioned, the mast was set up and the drill was secured in its position. According to the depth, two to three cleaning tanks with a capacity of 1 m³ each were placed parallel to the drill. The drilling fluid was piped from the drill hole into the first tank via the swivel head screwed onto the casing pipe. A GRINDEX suction pump, which was installed in the first tank, transported the drilling fluid into the second cleaning tank via a desander, which separated the abrasive fines from the fluid. From there on, the selfsuctioning Triplex drilling fluid pump of the drill pumped the drilling fluid into the drill hole with 40 bar. Placing the HW Casing – The task of the 41/2“ casing (HW-Casing) is to protect the drill hole in the loose rock from belatedly falling rocks and discharge the drilling fluid in the annular space between the core drilling system of levers and the casing via the casing swivel head. Depending on the overburden, up to 20 m of casing were introduced.
Image 6: Drilling operation
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TRANSFER OF TECHNOLOGY Core Drilling (HQ3) – The customer wanted a coring exploration from the first drilling meter. So it has been cored up to the in-situ rock mass. The casing was sealed to the rock mass with clay and the casing swivel head was installed. The core barrel system HQ3 is designed so that the inner tube can accommodate a liner of steel or plastic which the core is introduced into forcedly while drilling.
Image 7: Composition of the core barrel system HQ3
First, the drill hole was flushed free with the drill rods until the bottom of the drill hole was reached for further coring. In 3-meter core drilling lengths, the inner tube was pulled to the surface (see image 07 ) over an overshot (2) from the outer tube (drill rod) by means of a winch. An priorly prepared inner tube with an empty plastic liner was exchanged with the full inner tube after disconnection and let back into the drill hole (1) until it latched itself again (8) through its gravity in the outer tube (10) (drill rod). The plastic liner (12) with the core lying inside was recovered from the inner tube and handed over to the customer’s geologists for testing and further processing. The 3-meter plastic liner of polycarbonate with 63 mm internal and 65 mm external dimension was able to accommodate the 61.2 mm core without difficulty. It only became problematic when the bit was not true to size. With a core diameter below 61.0 mm, the conus of the core lifter was no longer able to break the core to pull it. This bore the risk that the core might stay permanently bound with the rock mass and that the inner tube might be pulled to the surface without the core. Here, the sure instinct of the drillers, who successfully palpated the successful „core catching“ by feeling the rope, was of great importance.
Image 8 (upside & downside): core recovery by removing Liner from inner tube
Demobilizing from the Drill Location – After having reached the final depth determined by the geologists, the drill hole was rinsed and the drill rods were pulled out. The entire drilling equipment was loaded for transport to the next drill location together with the logistics team.
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TRANSFER OF TECHNOLOGY Image 9: Mobilisation between drill locations
Mobilizing to the next Drill Location – Each drill rig was assigned to a truck with a loading platform as well as another truck with a crane for the transports between the drill locations. In the course of the project, it was possible to reduce the initial mobilization from one drill location to another from 6 hours to less than 3 hours. Logging – Another subcontractor from the customer’s side carried out the geophysical logging of the drill hole. The tasks in their chronological order were scheduled in the morning meetings of the customer with all subcontractors. Cementation and Pulling out Casings – The cementation of the drill holes was to separate the layers carrying bitumen again. The joint venture partner’s drill rig was planned for a possible re-drill of the drill holes. Due to the technical difficulties with this machine, celler brunnenbau decided to import a self-propelled drill rig from their own company to Madagascar in a project break. An AGBO G200 was retooled as a combination drill rig for well sinking and exploration drilling. This cost intensive measure very quickly became a very economic one since the AGBO drill rig was also able to core wireline at a high performance level during the standby times of the rented OMNIS drill rig. It was even possible to convince the customer that the drill holes could be cemented with a light NORIP tube system without a drill rig. Further equipment for the second project phase was shipped to Madagascar in the winter months together with the AGBO drill rig. After the drill hole had been cleared for cementation by the customer, the cementation team came into action. The casings were pulled out with the AGBO G200 and the drill holes were cemented with the NORIP tube system in a contractor procedure.
HSE Certification – In 2009, celler brunnenbau was tested and certified according the British Standard OHSAS 18001 (Ocupation Health Safety Assessement Series). This certification decorates the quality and work protection management system of celler brunnenbau and made it possible to issue a joint bridging document with TOTAL
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for the entire drilling operation under the responsibility of the Joint Venture Bemolanga. This bilingual document in German/French contained all work processes, risk analyses and measures for hazard prevention. Measures – Generally, the same work, health and environment protection measures were applied as it is customary in Germany and France. Some examples: • Wearing PSA, Personal Safety Equipment • Safety instructions before each shift (Safety Meeting) • Collecting environmentally dangerous substances – disposal in Antananarivo • Exclusive usage of tested lifting and lashing straps • Electrical and mechanical testing of the machines by independent Malagasy experts • Vehicle monitoring via GPS surveillance – maximum speed of 50 km/h and destination • Radio equipment in each vehicle • Mobile radio equipment at each machine and for each drill superintendent • Welding permit • Alarm and rescue exercises • Attendance and absence check at the camp entrance by means of a plug-in board • Permanent presence of the customer’s work safety representative at the drill location
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TRANSFER OF TECHNOLOGY
Image 10: Advice on wearing the personal protective equipment
Incidents – Some incidents and almost accidents were registered in 2009. Three employees were stung by scorpions. Due to the correct treatment with an antidote by the camp doctor, the employees were fit for work again the next day. A heart attack and an attack of gout in the case of OMNIS employees in their leisure time prompted the OMNIS management to submit their employees to an additional and probably selective health check. This lead to a drastic reduction of the average age of the OMNIS drill team in Bemolanga. In spite of a timeintensive job training of the new drillers by the drill superintendents of celler brunnenbau, this measure finally lead to a significant performance increase of the OMNIS drill. In 2010, neither a single incident nor an almost accident was registered. Reportable Accidents – In the entire project duration, not a single reportable accident was registered under the responsibility of the Joint Venture Bemolanga. HSE Award – The Joint Venture Bemolanga was awarded by TOTAL with a safety prize for the implementation of the HSE bridging document. The Malagasy HSE manager of the joint venture outlined the safety measures and work safety instructions in the national language on a board as a safety toolbox (see image 10). This safety toolbox was placed at the entrance to each drill location and served as an instruction base for the safety instruction before each shift.
Image 11: Safety Toolbox
Accomodation All employees were accomodated in a container camp, at peak times it held almost 400 people. The camp had its own water treatment and power generation with diesel generators. Communication was possible via mobile networks of two providers, transmitters were installed close to the camp by the providers especially for this purpose. Catering was possible around the clock. Food was flown in by airplane from the capital. The camp was supplied at least once a day.
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TRANSFER OF TECHNOLOGY Chart 2: coring performance
Performance According to contract, 9,000 coring meters were to be drilled per ½ year with a core recovery of 95 %. In 2009, this target was reached thanks to the performance of the cb drill rig. The permanent geological evaluation of the core samples in the customer’s laboratory in Antananarivo resulted in a change of the drill programme in 2010. The original drill programme of 9,000 coring meters in 2010 included a smaller number of drill holes at a higher final depth. Actually, 34 drill holes at a considerably lower final depth and 2,000 coring meters less were drilled. This option of the customer was contractually stipulated and accordingly financially compensated. The performance difference between the OMNIS and the cb drill rig can be explained by the long standby times of the OMNIS drill rig due to technical defects. The correction of these defects was not precisely favoured by the decision-making processes within the government agency. Even the performance-related rental price was not able to bring about a repair decision in Antananarivo, especially before a weekend
2009
2010
Total
Number of boreholes
CS14 cb
5.445,7
3.902,2
9.347,9
93,0
CS14 OMNIS
3.969,1
1.933,0
5.902,1
64,0
675,0
675,0
7,0
6.510,2
15.925,0
164,0
AGBO cb Total
9.414,8
Conclusion celler brunnenbau accepted the logistic challenge after signing the contract in 2009 in spite of the tight time frame and successfully reached the drill target in the 2009 season as well as in 2010. The education and instruction of the drill team by our drill superintendents, the HSE measures and the mechanician performance for the warranty of a high availability of the drill rigs show a continuous increase of performance without work accidents. The permanent optimization of the logistics to provide for the mobilization between the drill locations reduced the non-drill time. In addition, the contacts of the project management towards the government agencies and institutions, local organizations, traders and freight forwarders helped to fulfill the contract within this short project time in an economical way.
Impressions of a successful project
Information about the author: Dr. Christoph Ganzer Senior Vice President celler brunnenbau GmbH & Co. KG Bruchkampweg 25 D-29227 Celle Tel.: +49 (0)5141 - 88 44 42 Fax: +49 (0)5141 - 88 44 10 | ganzer@celler-brunnenbau.de | | www.celler-brunnenbau.de |
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TRANSFER OF TECHNOLOGY Fig. 1: Potash works Sigmundshall
Use of directional drilling for underground exploration drilling Potash mine in Sigmundshall The potash mine in Sigmundshall is one site of the K+S Potash company. It is located northwest of Hannover, near Wunsdorf. The mine, which was added to the Steinhuder Meer-Bahn in 1906, was established in 1896 as the “Potash drilling company Wunsdorf”. The deposit has been explored by the Sigmundshall, Kolenfeld and Weser shafts. Since March 2007, the Thyssen Shachtbau Company had been subcontracted to conduct exploratory drillings with the counterflush- and cable core method, both horizontally, as well as vertically with corresponding deviation drillings. The exploratory program Weser poses high demands on personnel and the applied technique.
Background and Goal Since 1898 the potash works in Sigmundshall have been mining potash and magnesium salt in the salt dome Bokeloh, mainly for fertilizer and industrial salt production. In a district of approximately 2 km² northwest of the salt dome in the area of the Weser pit, no comprehensive exploration was done in depths below 725 m ground level. Up to the year 1923, the periphery of the mine shaft Weser had been excavated in deposits with different levels of the potash seam „Ronnenberg(sylvit)“ and „Stassfurt (Hartsalz)“. These locations had been considered in the planning of drilling design. The current connection to the Sigmundshall shaft is the 500 m level, from which the drilling exploration had to be started.
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Potash mine in Sigmundshall
Due to the stratifications and the steeply inclined, partly heavily folded layers, a direct steep downward drilling in the subjacent structures would have led to abrandant, acute-angled seam passages or sections. Furthermore the basic question was, whether, in addition to the supposed structures at the north side of the salt deposit, there would be other, undetected and economically recoverable potash deposits in the core area of the salt deposit. The exploration of these areas through drilling would have been very complex and would have required several setups. Therefore it was very helpful, that within the framework of a research project, it was possible to test a sensor for directed radar measurements in real conditions. The sensor was in the last phase of development. The requirements for the technical implementation of the drilling programme was developed from two exploratory goals, i.e. large-scale radar detection of the salt deposit core and drilling exploration of the side deposits, with the following steps: 1. Conducting vertical drilling from the 500 m level, with a diameter of 98 mm for the insertion of the radar sensor. 2. Radar measurement of vertical drilling for the exploration of the salt deposit core. 3. Drilling of fan-shaped deflectors from vertical drilling in the north-east direction with ascending course.
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TRANSFER OF TECHNOLOGY On the basis of the results of the radar measurement, it was possible to work on determining the borehole courses for the exploration of structures at the north-east side. As there were no hints about further, undetected seam structures in the deeper central section of the salt deposit, no further exploration was done.
Fig. 2: geological assembly drawing of the 500 m level of the potash works Sigmundshall
Technical equipment The technical equipment used for the task is introduced as follows.
Requirements concerning the drilling unit: • Drilling method: Wireline core NQ • Planned depth: max. 1.500 m • Drilling diameter: 85 mm • Application of a drill motor for deflections: 2° on 10 m
Applied drilling unit A drilling unit of Hütte company HBR 201, with the following technical parameters was used: • Carriage length: 5.260 mm
Drill string/Instrument
• Feed length 3.600 mm
NRQHP rods of the Longyear company were used in the applied drill string. Compared to the normal NQ rods, the advantage or important characteristics are that a more stable rodding connection is reached, due to the used thread type. In addition, the connection can be screwed with a lower torque, which leads to a lower stress and higher life time. This rodding type also allows for drilling with an incline of 2° on 10 m. Diapax drill bits were used for cutting in rock salt. These drill bits have proven their worth in all previous applications in potash and salt rocks.
• Feed force: 200 kN • Retraction force: 100 kN • Top drive: • Torque max.: 9.300 Nm • Rotations max. 370 rpm
These parameters allowed for smooth drilling with 3.0 m long drill rods, up to the required depth of approximately 1,500 m and the maximum of the deflection. • Example: max. driving power: 20 t • Drill string: 12 t • Friction resistances of a max. 30% in the deflections :3.5 t
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Pump In order to achieve the needed flow rate of the mud for usage of a drill motor, a Triplex pump of Oilwell company with a maximum of 320 l/min was used.
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TRANSFER OF TECHNOLOGY
Fig. 3: Schematic geological section of the Weser shaft area
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TRANSFER OF TECHNOLOGY
Fig. 4: Implemented drilling fan in the Weser area
Directional drilling equipment (DDS Directional Drilling Service Co) 1. The DDS steering tool, measuring probe, consists of inclinometers, magnetometers, sensors and corresponding control electronics. The measuring probe sends data to the interface unit through the cable (active control), where the data are processed with the help of a computer.
the start of the directional drilling, a matching between “highside� and the measuring device is done. The 300 l/min flow rate needed for the operation of the drill motor is covered by the application of a corresponding pump (see above).
2. The measuring probe is connected to the computer by the interface unit. Here, all standard data obtained from the steering tool, like borehole gradient, toolface and temperature are recorded, processed and analyzed, and the current depth, position of drilling in azimuth, etc. are calculated with a computer programme. Through a connected printer these data can be printed at any time.
A 2 7/8“ Motor (l= 4,4 m, approx.. 150 kg) with a torque of 635 Nm at 300 rpm and 300 l/min is used.
3. In order to continuously check the drilling course, the driller control stand is connected with the interface unit. The driller control stand shows the current position of the measuring probe, i.e the inclination, azimuth and toolface to the drillmaster. 4. The controllable drill motor, downhole motor with chisel, is applied in fields, in which a high accuracy of the borehole course is required and cannot be achieved with other methods. This motor has a built-in adjustable inclined connection (Bent Housing). Before
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Fig. 5: Drilling equipment HBR 201
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TRANSFER OF TECHNOLOGY Borehole safety in exploratory drillings In exploratory drillings extensive safety measures are put in place, in order to ensure safety of both man and mine with regard to leakage of unknown fluids and gases,. During the exploratory drillings in the sites of K+S Kali Company, a stand pipe of a minimum of 5 m is set. This pipe represents the connection between the mountain and the actual safety set. In principle, the leak tightness of the cementation bonding between mountain and stand pipe is proven after the setting of the stand pipe. In order to do so, the 1.5 fold of the calculated hydrostatic pressure has to be applied as test pressure, according to the depth at the drilling station and the pressure run time of 10 min has to be kept.
Fig. 8: Drilling unit with borehole protection (BOP)
The safety set consists of a T-piece with the safety valve, the full mouth plate, the blowout preventer (rodding preventer), the rodding valve (Kelly valve) and the rotary preventer. The rotary preventer does not belong to the safety group. In detail, these elements of the safety set perform the following tasks. The borehole can be closed with a full mouth plate against escape of fluids and/or gases under the condition, that the drill string can be pulled out of the drill pipe. The preceding T-piece offers the possibility of preventing the escape of mud through the safety valve on one hand, on the other hand it is possible to start the needed pressure release. In case of danger, the annulus with the drill string that is still in the drill hole can be closed with the rodding preventer; the drill string itself is closed through the rodding valve. The rotary preventer seals the annulus during drilling between drill string and the open rodding preventer.
Fig. 7: DDS – Drill motor (Bentsub)
Fig. 6: DDS – Driller console
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TRANSFER OF TECHNOLOGY Project History It was planned to conduct a vertical drilling with a depth of 700 m and a drill diameter of 85 mm in the drilling station, the former fan house, in a level of 440 m above sea level, with cable core method. Despite the exact setup, regular measurements with a multishot revealed a considerable deviation from the plumb line and the direction. In addition, the directional deviation was exactly opposite to the planned exploration area. After some considerations and discussions with the employer, we decided to apply the directional drilling set. Nevertheless, arithmetically speaking, there was the possibility to reach the first deviation point from the actual
run of the curve. In order to do so, we had to drill with the drill motor and corresponding angle, until we had again reached the vertical course of the drilling, before the first planned deviation point. We started with a small setting angle of 0.78째, without success. After that we increased to 1.15째, 1.5째, but it was not possible to achieve the desired change in direction and inclination. In order to be back in the plumb line before the first deviation point, the route became shorter and shorter. In addition, the correction would have been too steep in case of a too wide angle. Nevertheless we increased to 2.38째, and we were finally able to register the change we hoped for. The change was optimal, so that we could quickly apply the wireline drill set, in order to deliver the desired cores.
Fig. 9: Course of the vertical drilling
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TRANSFER OF TECHNOLOGY After measuring the drill hole we extended to 98 mm. Thereafter the drill hole was measured with EMR (electromagnetic radar). The four deviation points were determined after the analysis of the results of the EMR-measurement, according to the geological requirements and the technical possibilities. It was planned that from the vertical drilling, a deviation in the required direction would be drilled with a downhole motor and a setup of 2° to 10 m in four deviation points (at a depth of –320 m, –160 m, –120 m and –80 m). In order to drill the deviations in the above-mentioned depths, cementation plugs had to be inserted in these areas. Starting at the highest depth, a cement suspension was pumped up to the deviation point, with the help of packer and cementation pipings. After its hardening, it was possible to drill the deviation from the plumb line with a drill motor and an adjusted angle of 2° from this newly generated borehole floor. Through continuous build-up, the route of the curve was easily carried out to up to 45°
Subsequently, a core route of approximately 500 m was sunk from a starting duct, with cable core method. The same procedure was used three more times, at -160 m, at -120 m and at -80 m borehole depth.
Analysis After initial problems in the vertical area, all four deviations were conducted to the full satisfaction of the contracting body. The goal was achieved and the required information was obtained from the selected areas. Altogether approximately 3,200 m were drilled, out of which approximately 2,400 were cored.
Authors: Tilo Jautze; Thyssen Schachtbau GmbH & Dr. Ralf Holländer; K + S KALI GmbH
FOR MORE INFORMATION AND CONTACT:
Thyssen Schachtbau GmbH Sandstraße 107-135 45473 Mülheim an der Ruhr | Germany Tel.: +49 (0)208 - 30 02 0 Fax: +49 (0)208 - 30 02 3 27 eMail: info@ts-gruppe.com Internet: www.thyssen-schachtbau.de
Fig. 10: Drilling station on the 500 m level
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TRANSFER OF TECHNOLOGY
Wheel loaders as a basis for blasting vehicles, armature drill carriages and roof bolting rigs, as well as auxiliary vehicles by Franz-Josef Paus und Dr. Martin Kaufmann Hermann Paus Maschinenfabrik GmbH | Germany
by Wolfgang Rautenstrauch Mössinger+Wolter Maschinenbau GmbH | Germany
Paus manufactures automobile mining machinery and Moessinger+Wolter is a producer of drilling and scaling vehicles. This paper presents a review over the development of blasting vehicles and introduces a wheel loader, which serves as a basic unit for diverse applications in mining. The telescopic swivel loader can be supplied with various accessory equipment, which can either be fixed or exchanged with a quick change plate. After a description of the basic unit, accessory equipment is explained. At first the application as an explosives loading unit, as well as a self-propelled elevating work platform is introduced, followed by its operation as armature drill – and anchoring tool. The application as hammering scaling tool and service vehicle is also described. More standard equipment, such as shovel, fork tip carriers and other auxiliary equipment are also briefly dealt with.
Introduction With more than 200 staff, Paus produces construction machines, lifting systems, industrial vehicles, as well as vehicles for mining and tunneling. For more than 35 years, Paus has been producing automobile techniques for mining. Apart from the known tailor-made special solutions for clients in mining, the following vehicle types are manufactured: • Tractor shovels up to 5,5 t load capacity • Dump trucks up to 30 t load capacity • Universa 50 and Minca as platforms for various constructional systems
Pic. 1 Explosives loading vehicles in the midseventies and eighties
• Telescopic –rotary arm loaders for various auxiliary equipment
After a short overview over the development of blasting technique at Paus, the main focus of this presentation is on various applications of the telescopic rotary arm loader.
Development of Blasting Technique in Paus Company In the mid-seventies, the first blasting vehicles of Paus were manufactured according to the OBA CLZ vehicle construction guidelines of that time. At the beginning these vehicles were only equipped with liftable working platforms, but were later upgraded with swivels and telescopic functions. (Picture1).
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TRANSFER OF TECHNOLOGY Pic. 2 2008 – explosives loading vehicle with Hose winch and mixing device
Today, engineering of explosives loading vehicles is more sophisticated than before (Picture 2). Diesel-hydraulic or electro-hydraulic compressors are not only the norm today, increasing mechanization has also found its way through manipulators and Hose winch, particularly for charging of boreholes. Further developments have also affected filling of the Anfo container. The filling over a screw conveyor can be seen in picture 2. Other possibilities are the filling by a vacuum suction plant or through an intermediate vessel. A further development in the field of blasting technique is the application of emulsion explosives. Here, Paus cooperates with notable manufacturers and offers a carrier for the installation of an emulsion unit. (Picture 3).
Wheel Loader as Basis for Various Applications During the last 15 years, the telescopic swivel loader (TSL), which can be self-propelled from the carriage, was developed into a mining machine that is suitable for manifold applications thanks to a quick changing device. This variety and the synergetic effects with construction machines turn TSL into an attractive machine.
Description of the Telescope- Swivel Loader – Basic Unit RL 852 TSL The wheel loader RL 852 TSL is driven by a water-cooled Deutz 75 kW diesel motor. Through the hydrostatical traction drive, optimum running speed is achieved, even in changing inclinations. Through the articulated steering (±40°) and the small dimensions (Picture 4), a small turning radius is achieved. Due to the oscillation of the rear axle (±10°), in connection with the four wheel drive, the TSL adapts itself to even difficult floor conditions. The loading plant can be swiveled by 90° into each direction, and heights of approx 5.5 m can be achieved through the lifting, as well as by telescopic movements (Picture 4). In order to increase stability, the swing axle is automatically locked in swivel angles of more than ± 12°. Furthermore, the load is optically and acoustically monitored. Accessibility of components and ease of maintenance of the TSL are extremely high. The TSL is equipped with a closed ROPS/FOPS cabin for heights of up to 2.6 m, an open ROPS/FOPS- operator’s cab is available for lower heights of up to 2.3 m.
Applications Explosives vehicle Pic. 3 Example of an emulsion explosives loading vehicle
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A TSL with a quick change system was manufactured as a loading vehicle for a mine in Saudi Arabia. The 150 l pressure vessel for Anfo is firmly built on the cage. A compressor with a diesel engine and a delivery rate of
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TRANSFER OF TECHNOLOGY Pic. 4 Measurements and Kinematics of RL 852 TSL
1.8 m³/min at 6 bar is built at the rear. The remaining actual load on the cage with a filled pressure vessel for Anfo lies at 150 kg. The horizontal swivel range of the cage of approximately 2 m² lies at ±30°, so that a 6 m wide drift can be loaded from a standing position. The maximum achievable stretch is more than 7 m. A specific characteristic of the TSL is that it is approved as “self-propelled elevating work platform” according to EN 280. This means that not only cage movements can be controlled from the cage, but the entire vehicle can be moved and controlled in walking pace.
Platform operation Apart from the elevating work platform with an actual load of 500 kg, a further self-propelled platform is available. Hereby the actual load in the cage is 300 kg and the horizontal swivel range is ±90°, resulting in a maximum stretch of up to 10 m (Picture 6). Even in an elevated swivel range it is possible to omit usage of stilts. In order to ensure stability in case of a blowout, only foamed tires are needed. An acoustic sensor monitors the permissible longitudinal and lateral inclination of ±5°.
Pic. 5 RL 852 TSL T7 with compressor and Anfo charger
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TRANSFER OF TECHNOLOGY Pic. 6 RL 852 TSL with 300 kg platform
Applications for the platform operation in mining operations are for example the temporarily abandoning, advancing air tubes and other ducts, as well as service work.
Anchor Boring Rig and Bar Inserter On the basis of the TSL, MĂśssinger+Wolter delivered a diesel-hydraulic anchor boring rig and bar inserter for rotary drilling, with which drilling and anchor lengths of up to 3.5 m can be achieved.
The rollover swiveling angle at the end of the drilling jig lies at approximately 270° (Picture 7). The drilling jig can be swiveled, both vertically, as well as horizontally through hinged hydro-cylinders. A hydraulically driven compressor is installed at the rear. The boring and anchoring unit is operated with a remote control. Further application possibilities are, for example, the setting of radial anchors, the blast hole and extension drilling, as well as heading in escape tunnels. Alternatively it is possible to use hydraulic and drilling motors and hammers, as well as electro-drilling motors.
Pic. 7 Anchor Boring and Roof Bolting Rig MBW 03-RS of the MĂśssinger+Wolter Company
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TRANSFER OF TECHNOLOGY Pic. 8 RL 852 TSL Scaler
Hammer Draw Off A particularly successful version of the RL 852 TSL is the scaler, which is equipped with a hydraulic hammer at the end of the telescope. Up to 2010, one hundred pieces were produced in various versions. In picture 8, the NPK GH2 hammer is firmly built-in in the scaler. Here, the telescope is extended and the driver is safe, as he sits far from the location for scaling the roof. The operation of the hammer is done from the cabin through a foot switch or a joystick. In addition, the number of blows can be varied according to rock conditions. Hoses and cylinders are stored, protected by plates or tabs. The ROPS/FOPS driver’s cabin is protected by grids and strippers on the telescope. The clearing blade ensures a secure stand on the road. With a swivel range of ±45°, a stretch width of maximum 9 m with a maximum stretch length of 8 m can be scaled roof. The hammer which rotates by 100°, can also be used for bouldering. Since the hammer can be rotated and the telescope can be swung around, a very good view on the chisel tip is achieved.
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Pic. 8 RL 852 TSL Scaler
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TRANSFER OF TECHNOLOGY Bucket A further accessory equipment is a 1 m³ bucket with an actual load of 2 t. The maximum achievable height lies at approximately 5.5 m. The bucket is for example used in narrow roads, so that the mine cars can be loaded in parallel to rail tracks. Not only the space requirement, but also the road distance is minimized, according to the motto “pivoting instead of directing”. A further advantage is that, through the telescoping, an unloading over higher hurdles or a loading over lower hurdles is possible.
Fork Tips
Pic. 9 RL 852 TSL with quick change system for bucket
A fork tip carrier can also be attached to the quick change plate (Picture 10). The permissible load varies according to the pivoting angle and the height between 700 and 2,400 kg. An overload warning device informs the operator both acoustically, as well as optically about loading conditions. Heights of up to 4.5 m lower edge of the forks can be reached, as well as a lateral working area of a maximum of 10 m (tip of the fork). Here, the motto “pivoting instead of directing” is also relevant. It is possible to take up the palette from the deposit and to load a truck without traveling.
Service A special anchor scroll trench shield was developed for a potash mine (Picture 11 left) The protection shield of a cage can be pulled in, up to the level of the guard rail, so that the scrolls can easily be placed on the roof and can be unrolled left and right of the cage. The mat is fixed on the roof by pins. After the protection shield is lifted and the operator has entered the cage from the front, the cage is driven to the center of the hanging wall and the mat is bolted – starting from the middle in the direction of the blows. The TSL is also equipped with supports at its engine, in order to be able to work in roads with an ascending slope of up to approximately 18%. At the front vehicle, a shield with slide bar ensures a secure stand on the bedrock. The TSL shown in picture 11 at the right is in operation in a salt mine as a service vehicle. In addition to a 4 m³/min (8 bar) compressor, which is installed at the
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rear, a lubricating unit (fat barrel) and an oil barrel is also available. Corresponding hoses are led to the cage. Three hose drums are installed at the cage. In addition, there is a hydraulically driven welding apparatus with a 230 V power outlet on the cage. The TSL is used for maintenance of stationary plants.
Further accessory equipment For the sake of completeness it should be mentioned that for mines, which use the TSL both above and below ground (e.g. drift mining it is possible to add further equipment. For winter services it is possible to use snow blowers, snow plows and slat dispensers. The following accessory equipment can be used for road building and maintenance: • Shield with slide bar • Vibratory plates • Power sweeper • Load hook
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Pic. 10 RL 852 TSL with Quick Change System Fork Tip Carrier
In addition, various bucket types are possible, like light goods buckets, bottom dump shovels and clamshells. In summary, the telescope swivel loader is a universal mining vehicle, which offers unique kinematics and accessory equipment for each individual case.
FOR MORE INFORMATION AND CONTACT: Hermann Paus Maschinenfabrik GmbH Franz-Josef Paus , Dr. Martin Kaufmann Siemensstrasse 1-9 48488 Emsbüren | Germany Tel.: +49 (0)59 03 - 707 0 Fax: +49 (0)59 03 - 707 333 eMail: info@paus.de Internet: www.paus.de Pic. 11 Anchor Scroll Trench Shield
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Mössinger+Wolter Maschinenbau GmbH Wolfgang Rautenstrauch An der Steinhalde 32 44879 Bochum | Germany Tel.: +49 (0)234 - 36 95 6-0 Fax: +49 (0)234 - 36 95 6-20 eMail: info@moessinger-wolter.de Internet: moessinger-wolter.de
Pic. 11 maintenance vehicle
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TRANSFER OF TECHNOLOGY
ContiTech Conveyor Belt Group | Phone +49 5551 702-207 transportbandsysteme@cbg.contitech.de
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TRANSFER OF TECHNOLOGY Sandvik Mining and Construction Central Europe GmbH
JUNGFRAU – TOP OF EUROPE:
World-famous names in tourism and technology united at 3.454 m
100 years of Jungfrau Railways. The countdown has started. What was festively begun at the EXPO World Exhibition in Shanghai in the summer of 2010 will reach its crowning culmination on the Jungfraujoch on 1st August 2012. Between now and then there are still around 250 m of rock to be penetrated in the construction of the new visitor round-tour gallery – and a lot of work to be done. By the time it is finished, CHF 14.5 million will have been invested, and humans and machines alike will have been pushed to their limits: at present in three-shift operation – 24/7. Under the direction of the company Frutiger AG, Avesco is providing all the key devices, such as the drilling jumbo DD420 and the tunnel loader LH307 from the internationally renowned manufacturer Sandvik. The lasting development of the Jungfrau region into a year-round nature experience is already underway. The aim of the building operations, which are taking place at an elevation of around 3,500 metres, is to implement a spectacular allweather programme for the future. During the season, the Jungfrau Railways transport up to 5,000 visitors per day past the mighty trio of the mountain giants Eiger, Mönch and Jungfrau to the highest railway station in Europe. The company Frutiger AG was awarded the contract for the building works, which will allow the stream of visitors to be optimized. Ernst Zobrist is in charge of realizing the new infrastructure of this world of experience. The specifications that were defined by the customer are a challenge even for this experienced project manager.
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TRANSFER OF TECHNOLOGY Already in the bidding phase, Frutiger and Avesco got in contact with each other about the project. Due to decades of previous cooperation between the two companies, they quickly reached an agreement and could start the necessary work as soon as the contract was awarded. Avesco immediately provided all the key plant and trained personnel, thus demonstrating its strong position on the market. „For this special assignment in continuous operation, I rely on the experienced Avesco mechanics. They are thoroughly familiar with the Sandvik machines“ says Ernst Zobrist, expressing his confidence in the chosen partners. Transporting the heavy drilling jumbos and loaders to the construction site confronted the mechanics and the operators of the railway line with a particularly challenging task. In contrast, the logistics for the delivery of the Sandvik drilling bits – within 24 hours – is a standard job, performed almost every day. The low oxygen level at this altitude, however, troubles men and machines alike. For the machines, a drop in performance of around 10% per 1,000 metres in height has to be taken into account. Despite the high altitude, the Sandvik drilling jumbo DD420 drives the boreholes needed for the nightly blasting into the granite as if it were Swiss cheese. The permanent frost and the extreme weather take a greater toll on the miners than on their robust equipment from Sandvik. Using the Sandvik underground loader LH307, as ergonomic as it is powerful, the excavated material is transported to the end of a 60 m tunnel and disposed of in an ecological way into a crevasse near the top end of the glacier.
Furthermore, a Sandvik DC121R drill rig with a special feed for anchoring, as well as Toyo hammer drills are in operation at the highaltitude construction site. The equipment used is complemented by the Sandvik drill steel. Until the anniversary festivities on the top of Europe, all the participants will continue to pull together. Then, one would like to communicate the conclusion “E suuberi Sach!” – Swiss dialect for „a well-done job“ all over the world in many languages.
Frutiger AG The company Frutiger AG, based in Thun, is one of the leading construction groups in Switzerland. It was founded in 1869 and is family-run in the 4th generation by the owners Luc and Thomas Frutiger. In 2009, some 2,200 members of staff in the group‘s 26 companies achieved a group turnover of CHF 676 million. The company‘s underground construction project references include: • Kirchenwald tunnel • Gotthard alpine transit tunnel, Sedrun section • Roveredo bypass • Main tunnel Eyholz Visp • Round-tour gallery Jungfraujoch
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TRANSFER OF TECHNOLOGY
Avesco AG This family business with a long tradition was founded in Langenthal more than 130 years ago. Today, Avesco AG – formerly Ulrich Ammann AG, part of the Ammann Group – is an independent company. In the 5th generation, the owner Christoph Ammann, the management and staff have a credo of innovation and advancing development. In 2009, the 600 members of the Avesco staff achieved a turnover of approximately CHF 300 million. Since 1994, Avesco has been the exclusive Sandvik representative in Switzerland in the field of construction technology. For tunnel construction and quarry works, Avesco provides system solutions from Sandvik – from the drill rig via drill steel to software solutions. Examples of road and railway tunnel reference projects that were realized using Sandvik machines: • Gotthard alpine transit tunnel, Sedrun section • Monte Ceneri, all three sections of the project • Motorway tunnel at Concise, Lake Neuchâtel • Motorway tunnel in the Jura Mountains, N16, Porrentruy • Motorway tunnel Kirchenwald • Road tunnel bypass, Saas
Technical specification Sandvik DD420-40 The Sandvik DD420-40 is a two-boom electro-hydraulic jumbo for fast drilling in caverns and tunnels with cross sections of 8 – 49 square metres. The robust SB40 universal booms have a wide reach and fully automatic parallel positioning for fast and easy tunnelling. The booms can also be used for cross-
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TRANSFER OF TECHNOLOGY
cutting and anchor bolt hole drilling. The arrangement of the structures on the jumbo is designed to make them easy to keep in view and to provide good stability. This and the powerful four-wheel-drive, centre-articulated carrier ensure rapid and safe driving. With the DD420, Sandvik is the record holder in this class. Over 63,000 metres drilled per month give evidence of the exceptional standing of the Sandvik tunnel jumbos.
Drilling system
TC 7 Carrier Diesel engine Articulation Rear oscillation Ground clearance
MB OM904LA (Mercedes) 110 kW ± 40° ± 10° 320 mm
HLX5 Rock Drill Power class
Optional equipment
20 kW (impact energy)
TF 500 Feed Drilling depth up to a maximum of 6,490 mm
• *) Feed length 10’, 14’ or 16’ • *) Telescopic feed TFX-series • Rod retainer TRR1 for one feed • TRS two-rod system for one boom (includes TRR1) • Drill angle measuring instrument TMS D2 • Drill angle and depth measuring instrument TMS DDSS2 • Drill position and angle measuring instrument TCAD-DS • Data logging unit TLOG for TCAD • *) Double flushing with CT 16 compressor (11 kW) • Air mist flushing kit for auxiliary water/air connection • Flushing flow control
Carrier • Exhaust scrubber • Exhaust catalytic converter
Other optional equipment • Manual fire suppression system ANSUL, 6 nozzles • Pressure cleaning system with reel • Automatic greasing system (carrier and booms) • Biodegradable oils
* Replaces standard component
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TRANSFER OF TECHNOLOGY
Technical specification Sandvik LH307 The Sandvik LH series combines safety and productivity. It is equipped with a patented steel structure protecting the operator cabin against falling rocks or overturning. The ergonomic design of the LH307 is adapted to the work the operator will perform. The well-balanced weight distribution and the adequate power of the engine and the hydraulic system allow extreme loads to be handled with ease. Enormous manoeuvrability is the standard here.
Technical details LH307 Tramming capacity: Bucket range: Length: Width: Height: Turning circle (inner radius): Turning circle (outer radius):
6,700 kg 2.7 – 3.7 m3 8,631 mm 2,230 mm 2,200 mm 3,043 mm 5,812 mm
FOR MORE INFORMATION AND CONTACT:
Sanvik Mining and Construction Central Europe GmbH Hafenstrasse 280 45356 Essen | Germany Tel.: +49 (0)201 - 17 85 300 Fax: +49 (0)201 - 17 85 800 Internet: www.sandvik.com Sandvik Mining and Construction Central Europe GmbH Division Manager Tunnel Construction Volker Blum Tel.: +49 (0)172 25 22 04 3 eMail: volker.blum@sandvik.com Internet: www.mc.sandvik.com Avesco AG Head of Construction Technology Division Stefan ZĂźrcher Tel.: +41 (0)62 - 915 80 80 eMail: stefan.zuercher@sandvik.com Internet: www.avesco.ch
Sandvik
Sandvik is a high-technology engineering group with advanced products and a world-leading position within selected areas, such as cutting tools, equipment and tools for mining, stainless materials, special alloys, high-temperature materials and process systems. In 2010, Sandvik had 47,000 employees and representation in 130 countries, with annual sales of approximately SEK 83,000 million. Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of equipment, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries. Annual sales for 2010 amounted to about SEK 35,200 million, and the company has approximately 15,500 employees.
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TRANSFER OF TECHNOLOGY Metso Minerals
High pressure filtration laboratory and plant testwork:
Tube Press
The fundamental basis of any Tube Press application is an accurate assessment both of the core process, and of the associated mechanical and operational criteria. Metso Sala has well equipped facilities, with personnel who have long experience of solid/liquid separation.
Why mechanical dewatering? In dewatering applications, the most important question is the cost involved to reduce the moisture content of a slurry / suspension; both in regards to direct equipment investment and operation costs. The most cost effective alternative is an energy free process i.e. sedimentation. However, as particles get finer more energy has to be introduced to separate solid and liquid. Super fine material often needs a thermo drying step at the end to reach the process target. With the use of Mechanical Dewatering instead of thermal drying, significant cost saving and cost control is achieved. The use of High Pressure Filtration often gives the final rest residual and cake features that the process requires with less energy usage. Reducing moisture is a question of energy added. A single full size Tube Press can operate with just 11kW installed power. With test work, basic data for the specific material can be obtained including: equipment selection, residual moisture, filtration capacity and basic plant scaling.
Laboratory test work At the Metso laboratory based in Sala, Sweden properties of a sample can be tested and evaluated including particle size distribution, viscosity, pH, settling, effect of pressure (vacuum – high pressure) flocculants, temperature and filtering aids. With the Metso Piston Press the filtration characteristics under high pressure can be evaluated. The Piston Press is a standard laboratory filter, capable of filtering slurries at pressures up to 180 bars.
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TRANSFER OF TECHNOLOGY Elements that affect performance:
Dimensions
• Temperature (viscosity) • Pressure • Air blow • Solid concentrations in slurry • Cloth selection • pH • Filter aids (hydrophobism) • Particle shape and size (flocculants) and granulation via Pressure
The pressure and air effect on residual moisture With Tube Press Pilot Unit, full scale tests can be done to evaluate the effect of pressure and air drying. By the use of mechanical high pressure even strong capillary forces can be overcome. The additional use of air blow, where air is forced through the filter cake by hydraulic pressure, will further reduce the filter cake residual content.
Site test pilot equipment and features The Tube Press Test Unit SC 500-12/75 is a mobile fully automated pilot plant used to evaluate filtration characteristics of a specific slurry at the customers site. The test plant is installed in a 20 ft container complete including Tube, media booster, feed pumps, air compressor, hydraulic unit, control cabinet, filtrate tank, etc. The container includes equipment to perform smaller scale tests with a piston press and laboratory equipment. The unit is equipped with sensors to allow for all necessary measurement of the filtration conditions, which will be the base for plant scale-up. With the pilot unit process simulations can be run for all operating parameters which can be used in a full size plant including air-purge (pressing air through the cake) cake washing and cloth testing.
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TRANSFER OF TECHNOLOGY Sample condition and requirements In order to carry out slurry evaluation, a sample of approx 5 liters should be available. This sample must be well thickened and as representative as possible of the production feed. It is essential that any sample provided for test work is accompanied by details of its COSHH safe handling requirements (controls of substances hazardous to health). The laboratory undertaking the tests will provide details of what is required under these regulations. All samples provided, must be packed in appropriate containers and adequately marked with: • Origin of sample • Description of sample
Weight: 12 500 kg (suitable for top lift container attachment, forklift channels and crane) Dimensions: Standard 20’ container L x W x H, 6100 x 2450 x 2600 mm Power Supply: 3 x 380-480V, 63A (Converter 4763 Hz, primary 380-400-440-460-480V secondary 400V) Tube Press Filter: Max pressure 100Bar, gross volume 80 litre, filtering area 1,35m² Slurry Feed Pump: 9,2 kW 200 l/min 270 r/min / 60Hz, nominal 8Bar, max 16Bar (pressure regulating system) Wash Water Pump: 9,2 kW 200 l/min 270r/min / 60Hz, nominal 8Bar, max 16Bar
• As much physical/chemical data as possible.
Compressor: 4 kW 425 l/min / 12Bar (max 15Bar), Reservoir 270 litre
• Test or project reference
Hydraulics: 15 kW 40l/min
• Description of process condition
• Details of specific tests required • Details of sender
Generally laboratory test work is conducted free of charge, provided the sample is sent to the test site DDP. Detailed or large scale trials may be charged on an agreed basis. On completion of the test work all samples and containers may be returned to the customer.
Technical data tube press pilot unit • PLC system including graphic HMI display • Filtrate weight monitoring system • Slurry feed, temp monitoring system • Cake weight and volume monitoring system • On board laboratory including piston press
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TRANSFER OF TECHNOLOGY
Tube Press Tube Press The Tube Press is a membrane type filter press designed in cylindrical format and capable of operating at high filtration pressures up to 100 bar. The use of these high pressures enables a higher degree of separation of the liquid and solid phases.
The Tube Press is suitable for applications: • Alternatives to thermal drying • Where the process requires very low cake moisture. eg. smelters • Where cake handleability is critical. e.g. underground slimes • Where filtrate is a valued product • Where cake transport costs are significant • Where cake is to be disposed of to landfill
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Principle of operation Filtration takes place between two concentric cylinders. The outer cylinder is the casing, and the inner, the candle. The process slurry is pumped into the annular space between the filter media and the bladder. Hydraulic fluid, usually water, is then pumped between the bladder and the casing putting the slurry under pressures and causing filtration to take place. When filtration is complete the hydraulic fluid is withdrawn from the Tube unit using vacuum until the bladder is dilated against the casing. The candle is then lowered to the discharge position and a pulse of air is blown between the candle and the filter media. This causes the filter cloth to expand, fracturing the cake which is discharged under gravity. When complete the candle closes to the slurry fill position to repeat the cycle. Air purge and/ or cake wash can be incorporated into the cycle. At the completion of the filtration element, air or wash fluid is pumped between the cake and the bladder which is then forced through the cake by a further application of hydraulic pressure to be incorporated into the cycle.
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TRANSFER OF TECHNOLOGY Benefits • Driest possible cake solids • Maximum volume reduction • Exceptionally clear filtrate
Advantages of on-site tube press Tests will be undertaken on production slurry and will encounter any variability of production feed that occurs during the trial. The client will see the performance and in particular will be able to handle the cake and observe the filtrate clarity. The client has opportunity to operate the plant.
After sales service Our after sales service provides you with fully detailed operating and maintenance instructions, training, professional start-up services and technical assistance.
Opportunities In many industries a liquid phase in the process creates the need for liquid/solid separation so that the solids and/or filtrates so produced can be handled or disposed of.
Metso specialists are experts in a wide range of industrial processes. Our policy is to provide a thorough knowledge of our customers’ applications.
“Traditional” mechanical dewatering often leaves the cake too wet or too sticky to handle effectively and usually demands further treatment such as thermal drying. The Tube Press, because of its unique design, will automatically and economically dewater most slurries to produce a clear filtrate and, without any form of thermal drying, a hard, surface dry cake that is convenient to handle as a product for immediate storage or for disposal.
Research and development
Superior performance
It is Metso’s policy to continue to improve, thus the performance of new materials is assessed with a view to greater efficiency and reliability.
Porosity and cake moisture contents are significantly lower than those obtained with low pressure filters, consequently filtrate recovery is high. Filtration is conducted at a pressure level where the cake is produced as a hard surface dry, lump solid. Cake handling procedures are greatly simplified compared with those for low pressure filter cakes, which are typically plastic or pastelike and frequently surface wet.
Reliable support
Available data indicates that Tube Press output rates, in terms of dry solids per unit filter area, are much higher than for either vacuum or plate filter presses. This results both from the pressure dependence of filtration rates and the operational flexibility of the Tube Press which allows a closer approach to the optimum. Filtrate solids concentrations are generally zero, allowing immediate disposal or direct recycling.
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TRANSFER OF TECHNOLOGY
Laboratory and rental service Metso can filter your product on both a preliminary feasibility or on a full-scale production basis with either a lab-size unit or a production size Tube Press. With well equipped laboratories, our experienced technicians will return a report, plus a small filter cake and filtrate sample to the customer for inspection. It is essential that any sample provided for testwork is accompanied by details of its Safe Handling Requirements. If in doubt, the laboratory undertaking the tests will provide details of what is required under these regulations.
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We can also provide Tube Press rental units for in plant testing. Each rig is essentially a fully operational single Tube Press plant, based around either a 500-series Tube Press unit. All rental units are complete with support structure, together with skid-mounted pallet, for ease of shipment and installation, containing the functional services required for operation. The control system on each rig will allow for automatic and manual operation. Conventional filtration processes require continuous supervision and maintenance. The Metso Tube Press, however, is fully automatic which will yield big savings in manpower costs. The Tube Press saves energy, lowers environmental impact and makes your process productive.
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TRANSFER OF TECHNOLOGY Tube press – Sizes
Model
500 Series 1.5 m
500 Series 3 m
100
100
Length of candle (mm)
1 500
3 000
Candle diameter (mm)
389
389
Filter area (m²)
1.75
3.47
Effective volume (litres)
100
200
Candle weight (kg)
580
1 100
Total weight (kg)
2 000
3 000
Crane weight (kg)
6.17
9.17
Filtrationpressure - max (bar)
The Tube Press 500 serie is available mainly in two different sizes. 500 series. Casing diameter 500 mm. Nominal lengths available 1 500 mm and 3000 mm. Maximum pressure 100 bar (1 450 psi).
Model
L mm (inch) tube length
W mm (inch)
Weight (empty) ton
Filter area m² (ft²)
Max op. pressure bar (psi)
SC 500-1,2
3 500 (138)
860 (34)
1,8
1,35 (14,5)
100 (1 450)
SC 500-1,5
3 800 (150)
860 (34)
2
1,73 (18,6)
100 (1 450)
SC 500-3,0
5 200 (205)
860 (34)
3
3,45 (37,1)
100 (1 450)
Applications Typical filtercake moisture contents (Filtration Pressure 102 BAR). Coal fines and shales
19%
Magnesite
23%
Calcium carbonate precipitates
30%
Dyestuffs/Pigments
20%
Para-goethite
27%
Gypsum residues
14-18%
China clay
15%
Metal Sulphides
13%
Iron oxide fume
28%
BOS Sludge
15%
Quarry clay slimes
19%
Oxalates
14%
Seawater magnesia
27%
Molybdenum
Lead chromate retrieval
22%
Zinc Concentrate
12%
Zeolites
41%
Copper Concentrate
12%
Tin Concentrate
10%
Furnace/Converter
15-18%
8 - 10%
Ferrites
14%
Gold Concentrate
21%
Jarosite
22%
Nickel Concentrate
10%
Titanium Dioxide
20%
Silica Dioxide
50%
FOR MORE INFORMATION AND CONTACT: Metso Minerals Corporation Fabianinkatu 9 A, P.O. Box 1220 FI-00101 Helsinki, Finland Tel. +358 20 484 100 Fax +358 20 484 101 eMail: minerals.info@metso.com Internet: www.metso.com
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NEWS & REPORTS www.advanced-mining.com
Best results lead to the breakthrough If crusher technology by Metso looks after anything, then it’s your purse: the Barmac vertical impact crusher protects the rotor which controls the process in an autogenous layer of feed material in crushing. The mobile Lokotrack LT1415 protects the nerves, as its large intake opening prevents bridging. As a primary crusher, the LT140 saves time – in conjunction with the flexible Lokolink conveyor system it makes such progress in opencast quarrying that you can save a large proportion of your dumpers. Talk to us about the possibilities of staying successful even in difficult times. Your contact person: Karl-Heinz Hessler Tel.: ++49 (0)621 72700-611 Mobile: ++49 (0)177 6608438 karl-heinz.hessler@metso.com
Metso Minerals (Deutschland) GmbH Obere Riedstr. 111-115, 68309 Mannheim, www.metso.com
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NEWS & REPORTS Allmineral Aufbereitungstechnik GmbH & Co. KG
allmineral - successfull in Down Under:
three contracts from Rio Tinto, Australia
llmineral has been awarded three independent contracts to supply its leading mineral processing products a and equipment to the Rio Tinto Low Grade Iron Ore Pilot Plant. The Pilot Plant, which will be located at the Brockman 4 Mine Site in Western Australia,60km north west of Tom Price, will play a strategic part in the optimisation of beneficiation options for future Pilbara lower grade deposits.
Three contracts from Rio Tinto, Australia Through MSP Engineering – the contractor that successfully secured the complete jig package with Onyx Projects – allmineral will be providing an alljig® with a design capacity of up to 80 tph feed material. The alljig® separates high density iron ore from gangue material using the processes of stratification and separation. The jig is fitted with flexible design features that allow it to treat fines and lump material up to 32 mm as well as treating wide ranging particle size ratios of up to 1:8. allmineral also secured an order for its unique three product allflux® classifier, the model AFX 100 classifier. This unit is designed to treat up to 2 mm iron ore particles
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in two classification stages that upgrade the valuable mineral by size and density, and also do thickening and desliming in one step.
allflux@: Separating, thickening and desliming in one step
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NEWS & REPORTS gaustec@: Simple, flexible and robust
FOR MORE INFORMATION AND CONTACT:
allmineral Aufbereitungstechnik GmbH & Co. KG Baumstraße 45 47198 Duisburg | Germany Tel.: +49(0) 20 66 - 99 17-0 Fax: +49(0) 20 66 - 99 17-17 eMail:head@allmineral.com Internet: www.allmineral.com
The third allmineral product specifically developed for the beneficiation of hematite ores that will be supplied to this Pilot Plant is the model G 1000 gaustec® wet high intensity magnetic separator (WHIMS). The WHIMS separates iron ores, including paramagnetic and feebly magnetic minerals, up to a particle size of 3 mm if required but typically around 1mm. High gradient magnetic fields are used, which can be independently adjusted for each rotor, allowing scavenger and cleaner process steps to occur in one single machine. “The equipment being supplied comprises of our proven technologies in hematite beneficiation and we consider ourselves fortunate to be associated with the next generation large capacity downstream operations planned for the Pilbara,” said Dr Heribert Breuer. He went on to say: “We are confident that the upgrading processes for low grade iron ore have the potential to significantly add value to Rio Tinto’s existing and planned operations.” Onyx Projects is the engineering company that will provide the complete Pilot Plant facility to Rio Tinto, with start-up scheduled for late Quarter 4, 2011. allmineral belongs to the leading suppliers of processing plants and equipments for the mining industry worldwide. With its superb technologies the Duisburg based company is well known as a specialist for the processing and separation of coal, ore, slag, gravel and sand as well as various secondary raw materials. Around the globe more than 600 allmineral installations for the wet and dry separation are installed.
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alljig@: intelligent operating mode, reliable and very economical
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NEWS & REPORTS
ContiTech
Takes Over Chinese Conveyor Belt Maker on June 1, 2011 Acquisition bolsters position in Middle Kingdom • Plant to be expanded further • Industrial conveyor belts from local production in the future
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NEWS & REPORTS
Northeim/Tianjin, May 30, 2011. ContiTech is beefing up its position in China: On June 1, 2011, the Northeim, Germany-based ContiTech Conveyor Belt Group takes over the conveyor belt operations of Tianjin Xinbinhai Conveyor Belt Co., Ltd., Tianjin. On May 28, 2011 Claus Peter Spille, head of the mining world segment, and Dr. Hongbin Dong, the future general manager of Tianjin Xinbinhai Conveyor Belt, signed the contracts closing the deal with the local sellers. Both sides have agreed not to disclose the purchase price.
ContiTech has been active in China already for 30 years. ContiTech currently produces hose line systems, vibration components, air springs, surface materials, conveyor belts, drive belts, coated fabrics and other components and systems locally at nine modern production plants. It is thus able to very successfully serve the needs of automakers, machine and plant engineering and construction, mining, the printing industry, and rail transportation. ContiTech presently has 2.100 employees in China.
„This move gives us a new market in an upand-coming region and strengthens ContiTech’s position in China,“ says Hans-Jürgen Duensing, general manager of the ContiTech Conveyor Belt Group. “We already manufacture conveyor belts for industrial applications at a number of locations worldwide. Now we can supply the Chinese market with products made right in the country. We are set to further expand the plant.” Situated in the port city of Tianjin, 120 kilometers southeast of Beijing, the plant produces mainly conveyor belts for metal and cement processing and mining, as well as for power plants, port operations and the automotive industry. It has a workforce of around 150.
FOR MORE INFORMATION AND CONTACT:
ContiTech AG eMail: mailservice@contitech.de Internet: www.contitech.de
The ContiTech AG
With sales of €26 billion in 2010, Continental is among the leading automotive suppliers worldwide. As a supplier of brake systems, systems and components for powertrains and chassis, instrumentation, infotainment solutions, vehicle electronics, tires and technical elastomers, Continental contributes to enhanced driving safety and global climate protection. Continental is also an expert partner in networked automobile communication. Continental currently has approximately 155,000 employees in 45 countries. The ContiTech division holds a global market leadership position for many non-tire rubber products and is a specialist in plastics technology in the non-tire rubber sector. The division develops and produces functional parts, components and systems for the automotive industry and other important industries. The division has a workforce of approximately 26,000 employees. In 2010, it achieved sales of approximately €3.1 billion.
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NEWS & REPORTS CAT, Caterpillar
Cat® M Series 2 Motor Graders
Deliver Customer Value with More Power From Cleaner Engines, Added Operator Comfort and Productivity Gains
The newest motor grader models from Caterpillar, the 140M2 and 160M2, along with their all-wheel-drive (AWD) counterparts, the 140M2 AWD and 160M2 AWD, are equipped with clean-burning, fuel-efficient engines meeting European Union Stage IIIB emission standards. The new models also deliver added value for the customer by lowering operating costs and enhancing productivity, operator convenience and serviceability. M Series 2 models continue to improve on the legacy of quality set by the original M Series and are designed for a broad range of tasks, including heavy blade work, road maintenance, ripping and precision-finishing applications.
Clean, efficient combustion The new M Series 2 models all use the Cat® C9.3 ACERT™ engine with Variable Horse Power (VHP), and all have a wider net-variable-horsepower range than their M Series predecessors. The 140M2 and 160M2 have power ranges of 144 kW to 181 kW and 159 kW to 196 kW respectively. Net power ratings for the 140M2 AWD and 160M2 AWD are 151 kW to 181 kW and 166 kW to 196 kW, respectively.
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The C9.3 ACERT engine meets Stage IIIB emission standards utilizing the building blocks of ACERT Technology. The technology combines refined fuel, airmanagement and electronic systems with the Cat NOxReduction System and Cat Clean Emissions Module (CEM). The innovative air-management system, using optimized turbocharging, works with the electronically controlled, commonrail fuel-injection system to provide extremely clean, efficient combustion and optimum fuel economy.
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NEWS & REPORTS Emissions reduction The Cat NOx-Reduction System captures and cools a small volume of exhaust gas, then returns the cooled gas to the combustion chamber to reduce nitrogenoxide emissions. The CEM is an efficiently packaged aftertreatment unit that includes a Diesel Oxidation Catalyst (DOC), a Diesel Particulate Filter (DPF) and the Cat Regeneration System. The no-maintenance DOC assists in reducing the hydrocarbon within the exhaust stream and the DPF traps Particulate Matter (PM), or soot. Under most operating conditions, exhaust heat continually oxidizes particulate matter collected in the DPF through a process called passive regeneration. However, if conditions are such that supplemental regeneration is needed, the Cat Regeneration System elevates exhaust gas temperatures to oxidize soot within the DPF. The Cat Regeneration System is designed to work transparently, occurring automatically without any interaction needed from the operator and regenerating when conditions are optimal. Complementing low emissions, overall efficiency and fuel economy of the C9.3 ACERT engine is a hydraulically driven demand fan, which automatically adjusts its speed to match cooling needs. The fan reduces horsepower
draw, which further boosts fuel economy and allows more power to the wheels. Also, a new swing-out cooling fan package, with an easy-open latch, allows quick access to coolers for fast cleaning.
Operator amenities At the heart of the M Series 2 design is the Cat control system, which uses two electronic joysticks to provide complete, precise control of the machine. The control system results in nearly 80 percent fewer hand and wrist movements compared to conventional motorgrader controls; the net result is enhanced operator comfort and efficiency. The intuitive design helps both new and experienced operators be more productive. The new M Series 2 motor graders also feature electronic vertical adjustment of the joystick control pods, allowing each operator to tailor joystick height for optimum control and comfort, resulting in greater productivity. Selectable blade lift speed modes allow more precise control to match lift response to the job. The spacious M Series 2 cab, with standard air conditioning, uses angled doors and a patented sloping rear window to afford excellent visibility to the heel and toe of the moldboard and to the ripper. In addition, a
Motorgrader 140M2
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NEWS & REPORTS 250-amp alternator is available. To further promote jobsite safety, an optional rearvision camera provides a crisp, wide-angle view of the area behind the machine.
Integrated Technologies Beginning mid-2011, the M Series 2 models will offer the new Cat Grade Control Cross Slope system. Cat Grade Control is a complete machine control and guidance system which integrates traditional grade control with standard machine components at the factory. This optional factory-installed and calibrated cross slope system provides automatic cross slope control capability, ready to operate from the moment it leaves the factory. In addition, Cat Cross Slope is fully upgradeable and compatible with AccuGrade™ systems to grow with customers. In addition to Cat Cross Slope, the M Series 2 motor graders will also continue to offer the AccuGrade Ready Option which provides all the mounting hardware, controls and harnesses for easy installation of all AccuGrade kits. Motor grader users can also utilize Cat Product Link*, which allows remote monitoring of equipment to improve overall fleet-management effectiveness. Product Link is deeply integrated into machine systems. Events and diagnostic codes, as well as hours, fuel, idle time and other detailed information are transmitted to a secure web based application, VisionLink™. VisionLink includes powerful tools to convey information to users and dealers, including mapping, working and idle time, fuel level and more.
Drive train and hydraulics Operators can closely match machine ground speed to the operating situation with the 8F/6R direct-drive powershift transmission, which uses the Cat Electronic Clutch Pressure Control system to modulate gear changes and Controlled Throttle Shifting for smooth directional changes without the inching pedal. Programmable Autoshift lets the operator match shift parameters to the application. A manually controlled differential lock improves traction in adverse ground conditions. When engaged, a standard Automatic Differential Lock system locks and unlocks the differential as required to optimize traction while protecting the tandem chains and differential from possible damage. Multi-disc brakes at each tandem wheel provide large braking surfaces for sure stops and long brake life. The new M Series 2 models are equipped with an advanced electro-hydraulic system for implement control, featuring an independent oil supply to prevent contamination from other systems and to assure proper cooling for extended component life. The load-sensing hydraulic system delivers consistent, predictable cylinder response and provides balanced flow, allowing implements to be used simultaneously with minimal effect on implement and engine speeds.
Motorgrader 160M2
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NEWS & REPORTS Durable structures and DCM The M Series 2 front frame uses continuous top- and bottom-plate construction for exceptional strength, and the rear frame features a robust box-section hitch design, cast axle mounting and integrated rear bumper for durability in the harshest applications, such as ripping.
interference. A shimless moldboard-retention system maintains blade adjustment over extended operating intervals for precise control. The retention system also permits easy adjustment or replacement of worn inserts to significantly reduce maintenance time. For more information about Cat M Series 2 motor graders, contact the local Cat dealer or go to www.cat.com.
The massive, one-piece, forged-steel circle is built to absorb high stress loads, and the circle-drive slip clutch reduces the potential for damage from horizontal shock loads. Six circle shoes keep the circle tighter, longer, to assure maximum control in finish-grading applications. The A-frame-type drawbar, using a tubular design for high strength and optimum durability, features a replaceable ball, removable shims (to compensate for wear) and topadjust wear inserts.
* Product Link licensing not available in all areas. Please consult your Cat dealer for availability.
The optimally shaped moldboard and large throat clearance keep material moving easily, resulting in less horsepower draw, more production and greater fuel efficiency. The moldboard side-shift system uses a wellprotected cylinder mounted to the left to avoid snow-wing
Basic Specifications for 140M2 and 160M2 Motor Graders
Base Weight, kg
Net Variable Power Range, kW
140M2
17.196
144 - 181
140M2 AWD
18.088
151 - 181
160M2
17.296
159 - 196
160M2 AWD
18.188
166 - 196
FOR MORE INFORMATION AND CONTACT: Press Inquiries Europe, Africa and Middle East Mia Karlsson Tel.: +41 (0) 22 849 46 62 Fax: +41 (0) 22 849 99 93 eMail: Karlsson_Mia@cat.com Internet: www.cat.com Caterpillar Seit mehr als 80 Jahren baut Caterpillar Inc. mit an der Infrastruktur der Welt, und gemeinsam mit den Cat-Händlern wird ein positiver und nachhaltiger Wandel auf allen Kontinenten vorangetrieben. Bei Umsatzerlösen und Erträgen von $ 32,396 Milliarden im Jahr 2009 nimmt Caterpillar eine Spitzenposition in der Technik ein und ist weltweit der führende Hersteller von Bau- und Bergbaumaschinen, Diesel- und Erdgasmotoren sowie Industriegasturbinen. Weitere Informationen finden Sie auf www.cat.com
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NEWS & REPORTS CAT, Caterpillar
New Cat®-621H, 623H and 627H Wheel Tractor-Scrapers Feature New Designs and
Technology for High Productivity and Operator Comfort
T
he new Cat® 621H, 623H and 627H Wheel Tractor-Scrapers are designed to deliver superior productivity and enhanced operator comfort and efficiency through the use of increased power and capacity, new structures, electronic controls and ergonomic design. The new H Series designs change the way wheel tractor-scrapers look, run and ride—and increase their capabilities to move material at the lowest cost per ton.
H Series Wheel Tractor-Scrapers build on the proven durability and productivity of previous models with use of innovative technology. Sequence Assist and Load Assist automate many of the operator’s most demanding tasks, and when combined with Cat Grade Control, the new systems unburden veteran operators and help less experienced operators reach high productivity levels quickly. With the H Series introduction, Caterpillar is offering the 621 in a push-pull configuration for the first time. The system enables two scrapers to work together when loading, rather than requiring a push tractor. Other scraper models have proven that the push-pull configuration is the low cost solution in many applications. The new H Series machines replace the equivalent G Series machines when commercial production begins
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in August of this year. Each of the three models will be available with engines that meet US EPA Tier 4 Interim and EU Stage IIIB emissions standards and with engines for use in other regions. The 620H Series Wheel Tractor-Scrapers maintain the G Series configurations. The 621H is a single-engine, open bowl machine; the 623H has an elevating scraper and a single engine; and the open-bowl 627H has twin engines — one on the tractor and one on the scraper — and all wheel drive. Capacities are increased 2 cubic yards (1.5 cubic meters) to 24 cubic yards (18.3 cubic meters) for the 621H and 627H. The new bowl design is easier to load than the G Series bowl and has proven to enhance production. The 623H bowl maintains 23 cubic yards (17.6 cubic meters) capacity, but the elevator is stronger, more powerful and easier to adjust. The result is greater reliability and durability.
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NEWS & REPORTS New engines and drive train controls improve performance and operator comfort The new H Series wheel tractor-scrapers feature a more powerful engine in the tractor, and a more powerful engine in the scraper of the 627H. The Cat C13 engine in the tractor produces 407 hp (304 kW) — 18 percent more power compared to the G Series. And the C9.3 on the 627H scraper produces 290 hp (216 kW), an increase of 19 percent from the G Series machine. The new torque converter coupled to the scraper engine is designed to put more power to the ground. New software ensures integrated performance of the engine and transmission. The 8-speed planetary powershift transmission hardware is the same as the G-Series unit, but new controls and software drive greater performance. The system manages the torque converter and transmission to provide smooth operation, which enhances operator comfort and extends component life. Performance on grades and coming out of the cut is noticeably better through sustaining torque through shift points. On flatter hauls, shift points are optimized for a balance between fuel economy and performance. Complimenting the new power train and higher capacity are wet disc service brakes. The new brakes are similar to Cat off-highway truck brakes and deliver predictable and durable stopping power. The H Series machines also introduce engine compression retarding and the elimination of hydraulic retarding. Engine compression retarding can be modulated within low, medium or high ranges to optimize cycle times.
Technology assists operator and reduces rework
automatically sets the cushion hitch, bowl height, apron, ejector and elevator. Sequence Assist comes with a convenient load counter for tracking material moved. Load Assist is available on the 621H and 627H models. It builds on Sequence Assist by loading the bowl with the push of a button. As the machine enters the cut, the operator can activate Load Assist so the system takes over control of the cutting edge height, limiting tire spin based on integrated sensors and GPS technology to ensure consistent and full bowl loads. The operator is responsible only for the throttle and steering. Load Assist helps make inexperienced operators productive very quickly. Cat Grade Control is available on all three models and is designed to work seamlessly with Sequence Assist and Load Assist. Using satellite positioning technology, the system ensures cut protection by limiting how deep the scraper will dig. The optional system is available from the factory and fully integrated into the machine. The system also puts the site plan in front of the operator for increased efficiency and elimination of rework. Another benefit of Cat Grade Control is site mapping using the scraper.
New cab and operator station — designed for wheel tractor-scrapers The new cab is designed specifically to accommodate the tasks involved with operating scrapers. It‘s 21 percent larger than the G-Series cab, which gives the operator more room for movement and allows more window area for an expansive view of the work area. Also new and designed specifically for scrapers is the Cat Advanced Ride Management System. This new system, which is in testing and will be available soon after H Series machines go into commercial production, is a seat suspension that dampens vibration and prevents endstroke shock loads.
Caterpillar offers three new integrated technology options on H Series Wheel Tractor-Scrapers. Sequence Assist is available on all three models and uses integrated software and position sensing cylinders to automate many of the tasks an operator performs when loading, hauling and dumping. The operator simply sets preferences for bowl and apron height and subsequently pushes a button to ready the machines for loading, then for hauling, then dumping, and then the return to the cut. The system
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NEWS & REPORTS As part of the improved ergonomics, the steering column and pedals align with the right front post of the cab. This puts the operator in a more comfortable position when the seat is turned 30 degrees. A T-handle implement control is designed to fit comfortably in the palm of the hand and is aligned with the seat armrest for comfortable operation. The new wheel tractor-scrapers also feature multifunction hydraulics. The optimized hydraulic system, which uses piston pumps rather than vane pumps, enables the operator to operate the apron, ejector and bowl height control at the same time for faster cycle times. An integrated dash group offers displays for the optional Work Area Vision System (WAVS). Cameras on the machine provide views of the cutting edge, right side and rear. The system enhances safety and provides a new way to see the cutting edge during loading and to see to the rear of the machine when performing push-pull work with another scraper.
An optional powered access ladder facilitates getting in and out of the machine. The ladder raises and lowers, tucking up under the cab when not in use. A new cushion hitch configuration also enhances operator comfort. The 620 Series hitch has two accumulators — one high pressure and the other lower pressure. The high pressure accumulator softens the ride when the machine is loaded, and the lower pressure accumulator optimizes dampening an empty bowl. For more information about the Cat 621H, 623H and 627H Wheel Tractor-Scrapers, contact your local Cat dealer, or visit www.cat.com.
Basic Specifications for 621H, 623H and 627H
621H
623H
627H
Engine
Cat C13 ACERT
Cat C13 ACERT
T: Cat C13 ACERT S: Cat C9.3 ACERT
Net power
407 hp (304 kW)
407 hp (304 kW)
T: 407 hp (304 kW) S: 290 hp (216 kW)
Heaped capacity
24 cu yd (18.3 cu m)
23 cu yd (17.6 cu m)
24 cu yd (18.3 cu m)
Rated load
57,610 lb (26 127 kg)
55,201 lb (25 039 kg)
57,600 lb (26 127 kg)
Weight loaded
136,452 lb (61 883 kg)
143,009 lb (64 868 kg)
147,134 lb (66 740 kg)
Top speed loaded
33.5 mph (53.9 kph)
33.5 mph (53.9 kph)
33.5 mph (53.9 kph)
FOR MORE INFORMATION AND CONTACT: Press Inquiries Europe, Africa, Middle East Mia Karlsson Tel.: +41 (0) 22 849 46 62 Fax: +41 (0) 22 849 99 93 eMail: Karlsson_Mia@cat.com Internet: www.cat.com Caterpillar Seit mehr als 80 Jahren baut Caterpillar Inc. mit an der Infrastruktur der Welt, und gemeinsam mit den Cat-Händlern wird ein positiver und nachhaltiger Wandel auf allen Kontinenten vorangetrieben. Bei Umsatzerlösen und Erträgen von $ 32,396 Milliarden im Jahr 2009 nimmt Caterpillar eine Spitzenposition in der Technik ein und ist weltweit der führende Hersteller von Bau- und Bergbaumaschinen, Diesel- und Erdgasmotoren sowie Industriegasturbinen. Weitere Informationen finden Sie auf www.cat.com
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NEWS & REPORTS CAT, Caterpillar
Caterpillar Puts the Operator First
With Three New B Series Articulated Trucks
CAT 735B, 740B
Caterpillar introduces the next generation of articulated trucks. The new B Series models now include the 735B, offering a 36-ton (32.7-tonne) payload, the 740B with its 43.5-ton (39.5-tonne) payload, and the 740B EJ with popular ejector body, carrying a 42-ton (38-tonne) payload. All three models are available with either Tier2/Stage2 equivalent or Tier 4 Interim/Stage IIIB certified emissions configurations to meet the needs of customers around the world. Both configurations feature revised transmission and traction control systems that enable higher productivity. The new trucks also focus on reducing driver effort and cutting operator fatigue through improved cab design.
Reduced exhaust emissions - Tier 4 Interim/Stage IIIB
The result is a range of more powerful emissionscompliant diesel engines offering improved overall performance.
The three B Series trucks will be available with Tier 4 Interim/Stage IIIB certified Cat® diesel engines for those countries that require them. Caterpillar has employed proven electronic fuel and air supply components for maximum reliability, with a modular after-treatment solution, capable of withstanding the arduous working conditions within construction projects.
The systems employed on the Tier 4 Interim/Stage IIIB B Series trucks produce 90% less particulate matter (PM) and reduce nitrous oxides (NOx) emissions by as much as 50 percent. Emissions controls include a Diesel Particulate Filter (DPF) to trap soot. The necessary process of removing the soot is called regeneration. The “on-the-go” regeneration system allows the regeneration to take place without operator intervention and without
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NEWS & REPORTS
CAT 740B EJ
sacrificing working time. Regeneration can be completed in a number of ways, so that there is no need to change machine work patterns.
Optimized drive train Caterpillar has further improved its six-wheel-drive system. A new, fully proportional torque-distribution automatic traction control (ATC) system eliminates the need for any driver intervention to maintain maximum traction in difficult operating conditions. In the previous generation of articulated trucks, the operator had to manually engage floor- and dash-mounted switches to bring cross- and interaxle differential locks into play. With the new proportional ATC system, the truck automatically and constantly varies the required proportion of lock-up on both crossaxle and interaxle diff locks as underfoot conditions change. The automatic system leaves the
operator free to concentrate on driving the truck, without having to think about how to gain the best traction in different ground conditions. The new proportional ATC system works in harmony with the hydraulic steering system — without compromise in tight turning maneuvers. The optimized proportional ATC system results in improved traction in all operating conditions for reduced cycle times and improved productivity. The automated system also reduces the possibility of system abuse, cutting wear and prolonging component life and reducing costs. Caterpillar also has upgraded its field proven automatic transmission with the introduction of a number of significant technological improvements. These changes mean that gear changes are much smoother, as torque is maintained through each gear change, resulting in improved acceleration, especially on grades. Part
CAT 735B
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NEWS & REPORTS Throttle Shifting at lower speeds results in improved fuel efficiency and easier machine operation and provides the operator an automotive feel during gear changes.
also incorporates a live feed from the rear view camera, which is automatically engaged when reverse gear is selected.
The combination of increased engine power, improved transmission and proportional ATC results in improvements in machine and operator efficiency, cutting cycle times and boosting productivity. Smoother gear changing and reduced operator stress also improve overall operator satisfaction and comfort throughout the working shift.
The revised cab interior has a new headliner with switches for electric mirrors, regeneration operations and a heavy duty CD/radio. An upgraded driver’s seat with new multiple position adjustments improves the class-leading ride quality further, while new materials offer improved durability and long service life. A heated driver’s seat is available as an option. New operator and passenger grab handles improve stability when travelling over rough or sloping terrain.
Improved operator environment The B Series trucks are designed and built around the operator. Behind the tough exterior, with its powerful new styling, integrated heavy-duty bumper and fully enclosed belly guards, the Cat truck offers the ideal operator environment. A new injection molded dash panel with revised trim provides an improved fit and a more aesthetically pleasing working environment. The redesigned instrument cluster and fully customizable Color Multi-Purpose Display (CMPD) give the operator all of the information needed. Machine monitoring includes information as diverse as regeneration status, fuel levels, autolube status, load count and major component temperatures. The CMPD
The heating and air-conditioning system has been upgraded to improve efficiency and ensure the ideal climate in the cab. The engine hood raise switch is now positioned in the cab for ease of access and increased security. Other detail improvements include a new cab external grab rail, a repositioned ground level fuel filler for improved access, new machine width position marker lights and wider spaced turn indicators. Highintensity high-level work lights are now available as an option. All B Series models are produced at Caterpillar’s state-of-the-art production facility in Peterlee, UK. The site has benefitted from unparalleled financial investment, extensive employee skills training and a full product validation process, to ensure that every truck exceeds the expectations of customers around the world.
CAT 740B
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NEWS & REPORTS
CAT 740B EJ
Basic Specifications - Tier 4 Interim / Stage IIIB configuration (Tier2 / Stage II machines have marginally higher engine powers)
735B
740B
740B EJ
C15 ACERT
C15 ACERT
C15 ACERT
452 hp (337 kW)
489 hp (365 kW)
489 hp (365 kW)
Rated payload
36 tons (32.7 tonnes)
43.5 tons (39.5 tonnes)
42 tons (38 tonnes)
Body capacity (heaped)
25.8 yd3 ( 19.7 m3)
31.4yd3 (24 m3)
30.2 yd3 (23.1m3)
Engine Gross power (SAE J1995)
FOR MORE INFORMATION AND CONTACT: Press Inquiries Europe, Africa and Middle East Mia Karlsson Tel.: +41 (0) 22 849 46 62 Fax: +41 (0) 22 849 99 93 eMail: Karlsson_Mia@cat.com Internet: www.cat.com Caterpillar Seit mehr als 80 Jahren baut Caterpillar Inc. mit an der Infrastruktur der Welt, und gemeinsam mit den Cat-Händlern wird ein positiver und nachhaltiger Wandel auf allen Kontinenten vorangetrieben. Bei Umsatzerlösen und Erträgen von $ 32,396 Milliarden im Jahr 2009 nimmt Caterpillar eine Spitzenposition in der Technik ein und ist weltweit der führende Hersteller von Bau- und Bergbaumaschinen, Diesel- und Erdgasmotoren sowie Industriegasturbinen. Weitere Informationen finden Sie auf www.cat.com
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NEWS & REPORTS HAVER & BOECKER Screening Group
HAVER & BOECKER reaching new dimensions with the
NIAGARA T-CLASS®
HAVER NIAGARA T-CLASS® At bauma 2007 HAVER & BOECKER introduced the prototype of the new HAVER NIAGARA T-CLASS®. This machine design has since been used continuously and developed further. Today the company looks back on a large number of satisfied customers worldwide. HAVER & BOECKER recently introduced the NIAGARA T-CLASS® with a newly designed drive system, allowing more amplitude/rotary speed combinations than before. This in turn allows small cut sizes to be realized as well as difficult classifying jobs with large cut sizes. Further, the machine is equipped with a newly developed wearprotection system decreasing the replacement time of worn elements, thus reducing downtime.
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Within the scope of the NIAGARA T-CLASS® concept, screening machines with widths starting at 2.40 meters were built in the first phase of expansion. After the introduction of a time and cost-saving modular construction system, machines with screen decks of almost twice the width (i.e. up to 4.20 m) can be built today at the plant in Münster. A recently built 3.5-deck model D180 3000 x 7200 machine of this type was sold to German engineering and plant designer HAZEMAG in Dülmen. It separates 450 tons of limestone per hour at 25/15/8 and 4 mm. The dimensions of this screening machine are 3 m x 7.2 m, and the total screening surface amounts to 72 m². It weighs about 25,000 kg. In order to achieve the throughput and cut sizes requested by the customer, the NIAGARA T-CLASS® is
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NEWS & REPORTS equipped with two bearings and a 75 kW drive unit. The screening machine is easy to access and to maintain, as the screen deck spacing is capaciously dimensioned. This provides ideal work conditions for the operating personnel. The screen frame of the HSG machines is engineered in a traverse design. The deck structure is clamped onto the frame with a patented retaining bracket and without welded seams. The brackets form the mounting area for the screen panel support system. Through the positioning of the brackets, spacing of the longitudinal supports can be varied. Thanks to bracket shapes with horizontal and vertical mounting areas, this concept can be applied equally well to modular as well as side- or end-tensioned screen media. At the same time, these brackets also support a newly developed wear protection system (HAVER Snap Guard) of modular structure and allowing easy replacement.
FOR MORE INFORMATION AND CONTACT: HAVER & BOECKER Screening Group Robert-Bosch-Straße 6 48153 Münster | Germany Tel.: +49 (0)251 - 97 93-0 Fax: +49 (0)251 - 97 93-156 eMail: niagara@haverboecker.com Internet: www.haverscreeninggroup.com
Machinery Division Münster Marketing and Public Relation Christiane Temming Tel.: +49 (0)251 - 97 93-102 Fax: +49 (0)251 - 97 93-156 eMail: c.temming@haverboecker.com Internet: www.haverboecker.com
HAVER & BOECKER demonstrates readiness for the future with their NIAGARA T-CLASS®, and continues to meet their customers’ growing requirement for customized solutions.
The HAVER & BOECKER team with a NIAGARA T-Class® screening machine built at the plant in Muenster, Germany.
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NEWS & REPORTS Atlas Copco Surface Drilling Equipment
New Names
make it easier to distinguish between different drill rigs
A
tlas Copco Surface Drilling Equipment is changing the naming structure of the drill rigs in the ROC-family. The new names will make it easier to distinguish between the various drill rigs, as well as clarify the different characteristics of the products. Implementation has started and by the end of 2012 all products will follow the new naming structure.
“The new naming structure is built up in a logical way, in purpose to simplify the understanding of the range”, says Hellen Ekefalk, Communications and Brand Manager, Surface Drilling Equipment.
Tophammer, down-the-hole and COPROD drilling methods are used right across the range and this is evident from the individual product designations such as FlexiROC T30 R, where T stands for tophammer and 30 for 3 inches.
The product range has been divided into four different categories, four series of ROC drill rigs with the following names: AirROC, PowerROC, FlexiROC and SmartROC. The product series can be described as follows
FOR MORE INFORMATION AND CONTACT:
• The AirROC series consists of pneumatic and manually operated drill rigs, easy to operate with simplicity in design and a robust steel structure.
Atlas Copco Surface Drilling Equipment Vice President Marketing Bo-Göran Johansson Tel.: +46 (0)19 - 670 - 72 59 eMail: bo-goran.johansson@se.atlascopco.com Internet: www.atlascopco.com
• The PowerROC series consists of hydraulic drill rigs with a straightforward design and trouble-free hydraulics. • The FlexiROC series consists of high technology rigs with a medium level of sophistication. • The SmartROC series consists of high technology rigs with a high level of sophistication and equipped with the latest optional equipment to minimize costs in each drilling and blasting operation.
The new structure makes it easier to distinguish between the models and easier to understand the advantages that each category has to offer. It also better defines the segment and application for which each rig is intended.
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Atlas Copco Surface Drilling Equipment Communications and Brand Manager Hellen Ekefalk Tel.: +46 (0)19 - 503 - 13 29 eMail: hellen.ekefalk@se.atlascopco.com Internet: www.atlascopco.com
Atlas Copco Surface Drilling Equipment is a division within Atlas Copco’s Construction and Mining Technique business area. It develops, manufactures, and markets rock drilling equipment and mobile crushers and screeners for various applications in civil engineering, quarries and open pit mines worldwide. The division focuses strongly on innovative product design and aftermarket support systems, which give added customer value. The divisional headquarters and main production center is in Örebro, Sweden..
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NEWS & REPORTS Atlas Copco
Atlas Copco
wins large orders in Saudi Arabia
S
tockholm, Sweden, May 19, 2011: Atlas Copco has received two significant orders related to the Ma’aden aluminum project in Saudi Arabia, highlighting its position as a leading supplier of compressed air and gas equipment in the region. The orders are valued at a total more than MUSD 50 (MSEK 300).
Atlas Copco will supply 20 turbo compressors for a power generation application in a new plant outside of Jubail, Saudi Arabia. The customer is a consortium of the Al-Arrab contracting company and Sepco III Electric Construction Corporation of China. The combined 2 400 MW power and desalination plant will provide power, steam and water for the aluminum smelter being constructed by the Ma’aden Saudi Arabian Mining Company. Atlas Copco earlier this year received a turnkey contract to supply the completecompressed air system for the Ma’aden aluminum smelter and will deliver five of its largest oil-free air compressors as well as two smaller compressors and dryers. “Atlas Copco’s proven competence and experience from these kinds of projects throughout the world, combined with the reliability of our equipment, were essential in winning these orders,” says Stephan Kuhn, Business Area President, Atlas Copco Compressor Technique. “Investments in aluminum smelters in the Middle East are growing and we have a strong presence in this market segment.”
FOR MORE INFORMATION AND CONTACT: Atlas Copco Business Area President, Compressor Technique Stephan Kuhn Tel.: +32 (0)3 - 870 - 29 38 oder +32 (0)474 - 881 154 Internet: www.atlascopco.com
Atlas Copco Media Relations Manager Daniel Frykholm Tel.: +46 (0)8 - 743 - 80 60 oder +46 (0)70 - 865 8060 Internet: www.atlascopco.com
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The power generation order was booked in the second quarter and is worth about MUSD 40. The machines are scheduled to be delivered in the first half of 2012. The order for the aluminum smelter was received already in the first quarter. The Ma’aden aluminum plant will have a capacity of 740 000 tons of aluminum and 1.8 million tons of alumina per year. The site will consist of an alumina refinery, aluminum smelter and roll mill.
Atlas Copco is an industrial group with world-leading positions in compressors, construction and mining equipment, power tools and assembly systems. The Group delivers sustainable solutions for increased customer productivity through innovative products and services. Founded 1873, the company is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2010, Atlas Copco had about 33 000 employees and revenues of BSEK 70 (BEUR 7.3). Learn more at www.atlascopco.com. Atlas Copco’s Compressor Technique business area develops, manufactures, markets, and services oilfree and oil-injected stationary air compressors, portable air compressors, gas and process compressors, turbo expanders, electric power generators, air treatment equipment and air management systems. It also offers specialty rental services. It innovates for superior productivity in applications such as manufacturing, construction, and the process industry worldwide. Principal product development and main manufacturing units are in Antwerp, Belgium.
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NEWS & REPORTS Kleemann GmbH
Kleemann Mobicat MC 110 Z
First Kleemann for Pinden
Pinden Ltd’s new Kleemann Mobicat MC 110 Z mobile jaw crusher
First Kleemann for Pinden Group KENT-based Pinden Limited has taken delivery of its first Kleemann crusher after many years’ operations using machines from an industry competitor. The Mobicat MC 110Z is one of a range from the Kleemann stable, which is sold in the UK by Wirtgen Limited. Pinden director, Steve Bishop, says the company opted for a change despite the machine’s higher cost, because of Kleemann’s reputation for superior build quality and its potential to deliver significant lifecycle fuel and other savings. “We had the machine on demonstration, first,” says Bishop. “We were convinced we can make considerable savings in fuel consumption over the lifetime of the machine. We also found output to be higher, and the quality of product was better, than previous machines. Normally we would replace our crushers after three years; we expect to get five years from the Kleemann, with lower component replacement costs over that time. Wear parts are of a much better quality.” The Kleemann features a pre-screen which reduces fines before crushing, greatly reducing wear on the machine’s manganese steel jaws.
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The Dartford firm is part of a group of companies which include Syd Bishop and Sons (Demolition) Limited. Its Pinden quarry is the site of one of the South East’s largest processors of demolition waste for the construction industry, producing 6F1/6F2 materials for roads and other applications in accordance with WRAP specifications. Crushing facilities have to respond quickly to rising seasonal demand or peaks resulting from large individual projects. “We learned from the demo’ that the machine was capable of very high productivity. In fact one shovel alone couldn’t keep up with it,” says Bishop. “It means that, when demand [for material] is high, we can step up the output as necessary. The machine is also good from a dust-suppression point of view, which is important, as the site is regulated by the Environment Agency, being a receiver of hazardous waste.” Kleemann southern area sales manager, Aidan Gillic, estimates the Mobicat should be good for annual fuel savings of up to £15,000 compared to competing machines. He says fixed jaw life could exceed 2,000 hours before replacement. “The geometry of the jaws also makes for a better end-product, which is easier to compact. The Mobicat hopper, crusher and discharge conveyor
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NEWS & REPORTS arrangement allows a smoother flow of material than others on the market. There’s less tendency for blockages. In addition, the magnet is hydraulically adjustable; the magnet remains parallel to the belt.” The Mobicat track-mounted single toggle jaw crusher is designed for pre-crushing natural stone and mineral construction waste for re-use. With a crusher inlet size of 1100 x 700mm, the Mobicat 110 Z is equally at home in quarrying or recycling operations. With its easy to transport size and weight of 45-50 tonnes, it has the largest scope of application of all mobile jaw crushers. The independently vibrating double deck pre-screen can be equipped with different meshes, according to the application. That way, pre-screen material can bypass the crusher or be stockpiled by the left or right side-mounted discharge conveyor belt, giving flexibility on construction sites where space is at a premium. A 266 kW low fuel consumption, low noise and low pollution diesel engine, flange mounted hydraulic pumps and a coupled electricity generator deliver the power for the crusher and the electric drive for the belt, conveyors, conveying chutes, and screens. A Siemens PLC control system with LCD display for manual and automatic operation come as standard on the Mobicat. A vibration-isolated, double switch cabinet housing and built-in overpressure system, along with connections for control cable to interlock auxiliary machinery and socket outlets for 230 and 400V components are provided.
Kleemann GmbH Kleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of companies doing business in the construction equipment industry. This Group boasts the four well-known brand names, Wirtgen, Vögele, Hamm and Kleemann. Its parent plant is located in Germany and other production facilities exist in the USA, Brazil and China. Customer service is provided on a global level through its 55 sales and service offices. Wirtgen Limited is the UK subsidiary of the Wirtgen Group. From road planning to crushing and screening, Wirtgen Limited supplies quality machinery to suit every application.
FOR MORE INFORMATION AND CONTACT:
Kleemann GmbH Mark Hezinger Manfred-Wörner-Str. 160 73037 Göppingen | Germany Tel.: +49 (0)71 61 - 20 62 09 Fax: +49 (0)71 61 - 20 61 00 eMail: mark.hezinger@kleemann.info Internet: www.kleemann.info
Optional features include an electric or permanent magnetic separator and, on the 110, a single deck, longitudinally tensioned, large area vibration screen that can be hydraulically lowered for mesh replacement for quick changeover.
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NEWS & REPORTS Volvo Construction Equipment
Volvo Construction Equipment
David Smith Contractors Ltd opt or more Volvo crawler excavators Fraserburgh based David Smith Contractors Ltd has added a further two, twenty four tonne EC240C excavators and a twenty nine tonne EC290C digger to their increasing fleet of Volvo Construction Equipment products.
Established back in 2002 by Proprietor David Smith, the Company has evolved as a civil engineering and groundworks contractors undertaking bespoke projects for blue chip companies such as major retail outlets and superstores as well as the important oil and gas sector in the north of Scotland. Having purchased their first Volvo just five years ago, the Company has added to its portfolio of Volvo equipment with seven articulated haulers, an L120C loading shovel, a compact EC55B, a brace of EC210C’s and with the latest purchase, two EC240C and an EC290C. “We continue to have an excellent relationship with team from Volvo and the machines have been reliable and productive as well,” explained David Smith. “The opinion of my operators is equally important and they appreciate the high standard of operator comfort and overall performance we’ve found with the machines.”
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The latest models to join the fleet herald new ventures that David Smith Contractors Ltd are entering into such as demolition contracts,crushing and quarrying contracts as well as a piling division. “Moving into these areas and to be able to offer our client base a complete package of services is vital for the long term,” said David Smith. “And to carry out the work in a cost effective manner means increasing the size of the machines and their capacities in terms of lifting and hydraulic capacity to suit the applications.” One of the new EC240C’s has been modified by the customer to accept a bespoke piling rig which includes the fitting of an Indexator rototilt hitch and a hydraulically driven sheet piling head of the company’s own design and manufacture. The two tonne head runs off the EC240C’s hammer shear circuit requiring up to 230 litres per minute in high mode and can handle sheet
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pile sections up to 14 metres in length at a reach of 7 metres. The selector block and solenoids for the rototilt have been repositioned and located within the superstructure of the machine as opposed to the usual mounting point on the rototilt itself to allow piling operations below or close to water. All the hose connections to the piling head and rototilt are fitted with quick release couplings to facilitate quick and easy changeover to other attachments and buckets. David Smith Contractors Ltd provides a complete range of Civil Engineering Services from demolition and earth moving to petrochemical site maintenance and road construction. The company operates from Crimond near Fraserburgh and provides a comprehensive service throughout Scotland. Volvo Construction Equipment Division markets wheeled loaders, articulated haulers, hydraulic excavators, graders, Volvo utility equipment and Volvo road equipment products in the U.K. There are eight strategically placed customer support centres and a network of compact equipment dealers to ensure high quality customer support is maintained throughout the country.
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FOR MORE INFORMATION AND CONTACT: Volvo Construction Equipment Marketing Services Mark Gunns eMail: mark.gunns@volvo.com Internet: www.volvogroup.com
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NEWS & REPORTS Volvo Construction Equipment
Volvo Construction Equipment
Arnold Plant Hire take two Volvo L50F loading shovels Arnold Plant Hire Ltd of Bredbury, Stockport has broken with tradition by purchasing two new Volvo L50F loading shovels for its extensive hire fleet.
Looking to replace a pair of competitive models for an on going long term contract hire, the company settled on the Volvo product following a successful demonstration and competitive evaluation. “We’ve had experience with excavators from the Volvo range that gave us good reliability and availability but this is the first time we’ve switched to their loading shovels,” explained Arnold Plant’s Service Director Alan Laithwaite. “This coupled to the outcome of the recent demonstration and the very positive feedback from the personnel on site persuaded us in taking a leap of faith with the L50F’s.” The pair of loading shovels has been put in charge of handling a wide variety of road materials ranging from road planings, aggregates, tar macadam to sub base and crushed concrete in a local authority’s stock yard servicing the demands from the Greater Manchester area. With the diverse range of product, both machines
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have been supplied with several attachments that can be interchanged thanks to the Volvo quick coupler. These include a 1.4m³ general purpose and a 2.0m³light material buckets as well as pallet forks, complementing existing attachments on site including high tip and heavy duty buckets. The L50F along with its smaller brother, the L45F, are two mid-sized wheeled loaders in Volvo Construction Equipment’s F series line up and share the same design of the rear chassis with its sloping engine hood - thanks to the transverse mounted 4.8 litre Tier III engine and hydrostatic motor, providing superb visibility all around the machine. The Volvo Care Cab was recognised as a key factor in selecting the L50F by the personnel on site who appreciated the high level of comfort, all round ergonomics, good functionality of the controls and air conditioning.
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With an operating weight of 9430kg, the L50F has a generous full turn tip load of 5900kg with the optimum bucket size of 1.4m続 and the engine output of 117hp is superbly matched to the hydrostatic transmission allowing full power shift under load when changing direction and between speed ranges. As with its bigger brothers in the range the L50F sports a Torque Parallel (TP) loader linkage which provides smooth, parallel lift, high roll back torque and good lifting power throughout the lift cycle. The Volvo hydraulic attachment bracket facilitates the easy change over of attachments. Established twenty years ago Arnold Plant Hire Ltd hires plant and machinery to the construction industry on long and short term contracts on a self drive nationwide basis. The company operates in excess of 100 items of mobile plant including mini-excavators from 1.5 ton to 7 ton; backhoe loaders; tracked excavators from 13 to 20 tonnes; wheeled loading shovels; telescopic handlers and hydraulic breakers. The entire fleet is maintained in house by a fleet of mobile and workshop based engineers. Volvo Construction Equipment Division markets wheeled loaders, articulated haulers, hydraulic excavators, graders, Volvo utility equipment and Volvo road equipment products in the U.K. There are eight strategically placed customer support centres and a network of utility equipment dealers to ensure high quality customer support is maintained throughout the country.
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FOR MORE INFORMATION AND CONTACT: Volvo Construction Equipment Marketing Services Mark Gunns eMail: mark.gunns@volvo.com Internet: www.volvogroup.com
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NEWS & REPORTS Telestack Ltd Fig. 1: Mobile radial telescopic shiploader in Port of Vostochny
Telestack install 2 x Mobile Shiploaders and 2 x mobile truck unloading units for loading coal in Port of Vostochny, Russia Telestack Limited continue to excel in providing innovative mobile Shiploading systems to its worldwide customer base. This has been emphasised in the manufacturing and development of a fully customised MOBILE shiploading system for the Port of Vostochny, Russia. The mobile shiploading system is loading coal directly from trucks to 2 x mobile truck unloaders and 2 x 50 metre (170ft) radial telescopic shiploaders. Telestack Limited has enjoyed great success when installing coal handling facilities throughout the globe, with this project highlighting the mobility and flexibility of the equipment to meet the ever changing needs of one of the largest coal handling Ports in Eastern Russia.
Mobile Shiploading System The installed units consist of 2 x mobile systems to load Handymax sized vessels at 1200TPH. The mobile shiploaders are 50 metres (170ft) in length with a range of movements to ensure adequate trimming of the vessel. The unique design of the Telestack conveyor systems allow for a full range of trimming capabilities, which are vital when loading these sized vessels. The telescopic feature allows the operator to telescope the inner conveyor (IN/OUT movement) so they can trim the vessel without altering the feed-in point or stopping the
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loading. The radial feature allows left/right movement via internal hydraulic drives to further enhance the trimming capabilities of the equipment, as the operator can radial from one fixed position, again without stopping production. These features, in combination with the luffing (raise up / down), allow for the most mobile and flexible loading equipment on the market. As with the majority of Telestack equipment, the customer availed of the extensive range of options for this equipment to enhance the loading procedure and customise the units for the handling of coal. This includes
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dust suppression measures throughout the equipment, including dust covers on the shiploader including the outer conveyor, telescopic dust covers on the inner conveyor and water suppression spray bars at the discharge point. These customised upgrades ensure every effort has been made to eliminate / reduce dust and spillage which are vital within the port environment. The mobility of the ship-loaders is done using a diesel engine driven tracked unit including a remote control for easy manoeuvrability around the site and to the next hatch during the loading process, see figure two.
Fig. 2: Tracked mobile unit for site movement c/w remote control
Fig. 3:Dual Access wheeled truck unloader fed from truck to fed mobile shiploader
Mobile Truck Unloader eliminates double handling The 2 x dual access wheeled mobile truck unloaders allow the operator to discharge the coal directly from trucks or wheel loaders to load the vessel. This eliminates the double handling of the material and means a more efficient material handling process. The truck unloader consists of a heavy duty apron chain belt feeder to handle the surge of material from the trucks and transfer this onto the incline and then to the shiploaders, see figure three and four.
Fig. 4:Dual Access wheeled truck unloader fed from truck to fed mobile shiploader
The dual access hydraulic raising / lowering ramps ensure an efficient cycle time for the trucks, as one truck is discharging the other is reversing into position for unloading as soon as the first truck is finished. This method ensures that production targets are maintained and are not hindered by the truck cycle times, which would be typical of single access truck unloaders, see figure five and six.
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NEWS & REPORTS Fig. 5: Wheeled Truck unloader in operating and transport position
The unit was also installed with an overband magnet on the incline of the truck unloader to remove any metal from the coal before the material was loaded to the Handymax vessels. The mobility and flexibility of these units ensure the loading process and production rates are increased / maintained for the operator. Telestack mobile bulk material handling systems are built to last, combining strength with the highest quality components available on the market. The success derives from achieving sustainable value for the client; using mobile bulk handling technology to enhance operational efficiency, minimise environmental impact and maximise flexibility. For any further information on this project, please feel free to contact info@telestack.com or www.telestack.com
FOR MORE INFORMATION AND CONTACT:
Telestack Limited Tel.: +44 (0)28 8225 1100 Fax: +44 (0)28 8225 2211 email: info@telestack.com Internet: www.telestack.com
Fig. 6: Wheeled Truck unloader in operating and transport position
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NEWS & REPORTS Powerscreen
FROM FLORIDA TO THE DOMINICAN REPUBLIC WITH POWERSCREEN! Powerscreen customers in the Dominican Republic will benefit from improved product availability and support thanks to a new support center recently opened by longstanding dealer, Powerscreen of Florida.
From Florida to the Dominican Republic with Powerscreen Powerscreen of Florida was founded in 1984 by Denis Grant and, over the last 27 years, it has earned a reputation as a leader in the sales, rental and aftermarket support of crushing and screening equipment in Florida, Georgia, the Caribbean, and Latin America. Located in Lakeland, Florida, the company has continually expanded its locations with support centers in Atlanta, Georgia, Haiti and most recently in Santo Domingo in the Dominican Republic.
brought the management skills he had learned as a baseball executive for the New York Mets in charge of international scouting. The results were immediate. Export sales now account for approximately 50 percent of company revenue and helped offset the lower domestic sales as the recession continues to depress business in the south-eastern US.
The company prides itself on retaining a dedicated staff of employees with many years of service, which is critical to establishing strong relationships with customers. As a testament to this philosophy, its first employee, Karla Regan, is still with the company, serving as bookkeeper and office manager, and has been an integral part of the company’s growth and success.
The company has continued to explore markets outside the US and strengthen its presence in the Caribbean. Key to this plan was the opening of warehouse support center in the Dominican Republic. Under the name of a newly formed company, Powerscreen Caribbean, they will continue to provide customers in the Caribbean with an excellent level of service, thanks to a knowledgeable staff, full parts inventory, service department and a complete stock of equipment available for sale or rent.
The company grew steadily in the 1990’s and early 2000’s with sales peaking in 2006. Around this time, the company hired Rafael Bournigal, who is Denis’ son-in law, to develop sales in international markets, particularly the Caribbean and Latin America. Rafael
In the past 18 months, Powerscreen Caribbean has had many successes in the Dominican Republic. One customer, Constructora Hermanos Yarull, bought 10 machines in the last year, to fulfil its commitment with Barrick Gold quarry. Constructora Hermanos Owner Pedro Yarull said,
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NEWS & REPORTS “Our relationship with Powerscreen Caribbean/ Powerscreen of Florida started many years ago through Rafael Bournigal. This company has great equipment, excellent after-sales service, and personnel who care about the success of the customer. We have many Powerscreen® products including a Premiertrak jaw crusher, three impactors, three Powerscreen Titan 1800 screen plants, three Powerscreen Chieftain Rinsers and many more. These machines are critical in our construction projects, including a major contract we have in the Barrick Gold mine in the city of Maimon, Dominican Republic. This company is our main crushing and screening plant supplier and we will continue to work with them.” Ferreteria Ochoa is said to be the largest company in the Dominican Republic and Latin America for block production. They are located in Santiago, which is the second largest city in the Dominican Republic. Diego Olivares, Managing Director, has just bought a new Chieftain 1400 track machine for his company. Over the years Ferreteria has acquired numerous machines from Powerscreen of Florida including the Warrior 1800 and the 4242SR. Olivares explained why he keeps coming back to Powerscreen Caribbean/Powerscreen of Florida, “We are very happy with the equipment and the honesty of the staff.”
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About Powerscreen With a rich heritage of design and manufacturing excellence, Powerscreen has grown to become a leading force in the original equipment manufacturing (OEM) sector. Powerscreen® machines cover the full range of material processing requirements in terms of mining equipment, quarrying equipment and crushing, screening and washing machines for the mining, quarrying, demolition and recycling industries. Powerscreen has developed a global network of over 120 dealers selling over 50 product lines across the world. Powerscreen dealers provide continuing customer support for both parts and service to ensure optimum performance from all Powerscreen® machines. From the Warrior 800 mobile screen through to the latest mobile crushing plant - the Pegson XA750 jaw crusher and taking in the Aggwash and Finesmaster washing and dewatering plant Powerscreen has a wide range of product to fit most applications. Terex® Pegson and Powerscreen® products and services were united under one powerful name, Powerscreen, in 2009 click here to view the company history. Powerscreen operations worldwide are part of the Terex Corporation. At Terex Corporation, we are driven by our mission to delight our customers with value-added offerings that exceed their current and future needs. Our commitment to this mission can be seen in everything we do, from our wide range of quality products to our focus on customer satisfaction. We strive to deliver products that are safe, reliable, cost-effective, and improve your return on invested capital. We offer an extensive range of equipment serving the construction, infrastructure, quarrying, recycling, shipping, transportation, refining, utility, and maintenance industries.
FOR MORE INFORMATION AND CONTACT: Powerscreen - Terex GB Limited email: sales@powerscreen.com Internet: www.powerscreen.com
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NEWS & REPORTS Hitachi Construction Machinery (Europe) NV The new Hitachi parts depot in Oosterhout
Customer Service in Focus
HCM President opens HCME’s new European Parts Depot
HCM President opens HCME’s new European Parts Depot An official opening ceremony has taken place for the new Hitachi Construction Machinery (Europe) NV (HCME) European Parts Depot. The celebration was held on 2 May at the impressive Oosterhout facility in the south of The Netherlands and the guest of honour was Hitachi Construction Machinery Co., Ltd. (HCM) President Michijiro Kikawa. Mr Kikawa gave a speech to the other distinguished guests who attended the ceremony, among them Mitsuhiro Tabei, President of HCME. He then presented representatives from the Parts Depot with a special Japanese maple tree, which was planted in front of the building. The acer palmatum ‘Atropurpureum’ – as it is also known – traditionally signifies creativity, ambition and success in Japan, and is appropriately said to promote a long and healthy life.
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In his address, Mr Kikawa emphasised the importance of the new facility, saying: “It is a great honour to officially open this new Parts Depot, and to have the opportunity to join my colleagues from HCME at such an important event in our history. “The aim of the company investing in this larger, improved facility is to provide the best possible service to our dealers and customers. Parts availability has further increased due to the new facility’s greater capacity and efficiency. This will help Hitachi to boost parts sales and meet the demands of our expanding customer base.”
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NEWS & REPORTS The 53,000m² depot, which cost ₏12million, has a covered stock area that is three times the size of the previous Parts Distribution Centre, which was also situated in Oosterhout. It has the capacity to stock up to 90,000 individual parts lines at any one time and will be responsible for distributing them throughout Europe, Middle East, Russia/CIS and Africa. In addition to a special chemical storage area, it includes a 14-metre high storage area for larger items. Efficiency will be ensured by a dedicated Warehouse Management System, which will guide operatives in unpacking and storing received parts, as well as picking, packing and shipping ordered items. It will employ a total of 70 people, who will have the potential to handle up to 800 packages each day and 70,000 parts items every month.
FOR MORE INFORMATION AND CONTACT:
Hitachi Construction Machinery (Europe) NV Sicilieweg 5 1045 AT Amsterdam | Netherlands Tel.: +31 (0)20 44 - 76 700 Fax: +31 (0)20 33 - 44 045 eMail: info@hcme.com Internet: www.hcme.com
Hitachi Construction Machinery Co., Ltd. Internet: www.hitachi-c-m.com
Ceremonial opening of the new Hitachi parts depot in May 2011
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TRANSFER OF TECHNOLOGY
BROAD SERVICE SPECTRUM The BBM Group is active in a variety of future-orientated business areas: Our core business comprises mining, structural, underground and civil engineering as well as assembly. In addition, as an innovative company we have also embarked on the development and marketing of new IT technologies. Our services at a glance:
CONTACT: Operta-BBM
Dieter-aus-dem-Siepen-Platz 1 D-45468 Mülheim an der Ruhr PHONE +49 (0) 208 459 59-0 FAX +49 (0) 208 459 59-59 EMAIL info@operta-bbm.de
OPEN CAST MINING Excellent raw materials for successful construction projects Our quarries produce first-class rock for structural and civil engineering. Our stone fractions, high quality fine flints and architectural stone are used primarily in road construction and concrete production, and also in the chemical industry. BBM is also increasing in demand as a contract mining supplier for raw materials extraction. MINING Top quality services based on experience BBM is an outstanding supplier of specialist underground mining services, in particular in Germany. Working on behalf of large mining companies, we assume responsibility of complete lots or provide personnel for all forms of mining and assembly work. Our teams are available for flexible application right across Europe. Our own workshop maintains our fleet of machines. BBM has also succeeded in making a name for itself as a contract mining supplier in the underground mining sector.
DIVERSE ACTIVITIES ACROSS EUROPE The proprietor-managed BBM Group has enjoyed success on the market since 1990 and is active in a wide range of business areas. Networked with internationally renowned cooperative partners, we support demanding projects throughout Europe. In doing so we apply the skills of around 1,000 highly qualified employees, who work with competence and commitment to ensure the seamless fulfilment of our orders. It is with maximum flexibility that we set benchmarks in quality and reliability. Thanks to rapid decision-making and the central steering of all activities, we offer integrated solutions from a single source and generate tailored solutions – in all business sectors.
W W W. O P E RTA - B B M . D E Issue 02 | 2011
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ADVERTISEMENT
WE BUILD THE FUTURE Every project needs a vision – and the resources to transform it into reality. BBM combines both: Top quality demands throughout all of our activities in a wide range of areas, excellent corporate knowhow and expert knowledge of the skilled trades and technology. This results in excellent products and services, for which we are renowned and valued right across Europe. BBM is a reliable and in-demand partner, greatly trusted by its clients and cooperative partners. This high performance level and consistent orientation towards the demands of our customers makes us exceptional. We accept challenges and create added value: As a dynamic company that will continue to grow in the future and tap into new markets across Europe. BBM brings projects to a successful conclusion – take our word for it and profit from our rich wealth of experience.
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NEWS & REPORTS Bell Equipment Deutschland GmbH Absetzer: Pro Fahrzeug bis zu 2800 Tonnen Tagesleistung im Doppelschichtbetrieb machen die Bell B50D zu Schlüsselmaschinen im Tagebau Schöningen der E.ON Kraftwerke GmbH.
E.ON setzt auf GroSSdumper von Bell
Sparen im großen Still! I
m Kohle-Abbau und Abraum-Management werden im Tagebau Schöningen der E.ON Kraftwerke GmbH neben Bergbau-Großgeräten auch 6x6-Knickdumper eingesetzt. Anlässlich der turnusgemäßen Erneuerung seiner Transportflotte entschied sich das Unternehmen nach eingehenden Tests für das 50-Tonnen-Topmodell von Bell Equipment: bis Mitte 2011 werden insgesamt 15 Bell B50D nach Helmstedt geliefert. Gemeinsam mit zwei verbleibenden Altfahrzeugen gewährleisten die Bell-Großdumper die Transportleistung der bislang aus 18 Vierzigtonnern bestehenden mobilen E.ON-Förderkette und senken die Betriebskosten entscheidend.
Der Tagebau Schöningen im Helmstedter Revier wurde 1979 aufgeschlossen. Drei Baufelder erstrecken sich über insgesamt 600 Hektar Fläche unmittelbar an der ehemaligen innerdeutschen Grenze. Bis 2017 ist der Abbau terminiert – derzeit fördert die E.ON Kraftwerke GmbH pro Jahr rund 1,9 Millionen Tonnen Braunkohle zum Betrieb des Kraftwerks Buschhaus mit einer Jahresproduktion von 2,5 Milliarden Kilowattstunden Strom.
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Der Abbau erfolgt mit Schaufelradbaggern, Bandanlagen und Absetzern sowie mit konventionellen Kettenbaggern und der zugehörigen Transportflotte aus 6x6-SchwerlastDumpern. Diese arbeiten vor allem an den Rändern oder in tiefen Lagen des bis zu 12 Meter dicken Braunkohle-Hauptflöz im Baufeld Süd, wo der Einsatz der Schaufelradtechnologie (Schnitttiefe 4 m) mangels Mächtigkeit der Restschichten unwirtschaftlich wird. Dabei bewegt die mobile Technik
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NEWS & REPORTS Geladen wird im Tagebau Schöningen mit insgesamt 5 5-m³-Kettenbaggern. 200 mm-Bordwanderhöhung ab Werk und die automatische Heckklappe steigern das Nennvolumen der Bell B50D auf rund 30,5 Kubikmeter (SAE 2:1). Beidseitige „Ladeampeln“ erleichtern das Beladen mit stark variierenden Abraumqualitäten oder in der Kohleförderung.
auch große Massen an Abraum, der in Helmstedt in einem Abraum/Kohleverhältnis 3:1 ansteht: insgesamt 8 Millionen Kubikmeter stark heterogenes Material werden jährlich im Tagebau Schöningen durch die Bergbau-Großgeräte und die mobile Flotte abgedeckt und wiederverfüllt. Die große Ausdehnung des Baufelds und die inzwischen erreichte Abbautiefe von gut 150 Metern stellen höchste Anforderungen gerade an die Schwerlast-Dumper. Im ganzjährigen Zweischicht-Betrieb fahren sie im Wechsel Kohle oder Abraum, wobei die Umlauflängen je nach Material und Standort der 5-m³-Tieflöffelbagger stark variieren. Derzeit liegen die Distanzen bei etwa 1800 Metern (Kohle) bzw. 3500 Metern (Abraum) auf schwerem lehmigen Untergrund mit engen Kehren und mit Steigungen bis 17 %.
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Offener Wettbewerb Durchschnittlich 2500 Betriebsstunden pro Jahr erreichen die in Helmstedt eingesetzten Dumper. Mit eigenen Werkstattkapazitäten ist die Abteilung Fahrzeugmanagement im Tagebau Schöningen unter Leiter Joachim Nagel für die tägliche Verfügbarkeit der Transportflotte verantwortlich. Gleiches gilt für die Erneuerung des Fahrzeugbestandes, die im vergangenen Jahr für die insgesamt 18 Vierzig-Tonner nach gut 7.500 Betriebstunden pro Fahrzeug anstand. E.ON ging die Investitionsentscheidung generalstabsmäßig an: Im offenen Wettbewerb bewarben sich die Topmodelle der führenden Dumper-Hersteller in einem 14-tägigen Dauertest nach spezifisch aufgestellten Kriterien. „Wir erstellten ein Testprogramm, das möglichst genau die typischen Betriebsbedingungen bei uns abbildete“, erklärt Joachim Nagel. „Auf identischen Strecken ermittelten wir die gefahrenen Tonnagen und Kubaturen, verglichen Umlaufzeiten und Treibstoffkonsum per GPSgestützter Streckenerfassung und bewerteten das Fahrverhalten der einzelnen Modelle in der Praxis. Dabei legten wir besonderen Wert auf die Bremscharakteristik unter Last und die Stabilität der 6x6 beim Abkippen der unterschiedlichen Materialien und auf wechselndem Untergrund, zum Beispiel auch gegen den Hang.“ Im Sinne des modernen TCOAnsatzes (Total Cost of Ownership) ermittelten die E.ON-Fahrzeugmanager zusätzlich zu den Leistungs- und Verbrauchsdaten auch laufzeitabhängige Servicekosten und voraussichtliche Maschinen-Restwerte, die gemeinsam mit dem notwendigen Personalaufwand in die langfristige Produktivitäts-Analyse einflossen.
Leistung setzt sich durch Über seinen regionalen Vertriebspartner Kurt König Baumaschinen mit der nahe gelegenen Niederlassung Magdeburg schickte Bell Equipment den Bell B50D ins Rennen. Als einziger echter „50-Tonner“ mit einer Nutzlast von 45,4 t besaß das 390 kW starke Bell-Flaggschiff zwar die vermeintlich beste Papierform. Gegen die gleichfalls potent motorisierten und teilweise mit aufwändiger Fahrwerkstechnik ausgestatteten „40-Tonner“ der
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NEWS & REPORTS Auf Steigungen bis zu 17 % überzeugen die Bell-Fünfzigtonner mit kraftvollen 390 kW Leistung und harmonischen Schaltvorgängen.
Konkurrenz mit freigegebenen Nutzlasten bis 39,5 t, musste sich das breitspurige, auf große Reserven ausgelegte Bell6x6-Konzept im Praxistest jedoch erst beweisen. „Im Fahrbetrieb hat der Bell B50D vor allem durch seine sehr ausgewogene Charakteristik überzeugt. Antrieb und Verzögerung sind jederzeit präsent und lassen sich stets genau dosieren. Das betrifft vor allem auch den Retarderbetrieb, der bei unseren Fahrzeugen 5 Prozent der Gesamt-Fahrzeit ausmacht, “ fasst Joachim Nagel die Testeindrücke zusammen. Auch bei Transporttonnagen und -kubatur konnte die 28-m³-Standardmulde des Bell B50D punkten: „Die Geometrie der Bell-Mulden passt sehr gut zu den Ladespielen unserer 5-m³-Bagger. Trotz stark wechselnder Abraum-Schüttdichten von 1,5 bis 2,2 t/m³ bringen die Bell dank integrierter ‚Ladeampel’ und ausreichender Toleranz zuverlässig das mögliche Maximum auf die Strecke.“ In der „leichten“ Helmstedter Kohle (Schüttdichte: 0,9 t/m³) zählt freilich auch anderes: Mit rund 34,5 Tonnen Leergewicht wiegt der Bell B50D netto um nur vier bzw. unter zwei Tonnen mehr als der
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40-Tonnen-Wettbewerb mit vier bis sechs Kubikmeter Nennvolumen weniger – rein verbrauchstechnisch ein Vorteil bei Leerfahrten, der sich selbst mit großen Bordwand-Erhöhungen nicht auffangen lässt. „Am Ende lag der Bell B50D in der Produktivität über die von uns veranschlagte Nutzungsdauer von vier Jahren deutlich vorne“, stellt Joachim Nagel fest. „In den laufenden Betriebskosten brachte der Test nur marginale Unterschiede – entscheidend war, dass wir mit nur 15 Neumaschinen und zwei bestehenden Altgeräten die gleiche Leistung gegenüber unserer bisherigen 18er-Flotte oder einem möglichen Ersatz mit den getesteten 40-Tonner erreichen und so künftig ein Fahrzeug einsparen.“
Hohe Verfügbarkeit garantiert Nach Auftragsvergabe im Mai 2010 wurden die ersten Bell B50D ab Anfang Oktober geliefert. Im Februar arbeiteten bereits sieben Fünfzigtonner in Helmstedt,
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NEWS & REPORTS bis Mitte 2011 treten die restlichen Großdumper ihren Dienst an. Bereits beim deutschen Mulden-Produzenten GFT Gotha wurden die 28-m³-Standardmulden nach strengen Hersteller-Standards mit 200-mmMuldenerhöhungen versehen, was das SAE-2:1-Nennvolumen gemeinsam mit der automatischen Heckklappe auf rund 30,5 m³ erhöht. Bis zu 30 Tonnen betragen jetzt die Braunkohle-Transportchargen, zuverlässig am Nutzlastlimit fahren die Bell B50D mit grobstückigem Lehm oder stark fließendem sandig-kiesigem Abraum.
Ein wichtiges Kriterium beim Kaufentscheid waren die guten Kippeigenschaften der Bell B50D. Neben der leistungsfähigen Muldenheizung kommen dabei vor allem die umfangreichen Assistenzfunktionen der Bell-Maschinensteuerung zum Tragen, die den Fahrer bei den Routinevorgängen unterstützen.
Im täglichen Betrieb nutzt E.ON auch die satellitengestützte Bell-Maschinenüberwachung Fleetm@tic. „Wir setzen Fleetm@tic vor allem zur genauen Erfassung der Transportleistungen ein“, erklärt Joachim Nagel. „Aufgeschlüsselt in Tages-, Wochenoder Monatsberichte können wir damit die Gesamtleistung unserer Förderkette beurteilen und gegebenenfalls optimieren. Durch Zugriff auf maschinenspezifische Ladeprotokolle und hinterlegte Statusmeldungen arbeiten wir gemeinsam
Förderkette: Im Wechsel fahren die E.ON-Dumper Kohle oder Abraum im weitläufigen und inzwischen bis 150 Meter tiefen Baufeld Süd des Tagebaus Schöningen im Helmstedter Braunkohlerevier.
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NEWS & REPORTS mit unseren Fahrern an der Einzel-Performance.“ Auch im Bereich der Wartungsplanung leistet das Online-System Fleetm@tic wertvolle Dienste: fällige Regelwartungen werden gemeldet, im Rahmen der auf 10.000 Betriebsstunden angelegten Bell-Verfügbarkeitsgarantie können die zuständigen Techniker etwaige Fehlfunktionen frühzeitig erkennen. Grundsätzlich positiv sind die Betriebserfahrungen nach den ersten 1000 Einsatzstunden: „Bereitstellung und Inbetriebnahme verliefen planmäßig, alle Bell-Dumper fügten sich reibungslos in die Betriebsorganisation ein“, urteilt Joachim Nagel. „Unsere Fahrer loben die Bedienungsfreundlichkeit der Fahrzeuge – neben den wirklich überzeugenden Leistungen auf der Strecke, insbesondere auch die sinnvollen Automatik-Funktionen, die Routine-Abläufe beim Laden oder Kippen erleichtern.“ Auch Leistung und Verbrauch stimmen: „Wir haben für Einzelfahrzeuge bereits Transportspitzen von über 2800 Tonnen pro Doppelschicht ermittelt, bei Umlaufdistanzen um 1500 Meter und durchschnittlichen Einzelchargen um 43 Tonnen – bei einem Durchschnittsverbrauch von 23,0 l/h! Selbst bei besonders langen Umläufen unter Maximallast am Berg lag der Konsum lediglich um 40 Liter pro Stunde. Tatsächlich überraschten uns die großen Bell im Betrieb mit niedrigeren Verbrauchswerten als unsere bisherigen 40-Tonner.“
WEITERE INFORMATIONEN UND KONTAKT:
Bell Equipment Deutschland GmbH Willy-Brandt-Str. 4-6 36304 Alsfeld | Deutschland Tel.: +49(0) 66 31 - 91 13 0 Fax: +49(0) 66 31 - 91 13 13 eMail: center@de.bellequipment.com Internet: www.bellequipment.de
Wichtigen Anteil an der Leistungsfähigkeit der Großdumper hat die ergonomische Gestaltung des Fahrerarbeitsplatzes. Wichtige Statusmeldungen der Maschinensteuerung sind stets im Blick – alle Funktionen des zentralen Schaltermoduls lassen sich intuitiv bedienen.
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Nach gut 1000 Betriebsstunden ist Joachim Nagel, Leiter Fahrzeugmanagement im Tagebau Schöningen, mit den Leistungen der Bell B50D hoch zufrieden. Das gilt auch für den Einsatz des Flottenmanagement Systems Fleetm@tic, das wichtige Schlüsseldaten der Fahrzeuge in leicht auswertbare Protokolle zusammenfasst.
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NEWS & REPORTS Komatsu Europe International N.V.
Komatsu Europe International Launches New HM300-3 Articulated Truck New HM300-3 Articulated Truck
Special features:
Vilvoorde May 2011 — Komatsu Europe International introduces the HM300-3 articulated truck. With a flywheel horsepower of 325 hp (242 kW), the HM300-3 is powered by a Komatsu SAA6D125E-6 engine that is EU Stage IIIB and EPA Tier 4 Interim emission certified. Built upon a proven EU Stage IIIA engine platform, Komatsu has leveraged its leadership in technology and innovation to design an environmentally friendly dump truck with more power and lower fuel consumption.
EU Stage IIIB / EPA Tier 4 Interim Emission Certified Engine
The HM300-3 features a gross vehicle weight 52,230 kg with a payload of 28.1 tonnes at its maximum ground speed of 58.6 km/h. A completely redesigned traction control system combined with an optimized cabin layout and increased durability makes the HM300-3 a comfortable, highly productive and low cost production unit.
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Built upon proven Komatsu EU Stage IIIA technology, the SAA6D125-6 engine provides increased horsepower while lowering fuel consumption and emissions. As a leader in hydraulic technology, Komatsu has developed a hydraulically actuated Komatsu Variable Geometry Turbocharger (KVGT) and an Exhaust Gas Recirculation (EGR) valve, resulting in better precision and air management as well as longer component life. The Komatsu Diesel Particulate Filter (KDPF) has an integrated design that will not interfere with daily operation but keeps the operator aware of its status.
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NEWS & REPORTS Greatly improved traction system The HM300-3 features the new Komatsu Traction Control System (K-TCS). The K-TCS automatically provides optimum traction when operating in soft ground conditions. As ground conditions worsen and tire slippage is detected by speed sensors located on four wheels, automatic application of the inter-axle differential lock occurs. If tire slippage continues to be detected then four independent brakes can be applied to slipping wheels to regain traction. The HM300-3 is enhanced with K-ATOMiCS— Komatsu Advanced Transmission with Optimum Modulation Control System. K-ATOMiCS offers a six-speed, fully-automatic transmission that uses an advanced electronic system to eliminate shift shock and torque cutoff to improve operator and power train efficiency. It automatically selects the ideal gear based on vehicle speed, engine rpm and the shift position chosen, which results in a powerful acceleration, smooth down shifting and synchronized engine speed when climbing slopes. This ultimately minimizes operator fatigue, keeps the load in the body and increases productivity. A large automatic retarder system allows the operator to select the optimum operating speed on downhill travel under full load, allowing a save operation under a wide scope of working conditions.
Increased payloads Through body design optimization, the HM300-3 features increased body capacity and payload. The low 2820mm loading height easily matches with 30ton to 60-ton hydraulic excavators or 5 yd³ to 7.5 yd³ wheel loaders. In addition, the two single-staged body lift cylinders provide a 70-degee dump angle for easy unloading
Enhanced operator environment The new cab design provides a comfortable and quiet work environment so operators can maximize their productivity. The ROPS/FOPS Level 2 certified cab features a new rounded front dash panel with easy to reach switches. The new comfortable high back, heated air ride seat with 2 - point seat belt
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improves operator comfort and all-round visibility. An auxiliary input was added to connect an MP3 player or other devices along with two 12-volt ports that have been incorporated into the cab. A new high resolution 7” LCD monitor features enhanced capabilities and displays information in 25 languages for global support. With the monitor, the operator can easily modify settings for items such as the Auto Idle Shutdown or the auto-reversing fan; check operational records, such as driving history or fuel consumption; monitor the KDPF or check the time remaining before the next required maintenance. The monitor also offers the option of using the ECO Guidance function, which provides operational tips to reduce fuel consumption. A separate high resolution back-up camera is standard with every machine and is mounted on the right hand side of the console for operator convenience.
Convenient Maintenance and Serviceability The HM300-3 provides easy service access to reduce costly downtime. It has a redesigned engine hood with an optimized narrow shape for better visibility, and to allow easy access to all major maintenance points. The new machine a standard hydraulically driven auto-reversing fan to help keep the radiator and charge air cooler clean –and to further lower fuel consumption. The machine is equipped with the exclusive Komatsu EMMS (Equipment Management Monitoring System), which has enhanced diagnostic features that give the operator and technicians greater monitoring and troubleshooting capabilities. EMMS also continuously monitors all critical systems, preventative maintenance, and provides troubleshooting assistance to minimize diagnosis and repair time.
KOMTRAX™ : an easy follow-up system The new HM300-3 is equipped with the latest KOMTRAX™ technology which provides daily machine information through a secure website utilizing wireless technology. New features include
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NEWS & REPORTS energy saving reports with tips for a more fuel efficient operation, location, cautions, load ratio, and maintenance alerts and a follow-up of the DPF status. All data is relayed to the web application for analysis. The KOMTRAX™ fleet monitoring system increases machine availability, reduces the risk of machine theft, allows for remote diagnosis by the distributor, and provides a wealth of other information to drive business efficiency and productivity
FOR MORE INFORMATION AND CONTACT: Komatsu Europe International N.V. Kevin Broman Tel.: +32 (0)22 55 - 24 58 eMail: kevin.broman@komatsu.eu Internet: www.komatsu.eu
Komatsu Europe Launches D65-17 Dozer Vilvoorde, May 2011 - . Komatsu Europe International announces the introduction a new line of D65-17 crawler dozers, powered by the fuel efficient and larger displacement, 8.9 Litre, EU Stage IIIB - emission certified Komatsu SAA6D114E-5 engine. The D65-17 is built upon the proven Komatsu technology used for the EU Stage IIIA emission regulation. Komatsu has leveraged its leadership in technology and innovation to design an environmentally friendly engine that increases net power while decreasing an additional 5% fuel consumption over the EU Stage IIIA model it replaces. A standard (EX), low ground pressure (PX) and a wide track (WX) model are available to offer customers flotation and weight distribution options that best match their applications. Operating weight ranges from 22 tonnes to 23.8 tonnes depending on the version. The new models push with a net (ISO 9249 / SAE J1349) 205 HP at 1950 rpm. Developed primarily as a multipurpose unit for applications ranging from heavy duty dozing to fine grading, the D65-17 combines the revolutionary SIGMADOZER* blade with a highly efficient automatic transmission with torque converter lock-up to
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achieve exceptional productivity and extremely low fuel consumption. A new Komatsu 6-way Power Angle Tilt (INPAT) blade is available for all models, creating a balanced and agile tractor for light and heavy-duty dozing operations. The blade provides the precise grade cutting required for site prep, road construction or house pad applications. The new dozer is equipped with the latest KOMTRAX™ technology which provides daily machine information through a secure website utilizing wireless technology. New features include energy saving reports with tips for a more fuel efficient operation, location, cautions, load ratio, and maintenance alerts and a follow-up of the DPF status. All data is relayed to the web application for analysis. The KOMTRAX™ fleet monitoring system increases machine availability, reduces the risk of machine theft, allows for remote diagnosis by the distributor, and provides a wealth of other information to drive business efficiency and productivity
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TRANSFER OF TECHNOLOGY
Innovative and Efficient Solutions for challenging tasks in extraction, surface mining and surface forming.
T1255 Terrain Leveler
Vermeer has transcribed its long-standing experience in the area of rock mills into its new surface mill. The T1255 is characterized by protected technology, intelligent design, excellent production and system stability. Meanwhile the Terrain Leveler can process an area of up to 3.7 m width and 61 cm depth in one single run.
The machine has been designed to ablate all kinds of rocks, gypsum, coal and other material (e.g. concrete). This is done using a big, hydrostatically steered milling drum, which ablates the rock in a more efficient way and with a higher cutting depth. The result: More coarse material with a low proportion of fine fraction.
www.vermeer.de Deutschland GmbH Puscherstr. 9 90411 Nuremberg, Germany
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Tel.: +49 (0) 911 5 40 14 0 Fax: +49 (0) 911 5 40 14 99
ANZEIGE ADVERTISEMENT www.advanced-mining.com
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NEUHEITEN PREVIEW Steinexpo & REPORTAGEN 2011
Mining Technology Consulting Field of activity • Feasibility studies
• equipment selection
• Exploration
• drilling & blasting
• geological modelling
• slope stability & monitoring
• geostatistical resource estimation
• assessment of geotechnical risk
• resource classification
• hydrological investigation
• mine design
• health & safety in mining
ON Steine
Pavilion xpo! P210
• mine optimization
Geological Investigation Exploration • Survey & Mapping • Mineral exploration program • Geological investigation • Geochemical investigation • Geological and structural analysis • Microscopic investigation and mineralogical analysis
Geological Modelling • Data collection and review of projects • Database validation and verification • Exploration and data management • 3D geological, structural and mineralization interpretation and modeling • Statistic and geostatistic analysis • Geostatistical resource estimation • Resource classification, reporting andreconciliations
Mine Design & Mine Optimization Mine Planning • Design and optimization of pit layout • Mine development planning • Scheduling • Design of mine dumps • Optimum location of surface facilities
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NEUHEITEN & REPORTAGEN Equipment Selection & Modelling • Loading and haulage • Transport route optimization • Optimization of primary crusher location (Mobile / semimobile / stationary crusher) • Economic evaluation
Slope Stability & Monitoring • Geotechnical investigation • Groundwater investigation • Slope stability assessment • Slope design • Implementation of geotechnical instrumentation • Slope monitoring • Assessment and management of geotechnical risks
Drilling & Blasting • Planning of drilling and blasting • Blast vibration control • Control of borehole deviation • Economic evaluation
Compact courses For the international mining industry on mining methods and technology: • Seminars, conferences, courses, lectures and workshops
MTC We look forward to an excellent exhibition and a reunion with our customers and business partners. Although we would like to use the exhibition to make new contacts. For this, we invite you to our pavilion P210 for expert discussions. We look forward to your visit! FOR MORE INFORMATION AND CONTACT:
Mining Technology Consulting Professor Dr.-Ing. habil. H. Tudeshki
Albrecht-von-Groddeck-Str. 3 D-38678 Clausthal-Zellerfeld
Tel.: +49(0) 53 23 - 98 39 33 Fax: +49(0) 53 23 - 96 29 90 8
www.mtc-tudeshki.com
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EVENTS
2011
THE AMS-EVENT CALENDER July 2011 06 - 08 Jul 2011 HydroCopper 2011
Viña del Mar, Chile
www.hydrocopper.cl
13 - 15 Jul 2011 Copper China
Shanghai, China
www.copperexpo.com.cn
19 - 22 Jul 2011 5th International Light Metals Technology Conference
Lüneburg, Germany
www.lmt2011.de
28 - 30 Jul 2011 Riau Industrial Expo
Pekanbaru, Indonesia
www.riau-expo.com
August 2011 16 - 21 Aug 2011 2nd International Specialized Exhibition „Innovation Materials and Technologies“ Moscow, Russia
www.mirexpo.ru/eng
25 - 29 Aug 2011 The 3rd Annual CSG Associated Water Conference
Brisbane, Australia
www.iir.com.au/csgwater
Homberg/Niederofleiden, Germany
www.steinexpo.de
Munich, Germany
www.geomunich2011.de
06 - 09 Sep 2011 AIMEX 2011 - Asia-Pacific's International Mining Exhibition
Sydney, Australia
www.aimex.com.au
06 - 09 Sep 2011 Silmex Sosnowiec
Sosnowiec, Poland
www.exposilesia.pl
07 - 09 Sep 2011 8th International Mining Plant Maintenance Meeting - MAPLA 2011
Antofagasta, Chile
www.mapla.cl
07 - 09 Sep 2011 6th International Mine Equipment Maintenance Meeting - MANTEMIN 2011
Antofagasta, Chile
www.mantemin.cl
07 - 10 Sep 2011 Energie und Rohstoffe 2011
Freiberg, Germany
www.energie-und-rohstoffe.org
08 - 09 Sep 2011 11. BergbauForum 2011
Köln, Germany
www.bergbauforum.de
08 - 09 Sep 2011 GDMB-Fachausschuss für Aufbereitung und Umwelttechnik
Frankfurt/Oberursel, Germany
www.gdmb.de
31 Aug - 03 Sep 2011 STEINEXPO 2011 8. Internationale Demonstrationsmesse für die Baustoffindustrie
September 2011 04 - 07 Sep 2011
Fragile Earth - Geological Processes from Global to Local Scales, Associated Hazards and Resources
12 - 16 Sep 2011 8th International Symposium on Field Measurements in GeoMechanics (FMGM) Berlin, Germany
www.fmgm2011.org
14 - 17 Sep 2011 Brazilian Symposium on Geological Heritage
Rio de Janeiro, Brazil
www.metaeventos.net/simposiopatrimoniogeologico
Aachen, Germany
www.gdmb.de
19 - 20 Sep 2011 Mine Site Automation and Communication
Sandton, Johannesburg, South Africa
www.mineautomationafrica.com
19 - 21 Sep 2011 World Independent & Junior Oil and Gas Congress Asia
TBC Singapore, Singapore.
www.terrapinn.com
21 - 24 Sep 2011 Mining Indonesia Jakarta
Jakarta, Indonesia
www.pamerindo.com
28 - 30 Sep 2011 GDMB-Fachausschuss Kupfer
Alpbach, Austria
www.gdmb.de
04 - 07 Oct 2011 Surface Mining in XXI century
Krasnoyarsk, Russia
www.russianmining.com
09 - 12 Oct 2011 Mineral Processing 2011
Lake Tahoe, NV, USA
www.mining-media.com/index.php/events/mineral-processing.html
13 - 14 Oct 2011 Jahresversammlung der GDMB
Goslar, Germany
www.gdmb.de
13 - 14 Oct 2011 Gemeinsame Vortragsveranstaltung "Neue Rohstoffprojekte in Deutschland"
Goslar, Germany
www.gdmb.de
19 Sep 2011 13. ABK - Aachener Altlasten- und Bergschadenkundliches Kolloquium
October 2011
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EVENTS Die Baumaschinen-Demonstrationen der zehn beteiligten Marken auf der Gemeinschaftsfläche werden während der diesjährigen steinexpo professionell moderiert. Fotos: gsz
steinexpo 2011 –
Baumaschinen-Demo mit Catwalk-Effekt! Juni 2011: Still vor sich hinarbeiten und brav beständige Leistung zeigen. So sieht ein normales Baumaschinenleben aus. Die moderne Baumaschinen-Demonstration auf Messen kann ebenfalls so ablaufen – muss sie aber nicht. Dass die Vorstellung der neuen Modelle durchaus eine professionelle Begleitung verträgt, befanden die Organisatoren der steinexpo gemeinsam mit den Herstellerfirmen. So wird in diesem Jahr erstmals bei der Steinbruch-Demonstrationsmesse in Nieder-Ofleiden das Geschehen in der Gemeinschaftsdemonstration moderiert. Im Einsatz sind auf etwa 22.000 m² des „Messegeländes“ im MHI-Steinbruch Nieder-Ofleiden Baumaschinen zehn verschiedener Hersteller. Die Demonstrationen finden alle 30 min an drei verschiedenen Ladestellen statt, wobei an einer Ladestelle zusätzlich die Rückverladung praxisgerecht demonstriert wird. Während das technische Planungsteam des Institut für Bergbau der TU Clausthal gerade die technischen Abläufe so koordiniert, dass
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diese vor den kundigen Augen der Fachleute – die regelmäßig mehr als 90 % der steinexpo-Besucher der ausmachen – bestehen können, entwickeln sich parallel dazu der Showrahmen mit passender Musik und Moderationskonzept. Alle Elemente verschmelzen schließlich zu einer einheitlichen Choreographie. Als Moderator konnte Raoul Helmer gewonnen werden. Bekannt sind dessen Moderationen nicht nur vom hessischen Rundfunk. Helmer hat es darüber hinaus
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EVENTS Die Baumaschinen-Demonstrationen der zehn beteiligten Marken auf der Gemeinschaftsfläche werden während der diesjährigen steinexpo professionell moderiert. Fotos: gsz
schon bei diversen Baumaschinen-Einsatzshows verstanden, ganze Zuschauerscharen gleichzeitig bestens zu informieren und gut zu unterhalten. Angespornt durch die positiven Resonanzen aus dieser so rauen und ehrlichen Branche, hat er auch den umfangreichen steinexpo-Auftrag mit Freude übernommen. Der Ablauf ist so geplant, dass der Moderator mit je einem Ausstellervertreter pro Marke im Interviewstil die besonderen Qualitäten der Arbeitsmaschinen hervorhebt und damit die Aufmerksamkeit der Besucher ganz gezielt auf wichtige Features lenkt. Steinexpo-Messechef Dr. Friedhelm Rese freut sich, den Besuchern ebenso wie den Ausstellern damit wieder eine neue Besonderheit dieser speziellen Messe anbieten zu können: „Ich will nicht sagen, dass die steinexpo mit ihrer 8. Durchführung schon in die Jahre gekommen wäre. Die Messe ist immer noch allein vom Konzept her eine Besonderheit, die speziell Fachbesucher anspricht. Dennoch ist uns die Integration neuer Elemente, mit denen sich die Exponate der Hersteller noch besser in Szene setzen lassen, regelmäßig ein Anliegen. Wo schwere Technik arbeitet, muss Unterhaltungswert nicht ausgeschlossen werden. Ich freue mich, dass wir beides diesmal in so enger Verzahnung anbieten können. Hinzu kommt, dass die Form der Vermittlung
natürlich auch andere Hersteller anspornen wird, etwas Besonderes auf die Beine zu stellen, um in der Besuchergunst zu punkten. Dieser Effekt kommt letztlich allen Ausstellern und der gesamten Messe zugute.“ Das Messegeschehen der steinexpo 2011 wird darüber hinaus erstmalig auch im Web-TV zu sehen sein. Als offizieller Medienpartner berichtet Bauforum24 TV jeden Tag über Neuheiten, Meinungen und Produkte direkt vom Messegelände. Im Messestudio werden die Sendungen mit Interviews und Berichten über neue Produkte und Branchennews direkt vor Ort produziert. Alle Sendungen sind wie gewohnt rund um die Uhr auf www.bauforum24.tv zu sehen. Für Smartphone Nutzer stehen sie auch unterwegs als Podcast für iPhone, Blackberry und Co. zur Verfügung.
WEITERE INFORMATIONEN UND KONTAKT:
Fachlich: Geoplan GmbH Josef-Herrmann-Straße 1-3 76473 Iffezheim | Deutschland Tel.: +43 (0)72 29 - 606 - 30 Fax: +43 (0)72 29 - 606 - 10 eMail: info@geoplanGmbH.de Internet: www.geoplanGmbH.de
Redaktionell: gsz-Fachpressebüro Pestalozzistr. 2 13187 Berlin | Deutschland Tel.: +43 (0)30 - 47 37 62 25 Fax: +43 (0)30 - 91 20 38 04 eMail: gsz@in-Berlin.com
steinexpo Als größte und bedeutendste Steinbruchsdemonstrationsmesse auf dem europäischen Kontinent feierte die steinexpo im September 1990 im Steinbruch Niederofleiden ihre Premiere. Die Messe wird im Drei-Jahres-Turnus durchgeführt. Im Rahmen eindrucksvoller Live-Vorführungen vor der Kulisse eines beeindruckenden Steinbruchs zeigen Hersteller und Händler von Bau- und Arbeitsmaschinen, von Nutzfahrzeugen und Skw sowie von Anlagen zur Rohstoffgewinnung und -aufbereitung ihre Leistungsfähigkeit. Einen weiteren Schwerpunkt der Messe bildet das Recycling mineralischer Baustoffe. Veranstaltet wird die steinexpo von der Geoplan GmbH, Iffezheim.
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IMPRINT PUBLISHING COMPANY
AMS Online GmbH An den Wurmquellen 13 a 52066 Aachen | Germany eMail: info@advanced-mining.com Internet: www.advanced-mining.com St.-Nr.: 201/5943/4085VST | USt.-ID: DE 262 490 739
EXECUTIVE MANAGER
Dipl.-Umweltwiss. Christian Thometzek
PUBLISHER
Prof. Dr.-Ing. habil. Hossein H. Tudeshki University Professor for Surface Mining and International Mining eMail: tudeshki@advanced-mining.com
EDITORIAL TEAM
Prof. Dr.-Ing. habil. Hossein H. Tudeshki Dr. Monire Bassir Dipl.-Umweltwiss. Christian Thometzek eMail: redaktion@advanced-mining.com
DESIGN & LAYOUT
Dipl.-Umweltwiss. Christian Thometzek eMail: Christian.thometzek@advanced-mining.com
BANK CONNECTION
Bank: Sparkasse Aachen, BLZ 390 500 00 Account-No.: 1070125826 SWIFT: AACSDE33 IBAN: DE 27390500001070125826
GRAPHICAL DESIGN
Graumann Design Aachen Dipl.-Des. Kerstin Graumann Augustastr. 40 - 42 52070 Aachen | Germany Tel.: +49 (0) 241 - 54 28 58 Fax: +49 (0) 241 - 401 78 28 eMail: kontakt@graumann-design.de Internet: www.graumann-design.de
PROGRAMMING INTERNET SITE
79pixel Steffen Ottow, B.Sc. BodestraĂ&#x;e 9 38667 Bad Harzburg | Germany Tel.: +49 (0) 53 22 - 7 84 16 57 eMail: steffen@79pixel.de Internet: www.79pixel.de
ISSUE DATES
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CONTENTS
The contents of our magazine as well as our website are compiled with utmost care and accuracy. However, the respective authors and companies are responsible for the the correctness, completeness and up-to-dateness of the published contents.
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